Series-Stacked Phase DC-DC Converter Topology for Stable 100% Duty Cycle

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Solution Overview

Problem

Existing series stacked phase DC-DC converters face interruptions due to positive feedback loops and require high-voltage rated devices, leading to inefficiencies and increased system costs.

Innovation Solution

The circuit design includes two top buck converter stages in parallel and a bottom buck converter stage in series, eliminating charge transfer between storage elements, thereby removing the positive feedback loop and allowing continuous stable operation without high-voltage rated devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If series stacked phase DC-DC converters are used to improve power conversion efficiency, then power dissipation is reduced, but positive feedback loops cause operational interruptions and instability

Engineering Contradiction:
Improvepower dissipationVSAvoidoperational stability
Core Design Contradiction:
Loss of energyVSReliability

Solution Approach 1:

The converter is divided into multiple independent phase modules (first phase module, second phase module, third phase module) that operate in parallel. Each phase contains its own switching network, inductor, and capacitor, eliminating inter-phase feedback loops while maintaining efficient power conversion through distributed processing

Inventive Principle:
Principle #1Segmentation

2Area of stationary object

If traditional series stacked converters are used to reduce component size, then space efficiency improves, but high-voltage rated devices are required increasing system cost

Engineering Contradiction:
Improveconverter footprintVSAvoidsystem cost
Core Design Contradiction:
Area of stationary objectVSEase of manufacture

Solution Approach 1:

The circuit architecture ensures that no single component experiences the full input voltage stress. By distributing voltage across multiple phases operating in parallel with proper coupling, standard-voltage-rated components can be used throughout, eliminating the need for expensive high-voltage devices while maintaining compact form factor

Inventive Principle:
Principle #12Equipotentiality

3Measurement precision

If dedicated power converter circuits are used to power integrated circuits, then voltage regulation is achieved, but the converter consumes more space than the integrated circuit itself

Engineering Contradiction:
Improvevoltage regulationVSAvoidconverter size
Core Design Contradiction:
Measurement precisionVSArea of stationary object

Solution Approach 1:

Multiple functional elements are integrated into shared structures: the coupling capacitor serves both phases simultaneously, the output inductor handles combined current from multiple phases, and the control logic manages all phases through a unified controller. This consolidation reduces total component count and footprint while maintaining precise voltage regulation capability

Inventive Principle:
Principle #5Merging (Combining)

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

The solution enables 100% duty cycle operation with reduced system costs and maintains efficiency by preventing interruptions and eliminating the need for high-voltage rated components.

Implementation Method 1

a first inductor coupled between the first and second flying capacitors through a first switch and a second inductor coupled between a third switch node and an output terminal

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a first flying capacitor coupled to the first switch node and a second flying capacitor coupled to the second switch node

Methodology Applied
Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20250211115A1Series stacked phase DC-DC converters with stable operation
Publication Date: 2025.06.26 EMPOWER SEMICONDUCTOR INC
  • US20250211115A1 patent drawing
  • US20250211115A1 patent drawing

AI summary

A power converter circuit is disclosed. In one aspect, the power converter circuit includes a first top buck converter circuit coupled in parallel to a second top buck converter circuit at a first connection node and at a second connection node, and a bottom buck converter circuit coupled in series to each of the first and second top buck converter circuits at the second connection node, a power input terminal coupled to the first and second top buck converter circuits, and a power output terminal coupled to the bottom buck converter circuit and to the first connection node.