Tapped Transformer Forward Boost Converter Low Power Efficiency

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Solution Overview

Problem

Conventional power converters face challenges in maximizing power conversion efficiency, minimizing component count and cost, and ensuring monotonic power transfer, particularly at low input power levels where resonant converters experience inefficiencies due to incomplete resonant current cycles.

Innovation Solution

The proposed switching mode power converter employs a tapped transformer with magnetization and leakage inductances to store and transfer energy, utilizing a tapped forward boost topology that allows for bi-directional power flow and reduces the number of discrete components by leveraging parasitic inductances within the transformer, thereby enhancing energy storage and transfer efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional power converters are used, then power conversion efficiency is maintained at normal power levels, but efficiency deteriorates at low input power levels due to incomplete resonant current cycles

Engineering Contradiction:

Improvepower conversion efficiencyVSAvoidresonant current cycle completion

Core Design Contradiction:

Loss of energyVSProductivity

Solution Approach 1:

The transformer secondary winding is divided into two separate windings (first secondary winding and second secondary winding) with different turns ratios. This segmentation allows the converter to selectively engage different resonant paths based on power level, ensuring complete resonant cycles even at low power by using the winding with appropriate turns ratio for the current operating conditions.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If the number of discrete components is reduced, then component count and cost are minimized, but component stress increases

Engineering Contradiction:

Improvecomponent countVSAvoidcomponent stress

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The transformer is designed with multiple windings that serve multiple functions: the first secondary winding and second secondary winding can both perform power transfer, and either can serve as the resonant winding depending on operating conditions. This multi-functionality reduces the need for separate dedicated resonant inductors while distributing stress across multiple components, maintaining reliability without increasing component count.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Use of energy by moving object

If a tapped transformer topology is used, then energy storage and transfer efficiency is enhanced, but device complexity increases

Engineering Contradiction:

Improveenergy transfer efficiencyVSAvoidtransformer winding configuration

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The transformer combines multiple windings with different turns ratios into a single integrated component. The first secondary winding and second secondary winding are both part of the same transformer structure, sharing a common core and magnetic path. This merging provides enhanced energy transfer efficiency through optimized magnetic coupling while avoiding the complexity of separate discrete inductors and transformers.

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

This configuration improves low-power performance by allowing more time for resonant energy transfer, reducing switching losses, and maintaining efficient energy transfer across a range of power levels, while minimizing component count and stress on converter components.

Implementation Method 1

a tapped transformer having a first winding coupled across the first inductance and a second winding

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

Resonant converters are converters that use inductive and capacitive (LC) reactive elements in resonance to transfer power from an input source to the output

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentUS9509221B2Forward boost power converters with tapped transformers and related methods

Publication Date: 2016.11.29 SOLANTRO SEMICON CORP

AI summary

In a switching mode power converter coupled between first and second terminal pairs, a first circuit path includes a first inductance and a first switch. A tapped transformer has a first winding coupled across the first inductance and a tapped second winding with a tapped winding portion. A second circuit path includes a capacitance coupled to a second inductance, and the second circuit path is coupled to the first inductance through the tapped winding portion in a third circuit path and through the second winding in a fourth circuit path. During their respective conduction periods, the first switch couples the first inductance across the first terminal pair, a second switch completes a circuit between the second terminal pair and the second circuit path or the third circuit path, and a third switch completes a circuit that includes another of the second circuit path and the fourth circuit path.