Sub-resonant series resonant converter having improved form factor and reduced EMI

• US 5,768,112 A
• Filed: 05/30/1997
• Issued: 06/16/1998
• Est. Priority Date: 05/30/1997
• Status: Expired due to Term

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delco Electronics Corporation (Motors Liquidation Co. GUC Trust)
• Inventors: Barrett, Alfred Henry
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): Han, Y. J.
• Application Number:
  US08/866,794
• Time in Patent Office: 382 Days
• Field of Search: 363/16, 363/17, 363/98, 363/132, 363/95, 363/97, 363/131
• US Class Current: 363/16
• CPC Class Codes: H02M 1/0064 Magnetic structures combining different functions, e.g. storage, filtering or transformation
• CPC Class Codes: H02M 1/4241 using a resonant converter
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/28 using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
• CPC Class Codes: H02M 3/33573 Full-bridge at primary 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
• CPC Class Codes: Y02P 80/10 Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier

Abstract

An improved sub-resonant converter which retains the advantages generally associated with simple series resonant converters while additionally providing improved form factor and efficiency, and reducing EMI. The overall tank circuit includes at least a first inductor and first capacitor connected in series, a second capacitor connected in parallel with the load circuit, and a second inductor connected in parallel with the second capacitor for providing voltage boost capability. In addition to reducing dv/dt in the load circuit, the second capacitor draws a current that has the effect of reducing the form factor of the supplied current while shortening the negative portion of its cycle so that reverse current through the anti-parallel diode of one switching device is terminated, or nearly so, by the turn on of the next switching device, thereby reducing EMI associated with a rapid initial rise in current at such turn on. In a preferred embodiment, the tank circuit also includes a third inductor connected in parallel with the first capacitor to narrow the switching frequency range, thereby extending the above-described form factor and EMI improvements over the entire load range of the converter. In addition, the tank circuit is preferably coupled to the load circuit via an isolation transformer.

Claims

1. A resonant converter for supplying current to a load circuit from a uni-polar source, including a resonant tank circuit coupled to said load circuit and comprising resonant tank elements defining a dominant resonant frequency of said tank circuit, and a bridge inverter circuit including alternately activated switching devices for supplying current from the source to the tank circuit, the improvement wherein:

the switching devices of the bridge inverter circuit are activated at a switching frequency below said dominant resonant frequency of said tank circuit so that the current in said tank circuit includes a positive interval during which current is supplied to the tank circuit through an activated switching device followed by a negative interval during which the current in the tank circuit reverses through an anti-parallel diode shunting said activated switching device; and

said resonant tank elements include a tank inductor and tank capacitor connected in series, an additional capacitor connected in series with said tank capacitor and tank inductor, a boost inductor connected in parallel with said additional capacitor, the load also being connected in parallel with said additional capacitor, said additional capacitor operating to reduce the form factor of the current in said tank circuit while shortening said negative interval of such current so that the tank circuit current flowing in an anti-parallel diode shunting a given switching device is terminated, or nearly so, when the other switching device is activated.

2. The resonant converter of claim 1, including:

an isolation transformer having a primary winding connected in parallel with said boost inductor and a secondary winding connected in parallel with said additional capacitor.

3. The resonant converter of claim 1, wherein the switching frequency of said switching devices is limited to a maximum value, and said boost inductor and additional capacitor form a load zero having a resonant frequency of about twice said maximum value.

4. The resonant converter of claim 1, wherein said resonant tank elements include an additional inductor connected in parallel with said tank capacitor, said additional inductor and tank capacitor defining a resonant zero at a frequency below said dominant resonant frequency, thereby defining a minimum switching frequency for said bridge inverter circuit.

5. The resonant converter of claim 1, wherein said load circuit includes a storage battery and a full-wave bridge rectifier for supplying DC current to said storage battery.

6. The resonant converter of claim 1, wherein said uni-polar source comprises a source of alternating current and a full-wave bridge rectifier.

7. A resonant converter for supplying current to a load circuit from a uni-polar source, including a resonant tank circuit coupled to said load circuit and comprising resonant tank elements defining a dominant resonant frequency of said tank circuit, and a bridge inverter circuit including alternately activated switching devices for supplying current from the source to the tank circuit, the improvement wherein:

the switching devices of the bridge inverter circuit are activated at a switching frequency below said dominant resonant frequency of said tank circuit so that the current in said tank circuit includes a positive interval during which current is supplied to the tank circuit through an activated switching device followed by a negative interval during which the current in the tank circuit reverses through an anti-parallel diode shunting said activated switching device; and

said resonant tank elements include a tank inductor and tank capacitor connected in series, a second capacitor and second inductor connected in parallel with each other and in series with said tank inductor and tank capacitor, the load being connected in parallel with said second capacitor and second inductor, said second capacitor operating to reduce the form factor of the current in said tank circuit while shortening said negative interval of such current so that the tank circuit current flowing in an anti-parallel diode shunting a given switching device is terminated, or nearly so, when the other switching device is activated.

8. The resonant converter set forth in claim 7, wherein said resonant tank elements include a third inductor connected in parallel with said tank capacitor, said third inductor and tank capacitor defining a resonant zero at a frequency below said dominant resonant frequency, thereby defining a minimum switching frequency for said bridge inverter circuit.

9. The resonant converter of claim 8, wherein the switching frequency is permitted to vary between said minimum switching frequency and a maximum switching frequency which is higher than said minimum switching frequency but lower than said dominant resonant frequency of said tank circuit.

10. The resonant converter of claim 7, wherein the switching frequency of said switching devices is limited to a maximum value, and said second inductor and second capacitor form a load zero having a resonant frequency of about twice said maximum value.