Switch Control Module Using Leakage Spike Energy Recovery
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Solution Overview
Problem
Existing switch mode power supplies face challenges in reducing voltage spikes caused by leakage inductance, leading to energy waste and increased manufacturing costs due to stringent component requirements and heat dissipation needs.
Innovation Solution
A switch control module is introduced, connecting a biased switch in series with an active switch, using low-voltage components to manage voltage spikes by controlling the switch state, and optionally incorporating a snubber with a current source or coupling components to absorb energy from leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external snubber components (resistor, capacitor, diode) are used to suppress voltage spikes, then the switch transistor is protected from voltage spike damage, but energy is wasted and manufacturing cost increases
Solution Approach 1:
The patent converts the harmful voltage spike energy into useful energy by using it to charge a capacitor that powers the control unit. The energy that would otherwise be wasted is now utilized to supply operation current to the control unit, achieving both voltage spike suppression and energy recovery simultaneously.
Solution Approach 2:
The patent merges the voltage spike suppression function with the control unit power supply function. By connecting the snubber capacitor to the control unit power input, the same energy storage component serves dual purposes: suppressing voltage spikes across the switch transistor and providing operating voltage to the control unit.
2Reliability
If external snubber components are used to suppress voltage spikes, then the switch transistor is protected, but the number of external components increases and manufacturing cost rises
Solution Approach 1:
The patent makes the snubber capacitor serve multiple functions: it acts as a voltage spike suppression component, a power storage element for the control unit, and eliminates the need for separate power supply components. This multi-functionality reduces the total component count while maintaining protection capabilities.
Solution Approach 2:
The patent combines the snubber circuit with the control unit power supply circuit, making them share common components. The capacitor and diode in the snubber circuit also serve as power supply elements for the control unit, thereby reducing the number of external components needed.
3Power
If high power switch mode power supply is designed, then energy conversion efficiency is improved, but energy stored in leakage inductance increases significantly requiring higher voltage tolerance components
Solution Approach 1:
The patent converts the harmful high-energy voltage spikes (which increase with power level) into useful energy by charging the snubber capacitor. This capacitor then powers the control unit, transforming what would be wasted energy into a useful power source, enabling high-power applications without proportionally increasing component stress.
Solution Approach 2:
The patent changes the voltage parameter distribution in the circuit by introducing the snubber capacitor. The capacitor absorbs voltage spikes and provides a controlled voltage source for the control unit, allowing the system to handle higher power levels while keeping control unit voltage requirements manageable.
4Reliability
If snubber components with higher voltage tolerance are used for high power applications, then voltage spike suppression effectiveness is improved, but manufacturing cost increases substantially
Solution Approach 1:
The patent converts high-voltage spike energy into useful power for the control unit, allowing the use of lower voltage tolerance components in the control unit while maintaining effective voltage spike suppression. The energy that would require expensive high-voltage components is instead utilized to power the control circuitry.
Solution Approach 2:
The patent changes the voltage parameter distribution by using the snubber capacitor to isolate and manage high-voltage spikes. This allows the control unit to operate at lower, more cost-effective voltage levels while the snubber components handle the high-voltage transient conditions.
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
Reduces voltage spikes and manufacturing costs by allowing the use of low-voltage components, minimizing energy waste, and eliminating the need for additional heat dissipation structures, while extending the module's applicability to high-power applications.
Implementation Method 1
there exists the leakage inductance LLK in the primary side winding NP. The energy stored in the leakage inductance LLK cannot be converted effectively to the secondary side winding NS. Instead, a voltage spike will be generated
Implementation Method 2
The switch mode power supply according to the prior art uses external components to implement the snubber 91. In fact, the energy stored in the leakage inductance LLK is dissipated passively by these external components
Data Source
AI summary
A switch control module for a switch mode power supply comprising a biased switch, an active switch and a control unit. The biased switch comprises a first node and a second node. The first node is coupled to a primary side winding. The active switch is connected to the second node. The control unit controls the ON/OFF states of the active switch and the biased switch is biased to be turned on initially. In this way, the active switch and the control unit are less likely to be damaged by voltage spikes generated by leakage in the primary side winding.