Split Partial Power Converter Topology for Lower Device Stress
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Solution Overview
Problem
Conventional backup power systems face inefficiencies and high costs due to the need for semiconductor devices with non-optimal Formulas of Merit (FOM) and high current handling, especially when converting battery energy to power loads during outages, leading to increased power consumption and reduced power density.
Innovation Solution
A bidirectional partial power converter that generates multiple auxiliary voltages from a single input voltage, allowing for efficient power distribution to multiple loads using a single integrated converter stage, reducing the need for multiple separate converters and optimizing semiconductor device ratings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional power converter topologies (buck, boost, 4-switch buck-boost) are used to convert battery energy to power loads, then the converter can provide backup power during outages, but the semiconductor devices must be rated according to total output voltage or total input voltage resulting in non-optimal Formulas of Merit (FOM) and high current handling requirements
Solution Approach 1:
The patent divides the power conversion function into two separate stages: a first partial power converter that generates an auxiliary voltage from the input voltage, and a second power converter that uses both the auxiliary voltage and input voltage to generate the output voltage. This segmentation allows each converter to operate at lower voltage/current ratings, improving the FOM of semiconductor devices while maintaining backup power capability.
Solution Approach 2:
The patent introduces an auxiliary voltage as an intermediary between the input voltage and the final output voltage. This auxiliary voltage serves as a mediator that enables the second power converter to achieve the desired output voltage with lower stress on semiconductor devices, thereby resolving the contradiction between reliability and device complexity.
2Power
If conventional converters handle high power levels (3kW) with narrow battery voltage conversion range, then the load can be powered during outages, but high currents impact efficiency, cost, and power density of both passive and active components
Solution Approach 1:
By segmenting the power conversion into two stages with different functions, the patent enables each stage to operate at optimized current levels. The first partial power converter handles voltage transformation with lower current, while the second converter handles power delivery with reduced current stress, collectively improving overall efficiency at high power levels.
Solution Approach 2:
The patent changes the voltage parameters by introducing an auxiliary voltage that is summed with the input voltage. This parameter transformation allows the system to deliver high power (3kW) while maintaining lower currents through optimized voltage levels, thereby reducing energy losses and improving efficiency.
3Power
If conventional converters are designed for high current handling to meet 3kW load requirements, then the load can be powered during outages, but the cost and power density are reduced due to larger passive and active components
Solution Approach 1:
The patent segments the power conversion function into two specialized converters, allowing each to be optimized for specific operating conditions. This enables the use of smaller, more cost-effective components in each stage compared to a single conventional converter designed for the full 3kW output, thereby reducing overall component size and cost while maintaining high power capability.
Solution Approach 2:
The first partial power converter serves multiple functions: it generates the auxiliary voltage needed for the second converter and can independently provide power output. This multi-functionality reduces the need for oversized components dedicated solely to high current handling, optimizing component size and cost for the combined system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution achieves ultra-high efficiency, lower voltage ratings for semiconductor devices, soft-switching capabilities, and bidirectional power flow, while reducing material costs and increasing power density by providing multiple output voltages from a single input source.
Implementation Method 1
a resonant circuit, including a resonant inductor and a resonant capacitor, operative to receive the input voltage and transform the input voltage into the auxiliary voltages
Implementation Method 2
a transformer, including a primary winding magnetically coupled to a secondary winding, operative to transform the input voltage into the auxiliary voltages
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A first partial power converter implementation receives and converts an input voltage into multiple auxiliary voltages including a first auxiliary voltage and a second auxiliary voltage. The first partial power converter produces a first output voltage as a first summation of the first auxiliary voltage and the input voltage; the first partial power converter produces a second output voltage as a second summation of the second auxiliary voltage and the input voltage. A second partial power converter implementation as discussed herein receives a first auxiliary input voltage referenced with respect to an output voltage of the power converter. The second partial power converter also receives a second auxiliary input voltage referenced with respect to the output voltage. The second partial power converter converts the first auxiliary input voltage and the second auxiliary input voltage into the output voltage to power a load.