Apparatus and method for high efficiency isolated power converter

• US 20090034299A1
• Filed: 07/31/2007
• Published: 02/05/2009
• Est. Priority Date: 07/31/2007
• Status: Active Grant

• Current Assignee: Lumenis Limited (Boston Scientific Corporation)
• Original Assignee: Lumenis Limited (Boston Scientific Corporation)
• Inventors: Lev, Dubitsky
• Granted Patent: US 7,796,406 B2
• Time in Patent Office: Days
• US Class Current: 363/17
• CPC Class Codes: H02M 1/0058 by employing soft switching techniques, i.e. commutation of transistors when applied voltage is zero or when current flow is zero using an auxiliary actively switched resonant commutation circuit connected to an intermediate DC voltage or between two push-pull branches of an inverter bridge H02M7/4811; in resonant inverters H02M7/4815; in inverters operating from a resonant DC source H02M7/4826
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• 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 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

Abstract

A DC-DC converter apparatus comprising half or full bridge, two-stage resonant converter, which may include series resonant (inductor, capacitor) devices. An isolated transformer having primary and secondary winding supplies current to full-wave secondary stage-bridge through the use of primary winding resonant devices employing primary stage-bridge. The magnetizing of said devices employs zero-current, zero-voltage resonant-transition switching technology, which reduces switching losses at all switching frequencies to almost zero. The regulation of output voltage at all loads and input voltages achieved by the control of the switching frequency and the phase between signals for primary and secondary stages. The proper intermittent of the frequency and the phase allows achieving the value of efficiency up to 97%.

Claims

1. A DC-DC converter comprising:

a first stage, comprising

a first controllable bridge adapted to control conduction of current to and from a first and a second poles of said converter to a first central tap using a first and a second switching means arranged in a totem-pole arrangement between said first and said second poles, the voltage between said first and said second poles is denoted Vin;

a first and a second capacitors connected in series between said first and said second poles forming a third tap between them;

a second stage, comprising

a second controllable bridge adapted to control conduction of current to and from a third and a fourth poles of said converter to a second central tap using a third and a fourth switching means arranged in a totem-pole arrangement between said third and a said fourth poles, the voltage between said third and said fourth poles is denoted Vout;

a third and a fourth capacitors connected in series between said third and said fourth poles forming a fourth tap between them;

a resonance circuit having a first path connected between said first and said second taps and a second path connected between said third and said fourth taps, said resonance circuit comprising at least a resonance inductor and a resonance capacitor, said resonance circuit having a resonance frequency;

a control unit adapted to switch ON and OFF each of said first, second, third and fourth switching means, and to receive indication of a reference voltage and of said Vin and said Vout.

2. A method of controlling a DC-DC converter, said converter comprising a first stage comprising a first controllable bridge adapted to control conduction of current to and from a first and a second poles of said converter to a first central tap using a first and a second switching means arranged in a totem-pole arrangement between said first and said second poles, the voltage between said first and said second poles is denoted Vin;

a first and a second capacitors connected in series between said first and said second poles forming a third tap between them;

a second stage, comprising a second controllable bridge adapted to control conduction of current to and from a third and a fourth poles of said converter to a second central tap using a third and a fourth switching means arranged in a totem-pole arrangement between said third and a said fourth poles, the voltage between said third and said fourth poles is denoted Vout;

a third and a fourth capacitors connected in series between said third and said fourth poles forming a fourth tap between them;

a resonance circuit having a first path connected between said first and said second taps and a second path connected between said third and said fourth taps, said resonance circuit comprising at least a resonance inductor and a resonance capacitor, said resonance circuit having a resonance frequency; and

a control unit adapted to switch ON and OFF each of said first, second, third and fourth switching means, and to receive indication of a reference voltage and of said Vin and said Vout,

the method comprising;

providing control signals to said first, said second, said third and said fourth switching means to control the actual frequency of said converter and the phase shift between said first stage and said second stage.

3. The method of claim 2 wherein said control signals are responsive to changes in said Vin, Vout and said reference voltage.

4. The method of claim 3 wherein said control signals are responsive also to the actual load connected to said Vout terminals.

5. The method of claim 4 wherein said control signals are provided so as to maintain the phase between said first stage and said second stage within a first operational region ranging from 0.2π

to 0.5π

or within a second operational region ranging from 0.5π

to π

.

6. The method of claim 4 wherein said control signals are provided so as to maintain the frequency of said first stage and of said second stage within a first operational region ranging substantially from frequency f_min to frequency f₁ or within a second operational region ranging substantially from said frequency f₁ to frequency f₂;

wherein f_min is the frequency at which for a given load of said converter the phase is substantially. 0.2π

when control signals of said primary and said secondary stages are in-phase with said resonance circuit and the reactive portion the current through said switching means is just large enough to enable soft switching;

wherein said f₁ is the frequency at which for a given load of said converter said phase is substantially 0.5π

when control signals of said primary stage and said secondary stage are yet in-phase with said resonance circuit; and

wherein said f₂ is the maximum available frequency at which soft switching is still possible for said converter and control signals of said primary stage and said secondary stage are in phase difference of substantially π

.

7. The method of claim 6 wherein said converter is operated only in said first operational region of phase ranging from 0.2π

to 0.5π

.

8. The method of claim 7, wherein said converter is operated only in said second operational region of frequency ranging from frequency f₁ to frequency f₂ to achieve efficiency of said converter not less than 92%-94%.