Universal AC adapter

• US 20050270812A1
• Filed: 06/01/2005
• Published: 12/08/2005
• Est. Priority Date: 02/24/2004
• Status: Active Grant

• Current Assignee: Vicor Corporation
• Original Assignee: VLT Incorporated (Vicor Corporation)
• Inventors: Vinciarelli, Patrizio
• Granted Patent: US 7,548,441 B2
• Time in Patent Office: Days
• US Class Current: 363/65
• CPC Class Codes: H02M 1/0074 Plural converter units whose inputs are connected in series
• CPC Class Codes: H02M 1/0077 Plural converter units whose outputs are connected in series
• CPC Class Codes: H02M 1/0096 Means for increasing hold-up time, i.e. the duration of time that a converter's output will remain within regulated limits following a loss of input power
• CPC Class Codes: H02M 1/14 Arrangements for reducing ripples from dc input or output
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/157 with digital control
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: H02M 3/33571 Half-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/33573 Full-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 7/00 Conversion of ac power input into dc power output; Conversion of dc power input into ac power output

Abstract

A method and apparatus for adaptively configuring an array of voltage transformation modules is disclosed. The aggregate voltage transformation ratio of the adaptive array is adjusted to digitally regulate the output voltage for a wide range of input voltages. An integrated adaptive array having a plurality of input cells, a plurality of output cells, or a plurality of both is also disclosed. The input and output cells may be adaptively configured to provide an adjustable transformer turns ratio for the adaptive array or in the case of an integrated VTM, an adjustable voltage transformation ratio for the integrated VTM. A controller is used to configure the cells and provide digital regulation of the output. A converter having input cells configured as a complementary pair, which are switched out of phase, reduces common mode current and noise. Series connected input cells are used for reducing primary switch voltage ratings in a converter and enabling increased operating frequency or efficiency. An off-line auto-ranging power supply topology is disclosed. An auto-ranging converter module (“ACM”) includes 2 or more input cells magnetically coupled to an output cell providing auto-ranging, isolation, and voltage transformation. The ACM converts a rectified line voltage to a low DC bus voltage. The topology allows regulation and power factor correction to be provided at a low voltage increasing energy density and efficiency and reducing cost. A fully integrated PCM may also include a hold-up circuit, a DC input, and a power regulator with or without power factor correction. A PCM with PFC may combine the hold-up and smoothing capacitors for further increases in power density. A universal AC adapter architecture is shown using a unipolar bus to distribute power to one or a plurality of stationary or mobile electronic devices.

Claims

138. A method of converting power from an AC source at a source voltage for delivery to a load at a DC load voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, comprising:

providing DC-DC voltage transformation and isolation in a first power conversion stage, the first stage having a CA input for receiving power from the source and a CA output for delivering a galvanically isolated UAAM voltage;

providing power regulation in a second power conversion stage having a PR input for receiving power from the CA output of the first stage, regulation circuitry, and a PR output for delivering power to the load;

the regulation circuitry being adapted to maintain the load voltage within a regulation range while the PR input voltage remains within a normal operating range.

139. The method of claim 138 wherein the providing DC-DC voltage transformation and isolation further comprises providing an integrated adaptive converter array having a first input cell and a second input cell, each input cell having a respective number, P_x, of turns, an output cell having a respective number, S_x, of turns, magnetic coupling between the turns to form a transformer common to the first and second input cells and the output cell;

and further comprising;

configuring the input cells in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage.

140. The method of claim 138 wherein the providing DC-DC voltage transformation and isolation further comprises:

providing an array of two or more VTMs, each VTM having an input, an output, and a substantially fixed voltage transformation ratio, K=V_out/V_in, over the normal operating range, where V_in is the voltage across the respective VTM input and V_out is the voltage across the respective VTM output, and providing isolation between its input and its output; and

configuring the inputs of the VTMs in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage.

141. The method of claim 138, 139, or 140 further comprising providing first stage circuitry for performing the first power conversion stage in a self-contained adapter module having terminals for connecting to the AC source and the PR input and providing second stage circuitry for performing the second stage power conversion external to the adapter module.

142. The method of claim 141 wherein the load comprises an electronic device and further comprising providing the second stage circuitry in the electronic device.

143. The method of claim 138 further comprising providing a DC input for receiving power from an external DC source directly coupled to the second power conversion stage.

144. A method of converting power from an AC source for delivery to a system including a load, the method comprising:

providing an AC adapter module (“

AAM”

) having input terminals for receiving power from the source, output terminals for delivering power at an UAAM voltage, and DC-DC voltage transformation (“

VT”

) circuitry, the AAM being a self-contained assembly;

providing power regulation (“

PR”

) circuitry having an input for receiving power from the VT circuitry and an output for delivering power to the load at a regulated DC voltage, the PR circuitry providing output regulation;

the VT circuitry having an input connected to the input terminals and an output connected to the output terminals and providing voltage transformation and isolation;

providing an energy storage component connected on the output side of the AAM, the energy storage component being external to the AAM.

145. The method of claim 144 wherein the VT circuitry further comprises an integrated adaptive converter array having a first input cell and a second input cell, each input cell having a respective number, P_x, of turns, an output cell having a respective number, S_x, of turns, magnetic coupling between the turns to form a transformer common to the first and second input cells and the output cell;

and control circuitry for configuring the input cells in a parallel connection for operation at a low line voltage and in a series connection for operation at a high line voltage.

146. The method of claim 144 wherein the VT circuitry further comprises an array of two or more VTMs, each VTM having an input, an output, and a substantially fixed voltage transformation ratio, K=V_out/V_in, over the normal operating range, where V_in is the voltage across the respective VTM input and V_out is the voltage across the respective VTM output, and providing isolation between its input and its output;

and control circuitry for configuring the VTMs in a parallel connection for operation at a low line voltage and in a series connection for operation at a high line voltage.

147. The method of claim 144 wherein the energy storage comprises a battery and further comprising providing charge circuitry for charging the battery.

148. The method of claim 144 wherein the PR circuitry further comprises a buck-boost converter with PFC circuitry.

149. The method of claim 144 wherein the PR circuitry further comprises power factor correction circuitry, and the energy storage component comprises a capacitor connected to PR output.

150. The method of claim 138 wherein the load comprises a plurality of loads and the providing power regulation in a second power conversion stage comprises a plurality of second power conversion stages delivering power to a respective one of the plurality of loads.

151. The method of claim 150 wherein:

a first one of the plurality of second power conversion stages delivers a first load voltage to a first one of the plurality of loads;

a second one of the plurality of second power conversion stages delivers a second load voltage to a second one of the plurality of loads; and

the first load voltage is different from the second load voltage.

152. The method of claim 151 wherein at least one of the plurality of second power conversion stages further comprises power factor correction.

153. The method of claim 151 wherein the first one of the plurality of loads comprises a first device and a second one of the plurality of loads comprises a second device, and the first device is separate from the second device.

154. A method of converting power from an AC source at a source voltage for delivery to a load at a DC load voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, comprising:

providing DC-DC voltage transformation and isolation in a first power conversion stage, the first stage having a CA input for receiving power from the source and a CA output for delivering a galvanically isolated UAAM voltage;

providing first stage circuitry for performing the first power conversion stage in a self-contained adapter module having input terminals for connection to the AC source and an output connected to the CA output for providing power to a second power conversion stage wherein the second power conversion stage is external to the adapter module.

155. The method of claim 154 wherein the providing DC-DC voltage transformation and isolation further comprises providing an integrated adaptive converter array having a first input cell and a second input cell, each input cell having a respective number, P_x, of turns, an output cell having a respective number, S_x, of turns, magnetic coupling between the turns to form a transformer common to the first and second input cells and the output cell;

and further comprising;

configuring the input cells in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage.

156. The method of claim 154 wherein the providing DC-DC voltage transformation and isolation further comprises:

providing an array of two or more VTMs, each VTM having an input, an output, and a substantially fixed voltage transformation ratio, K=V_out/V_in, over the normal operating range, where V_in is the voltage across the respective VTM input and V_out is the voltage across the respective VTM output, and providing isolation between its input and its output; and

configuring the inputs of the VTMs in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage.

157. The method of claim 154, 155, or 156 further comprising connecting the output of the self contained adapter module to a device comprising second stage circuitry for performing the second stage power conversion.

158. The method of claim 154, 155, or 156 further comprising rectifying the AC source and providing the rectified AC source to the CA input.

159. The method of claim 153 wherein the first and second devices comprises mobile devices.

160. The method of claim 138, 139, 140, or 154 further comprising providing filtering of the galvanically isolated UAAM voltage.