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Switching DC-to-DC converter utilizing a soft switching technique

  • US 6,304,460 B1
  • Filed: 05/05/2000
  • Issued: 10/16/2001
  • Est. Priority Date: 05/05/2000
  • Status: Expired due to Fees
First Claim
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1. A switching DC-to-DC converter for providing power from a DC voltage source connected between an input terminal and a common input terminal to a DC load connected between an output terminal and a common output terminal, said converter comprising:

  • an input inductor winding, a middle inductor winding, and an output inductor winding, placed on a common magnetic core to form an effective DC Transformer, and each winding having one dot-marked end and another unmarked end whereby any AC voltage applied to said middle inductor winding induces AC voltages in said input and output inductor windings so that all three AC voltages are in phase at dot-marked ends of said input, output and middle inductor windings;

    said input inductor winding connected at a dot-marked end thereof to said input terminal to form an input winding of a DC Transformer;

    said output inductor winding connected at a dot-marked end thereof to said output terminal to form an output winding of said DC Transformer;

    said middle inductor winding connected at a dot-marked end thereof to said common input terminal and said common output terminal to enable said DC Transformer operation;

    an input capacitor, having one end connected to an unmarked end of said input inductor winding and another end of said input capacitor connected to an unmarked end of said middle inductor winding;

    an input switch with one end connected to said common input terminal and another end connected to said unmarked end of said input inductor;

    an output switch with one end connected to said common output terminal and another end connected to an unmarked end of said output inductor winding;

    a complementary output switch, having one end connected to said unmarked end of said output inductor winding and another end of said complementary output switch connected to said unmarked end of said middle inductor winding;

    a branch comprised of a complementary input switch and an auxiliary capacitor connected in series;

    switching means for keeping both said input switch and said output switch closed for a duration of time interval DTS and, keeping both said complementary input switch and said complementary output switch closed for a duration of complementary time interval D′

    TS=(1−

    D)TS, where D is a duty ratio and D′

    is a complementary duty ratio within one complete and controlled switch operating cycle TS;

    means for connecting the ends of said branch to said converter whereby during said complementary time interval, current through said branch is equal to the sum of input inductor current flowing into said dot-marked end of said input inductor winding and middle inductor current flowing into said dot-marked end of said middle inductor winding reduced by output inductor current flowing out of said dot-marked end of said output inductor winding;

    wherein said input switch, said complementary input switch, and said complementary output switch are semiconductor current bidirectional switching devices, capable of conducting the current in both directions while in an ON state, and sustaining voltage in one direction while in an OFF state;

    wherein said output switch is a semiconductor voltage bidirectional switching device, capable of conducting the current while in an ON state, and sustaining voltage in both directions, while in an OFF state;

    wherein said switching devices turn ON and OFF at high switching frequency;

    wherein a DC-to-DC voltage conversion ratio of said converter depends linearly on said operating duty ratio D;

    wherein at any duty ratio D, both said input inductor DC current and said middle inductor DC current flow into said dot-marked ends of their respective windings, whereas said output inductor DC current flows out of said dot-marked end of said output inductor winding;

    wherein at any duty ratio D, the sum of said DC currents of said input inductor and said middle inductor is equal to the magnitude of said DC current of said output inductor;

    wherein said DC Transformer includes an equal number of turns for said input, output, and middle inductors and, at any operating duty ratio D, DC ampere-turns of said input inductor current and said middle inductor current are positive and generate positive DC fluxes which add together, while DC ampere-turns of said output inductor current are negative and generate negative DC flux to result in net zero DC flux in said common magnetic core, and wherein said common magnetic core has no air-gap;

    whereby said net zero DC flux in said common magnetic core enables full utilization of the magnetic core material to generate maximum inductances of said input, middle, and output inductors and said converter has current overload capability several times higher than nominal load current, and whereby said DC Transformer combines said input inductor winding, said output inductor winding, and said middle inductor winding to obtain unique and effective DC-to-DC power transfer from said input inductor to said output inductor with substantially reduced energy storage within said common magnetic core of said DC Transformer, thereby reducing size and weight of said converter by reducing said common magnetic core size and weight while simultaneously increasing efficiency and overload capability of said converter, and providing reduction of electromagnetic interference.

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