DC/DC ZVS full bridge converter power supply method and apparatus

• US 6,483,724 B1
• Filed: 02/15/2002
• Issued: 11/19/2002
• Est. Priority Date: 02/15/2002
• Status: Expired due to Term

• Current Assignee: Valere Power, Inc. (Delta Electronics Incorporated)
• Original Assignee: Valere Power, Inc. (Delta Electronics Incorporated)
• Inventors: Harvey, James Edward, Marabell, Donald, Fasullo, Gregory H., Blair, Barry Olen
• Primary Examiner(s): Riley, Shawn
• Application Number:
  US10/077,426
• Time in Patent Office: 277 Days
• Field of Search: 363/17, 363/132
• US Class Current: 363/17
• CPC Class Codes: H02M 1/0051 Diode reverse recovery losses
• CPC Class Codes: H02M 1/44 Circuits or arrangements for compensating for electromagnetic interference in converters or inverters
• 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

Abstract

Disclosed is a DC/DC converter apparatus comprising a full bridge non-resonant pulse-width-modulated (PWM) switching circuit, which includes inductive device(s), clamp diodes, and an output transformer rectifier and filter circuit. Capacitive and diode elements associated with bridge switching devices operate to switch current through the switches at substantially zero voltage (ZVS). The inductor element and clamp diodes are used to reduce the primary transition shoot through current resulting from reverse recovery of the transformer secondary rectification stage while also reducing emi and semiconductor stresses.

Claims

1. An LSL (Low Switching Loss) full bridge DC/DC converter, comprising:

first and second power input means for supplying a low ripple voltage to be converted to an isolated stable voltage;

first, second, third, and fourth switching devices interconnected to form a full bridge circuit between said first and second power input means, wherein each of said first, second, third, and fourth switching devices include a control input, switched power input and output terminals, a predetermined minimum capacitance and current blocking diode effect paralleled between said switched power input and output terminals and further wherein said first and third switching devices are connected to said first power input means and said second and fourth switching devices are connected to said second power input means;

a first bridge power output terminal interconnected to said first and second switching devices;

a second bridge power output terminal interconnected to said third and fourth switching devices;

first switching input means for providing an alternating voltage constant pulse width signal to said control input of said first and third switching devices;

second switching input means for providing an alternating voltage pulse width modulated control signal to said control input of said second and fourth switching devices;

an output transformer having primary and secondary windings;

a primary clamp circuit including at least one diode and an inductance;

means connecting said primary clamp circuit and the primary winding of said output transformer in series between said first and second bridge power output terminals; and

output rectification circuitry, including at least a rectifier and an inductance, connected to said secondary winding of said output transformer.

2. Apparatus as claimed in claim 1 wherein the output rectification circuitry comprises current doubling circuitry connected to each end of said secondary winding of said output transformer and to a point intermediate first and second inductances.

3. Apparatus as claimed in claim 1 wherein said primary clamp circuit abets the LSL action in said switching devices.

4. Apparatus as claimed in claim 1 wherein said primary clamp circuit dampens the effect of reverse recovery currents in said converter that are generated by said output rectification circuitry during switching device state transitions.

5. An LSL (Low Switching Loss) full bridge DC/DC converter, comprising:

first and second power input means for supplying a low ripple voltage to be converted to a different level voltage;

a full bridge circuit, including first, second, third, and fourth semiconductor switching devices and bridge circuit power output terminals, connected between said first and second power input means;

means for supplying PWM control signals to at least one of said semiconductor switching devices and control signals of a second type to at least one other of said semiconductor switching devices;

an output transformer having primary and secondary windings;

output rectification circuitry, including at least a rectifier and an inductance, connected to said secondary winding of said output transformer; and

a primary clamp circuit including an inductance for abetting LSL switching of said switching devices and/or a diode for dampening the effect of reverse recovery currents in said converter that are generated by said output rectification circuitry during switching device state transitions.

6. A method of increasing power conversion efficiency in a full bridge DC/DC converter, including a transformer connected to an output rectification and filter stage, comprising the steps of:

applying a square wave signal to two switches of the full bridge converter;

applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

clamping reverse recovery switching currents generated by the output rectifiers.

7. A method of increasing power conversion efficiency in a full bridge DC/DC converter, including a transformer connected to an output rectification and filter stage, comprising the steps of:

applying a square wave signal to two switches of the full bridge converter;

applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

circulating reverse recovery switching currents whereby they are returned through the transformer to supply current to output loads.

8. A method of increasing power conversion efficiency in a full bridge semiconductor switched DC/DC converter, including a transformer secondary winding connected to an output rectification and filter stage and a primary winding connected to the bridge, comprising the steps of:

applying a square wave signal to two switches in opposite legs of the full bridge converter;

applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

reducing primary transition shoot through current resulting from reverse recovery of the transformer secondary rectification stage.

9. The method of claim 8 where the transition shoot current reduction is obtained via an inductor element and diode clamp circuit connected to the primary winding.

10. An LSL (Low Switching Loss) full bridge DC/DC converter, comprising:

first and second power input means for supplying a low ripple voltage to be converted to a second voltage level;

a full bridge circuit, including semiconductor switching devices and bridge circuit power output terminals, connected between said first and second power input means;

a supply of PWM control signals to at least one of said semiconductor switching devices;

a supply of constant width control signals to another of said semiconductor switching devices;

an output transformer having primary and secondary windings;

a primary clamp circuit, including an inductance and a diode for minimizing adverse effects of reverse recovery currents in said converter; and

a connection of said primary winding of said output transformer and said primary clamp circuit in series to said power output terminals of said full bridge circuit.

11. Apparatus for increasing power conversion efficiency in a full bridge DC/DC converter, including a transformer connected to an output rectification and filter stage, comprising:

switching signal supply means for applying a square wave signal to two switches of the full bridge converter;

switching signal supply means for applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

means for clamping reverse recovery switching currents generated by the output rectifiers.

12. Apparatus for increasing power conversion efficiency in a full bridge DC/DC converter, including a transformer connected to an output rectification and filter stage, comprising:

switching signal supply means for applying a square wave signal to two switches of the full bridge converter;

switching signal supply means for applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

means for circulating reverse recovery switching currents whereby they are returned through the transformer to supply current to output loads.

13. Apparatus for increasing power conversion efficiency in a full bridge semiconductor switched DC/DC converter, including a transformer secondary winding connected to an output rectification and filter stage and a primary winding connected to the bridge, comprising:

switching signal supply means for applying a square wave signal to two switches in opposite legs of the full bridge converter;

switching signal supply means for applying a pulse width modulated signal to the remaining switches of the full bridge converter; and

clamp means for reducing primary transition shoot through current resulting from reverse recovery of the transformer secondary rectification stage.