VEHICLE INVERTER FOR POWERING CONSUMER ELECTRONIC DEVICES

• US 20100259098A1
• Filed: 04/08/2009
• Published: 10/14/2010
• Est. Priority Date: 04/08/2009
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Hampo, Richard, Huang, Fengtai
• Granted Patent: US 8,085,565 B2
• Time in Patent Office: Days
• US Class Current: 307/9.100
• CPC Class Codes: H02M 1/007 Plural converter units in cascade push-pull DC/DC converters with pre-regulator H02M3/3374; DC-AC converters following a DC-DC stage including a high frequency transformer H02M7/4807; DC-AC converters following a DC-DC conversion stage generating periodically varying voltages H02M7/4826
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 3/33507 with automatic control of the output voltage or current, e.g. flyback converters H02M3/33561, H02M3/33569 take precedence
• CPC Class Codes: H02M 7/483 Converters with outputs that each can have more than two voltages levels

Abstract

An inverter for inverter DC power, such as but not limited to the type commonly employed in vehicle power systems, in to AC power, such as but not limited to the type commonly employed to power consumer electronic devices. The inverter may be configured to electrically isolate primary and secondary stages without requiring separate primary and secondary stage power supplies.

Claims

1. An inverter for use in a vehicle having a DC power supply, the inverter comprising:

a primary stage having switching devices operable in response to primary stage control signals to boost a first DC output of the DC power supply to a second DC output;

a secondary stage having switching devices operable in response to secondary stage control signals to invert the second DC output into an AC output;

a primary stage controller configured to output the primary stage control signals used to control the switching devices of the primary stage to boost the first DC output to the second DC output;

a secondary stage controller configured to output a frequency modulated signals representative of the secondary stage control signals needed to control the switching devices of the secondary stage to invert the second DC output into the AC output;

a signal converter configured to convert the frequency modulated signals into the secondary stage controls signals used to control the switching devices of the secondary stage to invert the second DC output into the AC output; and

a regulator configured to power both of the primary and secondary stages using the first DC output of the DC power supply.

2. The inverter of claim 1 wherein the regulator is configured to regulate the first DC output to a first stage DC output for powering the primary controller and a second stage DC output for powering the secondary stage controller.

3. The inverter of claim 1 wherein the signal converter includes a transformer, a rectifier and a filter.

4. The inverter of claim 3 wherein the filter includes a high pass filter (HPF) and a low pass filter (LPF), each of the LPF and the HPF respectively being configured to selective activate one or more of the switching devices responsive to the frequency modulated signals having a first or second frequency.

5. The inverter of claim 4 wherein the secondary stage controller is further configured to selectively control output of the first and second frequency depending on desired characteristics of the AC output.

6. The inverter of claim 5 wherein the secondary stage controller is further configured to output a third frequency to selectively deactivate the switching devices of the secondary stage in order to prevent output of the AC output.

7. The inverter of claim 4 wherein the first frequency is approximately 50 kHz, the second frequency is approximately 150 kHz, and the third frequency is approximately 100 kHz.

8. The inverter of claim 3 wherein the signal converter is electrically connected between the secondary stage controller and the switching devices of the secondary stage, the transformer thereby electrically isolating the secondary stage switching devices from the primary and secondary stage controllers.

9. The inverter of claim 1 wherein the primary stage includes a push-pull-converter, a rectifier, and switch, the switch being operable between a center tapped position in which the rectifier acts as a center tapped rectifier and a non-center tapped position in which the rectifier acts as a bridge rectifier.

10. The inverter of claim 1 wherein the primary stage includes a rectifier having four diodes and a switch, wherein the diodes are arranged in a bridge configuration and the switch is operable between a center tapped position and a non-center tapped position, the center tapped positioning corresponding with the anode of two of the diodes being in a floating state and the non-center tapped position corresponding with the anode of the two of the diodes being connected to reference ground of the H bridge.

11. The inverter of claim 1 wherein the primary stage includes a rectifier having a plurality of diodes and a switch, wherein the plurality of diodes are arranged in a bridge configuration and the switch is operable between a center tapped position and a non-center tapped position, the center tapped positioning corresponding with the anode of at least a first portion of the diodes being in a floating state and the non-center tapped position corresponding with the anode of at least the first portion of the diodes being connected to an end of the transformer.

12. An inverter for use in a vehicle having a DC power supply, the inverter comprising:

a primary stage having switching devices operable in response to primary stage control signals to boost a first DC output of the DC power supply to a second DC output;

a secondary stage having switching devices operable in response to secondary stage control signals to invert the second DC output into an AC output;

a primary stage controller configured to output the primary stage control signals;

a secondary stage controller configured to output a frequency modulated signals representative of the secondary stage control signals at a frequency of more than 200 Hz; and

a signal converter configured to convert the frequency modulated signals into the secondary stage controls signals, the signal converter being further configured to output the secondary stage controls signals at a frequency of less than 200 Hz.

13. The inverter of claim 12 further comprising a regulator configured to regulate the first DC output to a control output for directly powering both of the primary and secondary stage controllers.

14. The inverter of claim 13 wherein the signal converter is connected between the secondary stage controller and the switching devices of the secondary stage and includes a transformer to electrically isolate the switching devices of the secondary stage from the secondary stage controller.

15. The inverter of claim 12 wherein the primary stage includes a push-pull-converter, a rectifier, and switch, the switch being operable between a center tapped position in which the rectifier acts as a center tapped rectifier and a non-center tapped position in which the rectifier acts as a bridge rectifier.

16. An inverter for use in a vehicle having a DC power supply, the inverter comprising:

a primary stage having switching devices selectably operable between active and inactive states to boost a first DC output of the DC power supply to a second DC output;

a secondary stage having switching devices selectably operable between active and inactive states to invert the second DC output into an AC output;

a primary stage controller configured to output primary stage control signals used to selectably operate the switching devices between the active and inactive states required to boost the first DC output of the DC power supply to the second DC output;

a secondary stage controller configured to output a frequency modulated signal representative of secondary stage control signals needed to selectably operate the switching devices between the active and inactive states required to invert the second DC output into the AC output;

wherein the secondary stage controller switches an output frequency of the frequency modulated signal between a first frequency, a second frequency, and a third frequency to shape the AC output, the first frequency being output during a positive portion of the AC output, the second frequency being output during a negative portion of the AC output, and the third frequency being output during a zero crossings between the positive and negative cycles; and

a signal converter configured to receive the frequency modulated signals and to passively converter the frequency modulated signal into the secondary stage control signals used to selectively activate and deactivate each one of the switching devices of the secondary stage as a function of whether the frequency modulated signal is at the first, second, and third frequency.

17. The inverter of claim 16 further comprising a regulator configured to regulate the first DC output to a control output suitable for powering both of the primary and secondary stage controllers.

18. The inverter of claim 17 wherein the signal converter is connected between the secondary stage controller and the switching devices of the secondary stage and includes a transformer to electrically isolate the switching devices of the secondary stage from the secondary stage controller.

19. The inverter of claim 16 wherein the primary stage includes a push-pull-converter, a rectifier, and switch, the switch being operable between a center tapped position in which the rectifier acts as a center tapped rectifier and a non-center tapped position in which the rectifier acts as a bridge rectifier.

20. The inverter of claim 16 wherein the frequency modulated signal is greater than 200 Hz and the secondary stage control signals are less than 200 Hz.