Universal AC adaptor

• US 8,462,527 B1
• Filed: 05/06/2011
• Issued: 06/11/2013
• Est. Priority Date: 02/24/2004
• Status: Active Grant

• Current Assignee: Vicor Corporation
• Original Assignee: VLT Incorporated (Vicor Corporation)
• Inventors: Vinciarelli, Patrizio
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US13/102,605
• Time in Patent Office: 767 Days
• Field of Search: 363/65, 363 67- 70, 363/84, 363/89, 363/125, 363/127, 323/265, 323/282, 307/82, 307/83, 307 85- 87, 307/113, 307/116, 307/125, 307/126, 307/130, 307/131
• US Class Current: 363/125
• CPC Class Codes: H02M 1/0074 Plural converter units whose inputs are connected in series
• CPC Class Codes: H02M 1/0077 Plural converter units whose outputs are connected in series
• CPC Class Codes: H02M 1/0096 Means for increasing hold-up time, i.e. the duration of time that a converter's output will remain within regulated limits following a loss of input power
• CPC Class Codes: H02M 1/14 Arrangements for reducing ripples from dc input or output
• CPC Class Codes: H02M 1/32 Means for protecting converters other than automatic disconnection
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/157 with digital control
• CPC Class Codes: H02M 3/1584 with a plurality of power processing stages connected in parallel
• CPC Class Codes: H02M 3/33571 Half-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/33573 Full-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 7/00 Conversion of ac power input into dc power output; Conversion of dc power input into ac power output

Abstract

Power from an AC source at a source voltage is converted for delivery to a load at a DC load voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range. DC-DC voltage transformation and isolation are provided in a first power conversion stage, the first stage having a CA input for receiving power from the source and a CA output for delivering a galvanically isolated unregulated AC adapter module (UAAM) voltage. First stage circuitry for performing the first power conversion stage is provided in a self-contained adapter module having input terminals for connection to the AC source and an output connected to the CA output for providing power to a second power conversion stage wherein the second power conversion stage is external to the adapter module.

Claims

1. A method of converting power from an AC source at a source voltage for delivery to a load at a DC load voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, comprising:

providing DC-DC voltage transformation and isolation in a first power conversion stage, the first stage having a CA input for receiving power from the source and a CA output for delivering a galvanically isolated unregulated AC adapter module (UAAM) voltage, wherein the providing DC-DC voltage transformation and isolation further comprises providing an integrated adaptive converter array having a first input cell and a second input cell, each input cell having a respective number, Px, of turns, an output cell having a respective number, Sx, of turns, magnetic coupling between the turns to form a transformer common to the first and second input cells and the output cell;

configuring the input cells in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage; and

providing first stage circuitry for performing the first power conversion stage in a self-contained adapter module having input terminals for connection to the AC source and an output connected to the CA output for providing power to a second power conversion stage wherein the second power conversion stage is external to the adapter module.

2. The method of claim 1 further comprising connecting the output of the self contained adapter module to a device comprising second stage circuitry for performing the second stage power conversion.

3. The method of claim 1 further comprising rectifying the AC source and providing the rectified AC source to the CA input.

4. The method of claim 1 further comprising providing filtering of the galvanically isolated UAAM voltage.

5. The method of claim 1 further comprising:

providing an electronic device including the second power conversion stage;

providing a connector electrically connected to an input of the second power conversion stage;

wherein the connector is adapted to mate with the output of the self-contained adapter module.

6. A method of converting power from an AC source at a source voltage for delivery to a load at a DC load voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, comprising:

providing DC-DC voltage transformation and isolation in a first power conversion stage, the first stage having a CA input for receiving power from the source and a CA output for delivering a galvanically isolated unregulated AC adapter module (UAAM) voltage; and

providing first stage circuitry for performing the first power conversion stage in a self-contained adapter module having input terminals for connection to the AC source and an output connected to the CA output for providing power to a second power conversion stage wherein the second power conversion stage is external to the adapter module;

wherein the providing DC-DC voltage transformation and isolation further comprises;

providing an array of two or more VTMs, each VTM having an input, an output, and a substantially fixed voltage transformation ratio, K=Vout/Vin, over the normal operating range, where Vin is the voltage across the respective VTM input and Vout is the voltage across the respective VTM output, and providing isolation between its input and its output; and

configuring the inputs of the VTMs in a parallel connection for operation at the low line voltage and in a series connection for operation at the high line voltage.

7. The method of claim 6 further comprising connecting the output of the self contained adapter module to a device comprising second stage circuitry for performing the second stage power conversion.

8. The method of claim 6 further comprising rectifying the AC source and providing the rectified AC source to the CA input.

9. The method of claim 6 further comprising providing filtering of the galvanically isolated UAAM voltage.

10. The method of claim 6 further comprising:

providing an electronic device including the second power conversion stage; and

providing a connector electrically connected to an input of the second power conversion stage;

wherein the connector is adapted to mate with the output of the self-contained adapter module.

11. An apparatus comprising:

an AC adapter module for converting power from an AC source at a source voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, and delivering rectified power to circuitry downstream from the AC adapter module, the AC source having a characteristic line frequency and characteristic line period;

the AC adapter module having an input for receiving power from the AC source, a first power conversion stage, and an output for delivering the rectified power to the downstream circuitry;

the first power conversion stage including (a) a transformer having at least one primary and at least one secondary winding, (b) a primary switching circuit connected to drive the at least one primary winding with power received from the input, (c) a secondary rectifier circuit connected to receive power from the at least one secondary and deliver rectified power to the output, and (d) a controller for operating the primary switching circuit in a series of converter operating cycles having a converter operating period that is much shorter that the characteristic line period;

the first power conversion stage being configured to convert power at a substantially fixed voltage-transformation ratio, K=Vout/Vin, over the normal operating range, where Vin is the voltage across the input and Vout is the voltage across the output, and provide galvanic isolation between its input and its output;

the AC adapter providing step-down voltage transformation essentially without voltage regulation and delivering power having voltage characteristics that are rectified and un-regulated at the output.

12. The apparatus of claim 11 wherein the AC adapter module further comprises:

a rectification circuit connected between the input and the first power conversion stage;

wherein the first power conversion stage receives power from the input through the rectification circuit.

13. The apparatus of claim 12 wherein the AC adapter module further comprises an enclosure for housing the first power conversion stage and the rectification circuit, the enclosure including input terminals for connecting the input to the AC Source and output terminals for connecting the output to electronic circuitry external to the enclosure.

14. The apparatus of claim 13 wherein the first power conversion stage comprises two or more input cells connected in series, each input cell having a respective primary switching circuit and a respective primary winding coupled to the transformer, and wherein the voltage across the input is divided between the input cells.

15. The apparatus of claim 14 wherein the first power conversion stage is adapted to switch the voltage transformation ratio between a first value and a second value.

16. The apparatus of claim 13 wherein the enclosure is formed into an AC wall-plug module and the input terminals are prongs adapted for insertion into an AC outlet.

17. The apparatus of claim 16 wherein the output terminals comprise an output connector adapted to mate with an electronic device and wherein the AC wall-plug module further comprises a low voltage power cord connected to carry the rectified and un-regulated power from the AC Adapter module to the output connector.

18. The apparatus of claim 11 further comprising an electronic device external to the AC adapter module having a connector adapted to mate with the output of the AC adapter module, the electronic device including a second power conversion stage having an input electrically connected to receive power from the output of the AC adapter module via the connector.

19. The apparatus of claim 18 wherein the second power conversion stage provides a regulated output for supplying power to electronic circuitry in the electronic device.

20. The apparatus of claim 18 wherein the second power conversion stage is adapted to adjust an envelope of current drawn by the second power conversion stage from the AC adapter to approximate a waveform of the voltage received from the AC adapter.

21. The apparatus of claim 18 wherein the second power conversion stage is adapted to adjust an envelope of current drawn by the second power conversion stage from the AC adapter to approximate a rectified sinusoid.

22. The apparatus of claim 11 further comprising a filter connected between the first power conversion stage and the output.

23. A method of converting power from an AC source at a source voltage, where the source voltage may vary between a high line voltage and a low line voltage in a normal operating range, the AC source having a characteristic line frequency and characteristic line period, the method comprising:

providing a self-contained AC adapter having an input for receiving power from the AC source and an output for delivering power at a galvanically-isolated and unregulated voltage to circuitry external to the AC adapter;

performing a first power conversion in the AC adapter using a primary switching circuit to drive a transformer primary winding using power received from the input;

operating the primary switching circuit in a series of converter operating cycles having a converter operating period that is much shorter that the characteristic line period;

performing the first power conversion at a substantially fixed voltage-transformation ratio, K=Vout/Vin, over the normal operating range, where Vin is the voltage across the input and Vout is the voltage across the output;

using the transformer to provide galvanic isolation between its input and its output;

using a secondary rectifier circuit to rectify power from a secondary winding of the transformer and deliver unregulated power to the output.

24. The method of claim 23 further comprising:

using an input rectification circuit in the AC adapter to receive the AC source voltage from the input and deliver rectified power to the primary switching circuit.

25. The method of claim 24 further comprising:

providing an enclosure for the AC adapter, the enclosure including input terminals for connecting the input to the AC Source and output terminals for connecting the output to electronic circuitry external to the enclosure.

26. The method of claim 25 wherein the first power conversion further comprises:

using two or more input cells connected in series, each input cell having a respective primary switching circuit and a respective primary winding coupled to the transformer, and wherein the voltage across the input is divided between the input cells.

27. The method of claim 26 wherein the first power conversion further comprises:

switching the voltage transformation ratio between a first value and a second value.

28. The method of claim 23 further comprising providing an enclosure in the shape of an AC wall-plug having prongs adapted for insertion into an AC outlet to serve as the input terminals.

29. The method of claim 23 further comprising providing:

an output connector adapted to mate with an electronic device;

a low voltage power cord connected between the output and the output connector to carry the galvanically isolated un-regulated voltage from the secondary rectifier circuit to the output connector.

30. The method of claim 23 further comprising:

providing an electronic device external to the AC adapter having a connector adapted to mate with the output of the AC adapter module;

providing regulation circuitry for performing a second power conversion in the electronic device, the regulation circuitry having an input electrically connected to the connector to receive power from the output of the AC adapter module.

31. The method of claim 30 wherein the second power conversion provides a regulated output for supplying power to electronic circuitry in the electronic device.

32. The method of claim 30 wherein the second power conversion adjusts an envelope of current drawn by the second power conversion from the AC adapter to approximate a waveform of the voltage received from the AC adapter.

33. The method of claim 30 wherein the second power conversion adjusts an envelope of current drawn by the second power conversion from the AC adapter to approximate a rectified sinusoid.

34. The method of claim 23 further comprising providing filtering between the secondary rectifier circuit and the output.