Reconfigurable thin-profile switched-mode power conversion array and method of operating the same

• US 5,682,303 A
• Filed: 05/28/1996
• Issued: 10/28/1997
• Est. Priority Date: 12/08/1993
• Status: Expired due to Term

• Current Assignee: Murata Power Solutions Incorporated (Murata Manufacturing Co Limited)
• Original Assignee: International Power Systems, Inc
• Inventors: Goad, Stephen D.
• Primary Examiner(s): Berhane, Adolf
• Application Number:
  US08/654,135
• Time in Patent Office: 518 Days
• Field of Search: 363/71.4, 363/16.65, 363/17.39, 363/20-26, 363/131-134, 363/143, 307/82, 323/271, 323/272
• US Class Current: 363/71
• CPC Class Codes: H02J 1/102 being switching converters H02J1/108, H02J1/12 take precedence
• CPC Class Codes: H02M 3/285 Single converters with a plurality of output stages connected in parallel parallel operation of a plurality of converters in dc distribution networks H02J1/10

Abstract

A high-power, switched-mode power conversion array having an input capacitance, an output capacitance, and a multiple, reconfigurable converter cells. Each of the converter cells convert an input voltage to an output voltage using switched-mode power conversion. The converter cells operate at a conversion frequency and are phase-shifted across one conversion period, so that each converter is switched ON in a time-overlapping relationship with at least one other one of the plurality of converters. As a result, the input and output current and the voltage ripple are substantially reduced, the ripple frequency of the array is increased, and the power capacity is increased. The converter cells can have a selectable conversion frequency, and thus, a selectable period. The apparatus also can include a programmable interconnection network selectably and reconfigurably connecting each cell to at least one other cell, an input node, or an output node, using serial or parallel connections. The programmable interconnection network can consist of an interconnection switch array, that include programmable elements. Selected programmable elements are connected with respective ones of the plurality of converter cells. The array can be dynamically-adaptive and be reconfigured to adapt to the preselected criterion on-the-fly. The array can also be a thin-profile array having an array aspect ratio of greater than 30.

Claims

1. A power conversion array comprising:

a. an input capacitance;

b. an output capacitance;

c. a plurality of converter cells, N in number, each having an input coupled in parallel to the input capacitance and output coupled in parallel to the output capacitance, each of the converter cells for converting an input voltage to an output voltage using switched-mode power conversion, each of said plurality of converter cells operating at an operating frequency having a time period of T, and being phase shifted from each other by a time increment T/N so that each cell is switched on in a time-overlapping relationship with at least one other of the plurality of converter cells, the plurality of converter cells being arranged to provide a thin profile configuration having an aspect ratio of at least 30, wherein each of the plurality of converter cells is switched ON for a time period of T_on ; and

d. an array controller and a clock, the clock generating a clock signal at the frequency of operation of the plurality of converter cells, the clock being coupled to the array controller, the controller providing a regulated control pulse to a delay circuit for generating a plurality of sequentially-delayed switching pulses and coupled to each of the converter cells to sequentially switch the converters with the switching pulses,

whereby input and output current and voltage ripple is substantially reduced, ripple frequency of the array is increased, power capacity is increased, and heat dissipation is substantially increased.

2. A power conversion array comprising:

a. an input capacitance;

b. an output capacitance;

c. a plurality of converter cells each having an input coupled in parallel to the input capacitance and an output coupled in parallel to the output capacitance, each of the converter cells for converting an input voltage to an output voltage using switched-mode power conversion, the plurality of converters operating at a conversion frequency and being phase-shifted across one conversion period so that each converter cell is switched on in a time-overlapping relationship with at least one other of the plurality of converter cells, the plurality of converter cells being arranged in a thin-profile configuration having an aspect ratio of at least 30; and

d. an array controller and a clock, the clock generating a clock signal at the frequency of operation of the plurality of converter cells, the clock being coupled to the array controller, the controller providing a regulated control pulse to a delay circuit for generating a plurality of sequentially-delayed switching pulses and coupled to each of the converter cells to sequentially switch the converters with the switching pulses,

whereby input and output current and voltage ripple is substantially reduced, ripple frequency of the array is increased, power capacity is increased, and heat dissipation is substantially increased.

3. The power conversion array of claim 2 wherein the delay circuit comprises a plurality of delay line modules coupled together in series, each delay line module providing a delayed trigger to initiate a next one of the delay line modules, each delay line module in turn generating a plurality of delayed trigger signals, the delay line modules being coupled to selected ones of the plurality of converter cells to provide the phase-delayed switched-mode operation of the converter cells.

4. The power conversion array of claim 3 wherein the delay line module comprises a multiple-tap delay line circuit and the delay circuit comprises a corresponding plurality of multiple line drivers, each driver being coupled to a corresponding multiple of the converter cells to drive the converter cells ON and OFF in response to the delayed trigger provided to the delay circuit.

5. The power conversion array of claim 2 wherein the regulated control pulse generated by the control circuit is a pulse-width-modulated signal.

6. A method of providing switched-mode power conversion between an input capacitance and output capacitance comprising the steps of:

a. providing an input power waveform;

b. sequentially coupling the input power waveform through N switched-mode converter cells coupled in parallel between the input and the output capacitances, the cells being arranged in a thin-profile configuration having an aspect ratio of about 30;

c. generating a plurality of switching signals through a cascaded delay, and sequentially switching each one of the plurality of switched-mode converter cells with a corresponding sequence of the switching signals, the input power waveform being switched with an operating frequency having a time interval period T and being sequentially coupled through each of the N switched mode converter cells by the resulting predetermined phase shifts of operation of each converter cell within the period at intervals of T/N in an at least partially time overlapping relationship; and

d. providing an output power waveform from the plurality of converter cells at the output capacitance coupled in parallel with the outputs of the plurality of converter cells,

whereby high power operation at high frequency is obtained with substantially increased heat dissipation and without frequency, size, and temperature limitations.

7. A method of providing switched-mode power conversion between an input capacitance and output capacitance, comprising the steps of:

a. providing an input power waveform;

b. sequentially coupling input power waveform through N switched-mode converter cells coupled in parallel between the input and output capacitances, the cells being arranged to in a thin-profile configuration having an aspect ratio of about 30;

c. generating a plurality of switching signals through a cascaded delay, and sequentially switching each one of the plurality of switched-mode converter cells with a corresponding sequence of the switching signals, the input power waveform being switched with an operating frequency having a period and being sequentially coupled in the same sequence to the output capacitance in response to the corresponding sequence of the switching signals through each of the plurality of switched-mode converter cells by the resulting predetermined phase shifts of operation of each converter within the period in an at least partially time-overlapping relationship; and

d. providing an output power waveform at the output capacitance coupled in parallel with the outputs of the plurality of converter cells,

whereby high power operation at high frequency is obtained with substantially increased heat dissipation and without frequency, size and temperature limitations.

8. A power conversion array, comprising;

a. a plurality of array input nodes having an input capacitance;

b. a plurality of array input nodes having an output capacitance; and

c. a plurality of converter cells, N in number, each cell having an input coupled to the input capacitance and an output coupled to the output capacitance, the plurality of converter cells for converting an input voltage to an output voltage using switched-mode power conversion, each of the plurality of converter cells operating at an operating frequency having a period of T, and being phase-shifted from each other by a time increment T/N so that each converter is switched ON in a time-overlapping relationship with a least one other of the plurality of converter cells being reconfigurably connected between a respective one of an array input node and an output of others of the power converter cells, the output of the ones being reconfigurably connected between a respective one of an array output node and an input of the others of the power converter cells,

whereby input and output current and voltage ripple is substantially reduced, ripple frequency of the array increased, and power capacity increased.

9. The power conversion array of claim 8 wherein each of the plurality of converter cells is switched ON for a time period of T_on.

10. A power conversion array, comprising:

a. a plurality of array input nodes having an input capacitance;

b. a plurality of array output nodes having an output capacitance;

c. a plurality of converter cells each having an input coupled to the input capacitance and an output coupled to the output capacitance, each of the converter cells for converting an input voltage to an output voltage using switched-mode power conversion, the plurality of converter cells operating at a conversion frequency and being selectably phase-shifted across one period of the conversion frequency so that each converter cell is switched on in a time-overlapping relationship with at least one other of the plurality of converters;

d. an array controller and a clock, the clock generating a clock signal at a frequency of operation of each of the plurality of converter cells, the clock circuit being coupled to the control circuit, the control circuit providing a regulated control pulse to a delay circuit for generating a plurality of sequentially-delayed switching pulses and coupled to each of the converter cells to sequentially switch the converter cells with the switching pulses; and

e. a programmable interconnection network, the network selectably connecting each of the plurality of converter cells to one of an adjacent neighboring cells and an array input node and an array output node, the network reconfigurably connecting each cell in one of a serial connection, a parallel connection, and a disconnection, in relation to the respective one of the neighboring cell and the array input node and the array output node,

whereby input and output current and voltage ripple is substantially reduced, the conversion array architecture is reconfigurable, ripple frequency of the array increased, and power capacity increased.

11. The power conversion array of claim 10 wherein the delay circuit comprises a plurality of delay line modules coupled together in series, each delay line module providing a delayed trigger to initiate a next one of the delay line modules, each delay line module in turn generating a plurality of delayed trigger signals, the delay line modules being coupled to selected ones of the plurality of converter cells to provide the phase-delayed switched-mode operation of the converter cells.

12. The power conversion array of claim 11 wherein the delay line module comprises a multiple-tap delay line circuit and the delay circuit comprises a corresponding plurality of multiple line drivers, each driver being coupled to a corresponding multiple of the converter cells to drive the converters ON and OFF in response to the delayed trigger provided to the delay circuit.

13. The power conversion array of claim 10 wherein the regulated control pulse generated by the control circuit is a pulse-width-modulated signal.

14. A method of providing switched mode power conversion between an input capacitance and output capacitance, comprising the steps of;

a. providing an input power waveform;

b. sequentially coupling the input power waveform through N switched-mode converter cells, the cells being reconfigurably coupled between the input and output capacitances;

c. generating a plurality of switching signals through a cascaded delay, and sequentially switching each one of the plurality of switched-mode converters with a corresponding sequence of the switching signals, the input power waveform being switched with an operating frequency having a time interval period T and being sequentially coupled through each of the N switched mode converter cells by the resulting predetermined phase shifts of operation of each converter within said period at intervals of T/N in an at least partially time-overlapping relationship;

d. providing an output power waveform having an output power profile at the output capacitance, the output capacitance being coupled with the outputs of the plurality of converter cells; and

e. reconfiguring the converter cells from a first preselected circuit topology to a second preselected circuit topology, responsive to a preselected output power profile, whereby high power operation at high frequency is obtained according to the preselected output power profile without frequency, size, and temperature limitations.

15. A method of providing switched mode power conversion between an input capacitance and output capacitance, comprising the steps of:

a. providing an input power waveform;

b. sequentially coupling the input power waveform through N switched-mode converter cells, the cells being reconfigurably coupled between the input and output capacitances;

c. generating a plurality of switching signals through a cascaded delay, and sequentially switching each one of the plurality of switched-mode converter cells with a corresponding sequence of the switching signals, the input power waveform being switched with an operating frequency having a period and being sequentially coupled in the same sequence to the output capacitance in response to the corresponding sequence of the switching signals through each of the plurality of switched-mode converter cells by the resulting predetermined phase shifts of operation of each converter within the period in an at least partially time-overlapping relationship;

d. providing an output power waveform having an output power profile at the output capacitance coupled with the outputs of the plurality of converter cells; and

e. reconfiguring the converter cells from a first preselected circuit topology to a second preselected circuit topology, responsive to a preselected output power profile, whereby high power operation at high frequency is obtained according to the preselected output power profile without frequency, size, and temperature limitations.