Two-Stage Power Converter for 48V Data Center Isolation
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Solution Overview
Problem
Current power converter technologies face challenges in achieving high efficiency and high power density while providing isolation and a wide range of operating voltages, particularly with input voltages of 48V, which are complex and inefficient, especially when directly supplying power to digital chips in data centers.
Innovation Solution
A two-stage power converter system is introduced, comprising a pre-stage circuit that converts the input voltage to a bus voltage, and multiple post-stage circuits connected in parallel to convert the bus voltage to output voltages, allowing for reduced capacitor volume and improved light load efficiency, with the bus voltage being set to optimize efficiency and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-stage isolation converter is used to convert 48V input voltage, then isolation is achieved, but the converter becomes complex and efficiency decreases
Solution Approach 1:
The patent divides the single-stage isolation converter into two separate stages: a first converter that performs voltage conversion without isolation, and a second converter that provides isolation. This segmentation allows each stage to be optimized independently, reducing overall complexity while maintaining isolation functionality.
Solution Approach 2:
The patent introduces an intermediate bus voltage stage between the input and output. The first converter converts 48V to an intermediate bus voltage, and the second converter isolates and converts to the final output voltage. This intermediary approach simplifies each individual conversion stage while achieving the required isolation.
2Reliability
If a single-stage isolation converter is used to convert 48V input voltage, then isolation is achieved, but efficiency and power density are reduced
Solution Approach 1:
By segmenting the conversion process into two separate stages, each converter can operate at optimized switching frequencies and duty cycles, reducing switching losses. The first converter handles the large voltage step-down efficiently, while the second converter provides isolation at a more manageable voltage level.
Solution Approach 2:
The patent changes the operating parameters by introducing an intermediate bus voltage level. This allows the first converter to operate with optimized parameters for high-voltage-to-low-voltage conversion, while the second converter operates with parameters optimized for isolation and precise voltage regulation, overall reducing energy losses.
3Power
If input voltage is increased to 48V to reduce current, then power density improves, but traditional BUCK circuit becomes difficult to implement due to small duty cycle
Solution Approach 1:
The patent segments the voltage conversion into two stages, allowing the first converter to handle the 48V to bus voltage conversion with an optimized duty cycle. This segmentation makes it feasible to implement high-voltage conversion that would be difficult with a single-stage BUCK circuit operating at very small duty cycles.
Solution Approach 2:
By introducing an intermediate bus voltage stage, the patent changes the operating parameters of each converter stage. The first converter operates with a more favorable duty cycle range, making the 48V input conversion practical and efficient, while the second converter handles the final voltage regulation.
4Volume of stationary object
If capacitor volume is reduced for smaller power supply, then occupied space decreases, but light load efficiency becomes problematic
Solution Approach 1:
The two-stage converter architecture allows for separate optimization of capacitor sizes in each stage. The first converter can use smaller capacitors optimized for high-power operation, while the second converter uses capacitors optimized for light-load efficiency, achieving both small overall volume and good light-load performance.
Solution Approach 2:
Each converter stage is equipped with capacitors having local qualities optimized for their specific operating conditions. The first stage capacitors are optimized for high-voltage switching, while the second stage capacitors are optimized for isolation and light-load operation, achieving overall system optimization.
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 two-stage power converter significantly reduces power consumption and occupied space, improves efficiency by reducing switching losses, and increases power density, making it suitable for high-power applications in data centers.
Implementation Method 1
a pre-stage circuit and a plurality of post-stage circuits. The pre-stage circuit is configured to receive an input voltage and convert the input voltage to a bus voltage
Implementation Method 2
the plurality of post-stage circuits are connected in parallel to an output terminal of the pre-stage circuit, and configured to receive the bus voltage from the pre-stage circuit and each converts the bus voltage to an output voltage
Data Source
AI summary
The present disclosure provides a power converter, including: a pre-stage circuit, configured to receive an input voltage and convert the input voltage to a bus voltage; and plurality of post-stage circuits, connected in parallel to an output terminal of the pre-stage circuit, and configured to receive the bus voltage from the pre-stage circuit and each converts the bus voltage to an output voltage. The power converter provided by the present disclosure can effectively solve the problems of isolation and the wide range of operating voltage, and can take both of high efficiency and high power density into consideration.