Power device for delivering power to electronic devices and methods of assembling same

• US 9,729,065 B2
• Filed: 05/18/2016
• Issued: 08/08/2017
• Est. Priority Date: 02/08/2013
• Status: Active Grant

• Current Assignee: Smart Prong Technologies, Inc.
• Original Assignee: Advanced Charging Technologies LLC
• Inventors: Weaver, Jr., W. J. Jim, Freeman, Michael H., Dieter, Robert, Santee, Brian, Freeman, Mitchael C.
• Primary Examiner(s): Nguyen, Matthew
• Assistant Examiner(s): Ahmed, Yusef
• Application Number:
  US15/157,732
• Publication Number:
  US 20160380545A1
• Time in Patent Office: 447 Days
• CPC Class Codes: H01R 31/065 with built-in electric apparatus
• CPC Class Codes: H02M 1/0009 Devices or circuits for detecting current in a converter
• CPC Class Codes: H02M 1/0032 Control circuits allowing low power mode operation, e.g. in standby mode
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 1/10 Arrangements incorporating converting means for enabling loads to be operated at will from different kinds of power supplies, e.g. from ac or dc
• CPC Class Codes: H02M 1/36 Means for starting or stopping converters
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/07 using capacitors charged and discharged alternately by semiconductor devices with control electrode , e.g. charge pumps
• CPC Class Codes: H02M 3/158 including plural semiconductor devices as final control devices for a single load
• CPC Class Codes: H02M 3/335 using semiconductor devices only
• CPC Class Codes: H02M 3/33507 with automatic control of the output voltage or current, e.g. flyback converters H02M3/33561, H02M3/33569 take precedence
• CPC Class Codes: H02M 3/33592 having a synchronous rectifier circuit or a synchronous freewheeling circuit at the secondary side of an isolation transformer
• CPC Class Codes: H02M 3/337 in push-pull configuration H02M3/33576 takes precedence; with self-oscillating arrangements H02M3/3382, H02M3/3385
• CPC Class Codes: H02M 3/3374 with preregulator, e.g. current injected push-pull
• CPC Class Codes: H02M 7/217 using semiconductor devices only
• 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

An energy efficient apparatus includes a switching device, a frequency dependent reactive device, and a control element is provided. The switching device is coupled to a source of electrical power and includes a pair of transistors and is adapted to receive a control signal and to produce an alternating current power signal. The frequency of the alternating current power signal is responsive to the control signal. The frequency dependent reactive device is electrically coupled to the pair of transistors for receiving the alternating current power signal and producing an output power signal. The frequency dependent reactive device is chosen to achieve a desired voltage of the output power signal relative to the frequency of the alternating current power signal. The control element senses an actual voltage of the direct current power signal and modifies the control signal delivered to achieve the desired voltage of the direct current power signal.

Claims

1. An apparatus for delivering power to electronic devices, comprising:

a semiconductor chip;

a power delivery circuit including;

a switched capacitor device adapted to be coupled to a power source, the switched capacitor device including a input switch for receiving an input power signal from the power source, a capacitor coupled to the input switch, and a pair of output switches including a first output switch coupled to a top plate of the capacitor and a second output switch coupled to a bottom plate of the capacitor and to ground, the input switch and the pair of output switches being formed on the semiconductor chip;

a buck converter coupled to the switched capacitor device; and

a transformer coupled to the buck converter for receiving a modified power signal from the buck converter and delivering an output power signal to an electrical device;

a controller coupled to the switched capacitor device and configured to regulate the switched capacitor device as a function of a voltage level of the output power signal; and

a startup circuit including a low power regulator circuit that is connected to the power source for providing start-up power to the controller;

wherein the controller is configured to;

detect the input power signal being received from the power source;

initiate a start-up routine including detecting a current draw of the electrical device upon detecting the input power signal;

initiate a sleep mode if the current draw of the electrical device is not detected including initiating a predefined sleep period and reinitiating the start-up routing upon expiration of the predefined sleep period; and

initiate a charging routine if the current draw of the electrical device is detected, the charging routing including sensing the input voltage level and transmitting control signals to the switched capacitor device to regulate the switched capacitor device as a function of the sensed input voltage level.

2. The apparatus of claim 1, further comprising a vampire load subsystem coupled to the low power regulator circuit and configured to disable the power delivery circuit if a current level of the DC output power signal is lower than a threshold current level, and to subsequently enable the power delivery circuit when the current level of the DC output power signal is higher than the threshold current level.

3. The apparatus of claim 1, wherein the controller is configured to regulate the switched capacitor device as a function of a current level of the output power signal.

4. The apparatus of claim 3, wherein the controller is configured to regulate the buck converter to increase the current level of the output power signal.

5. The apparatus of claim 1, further comprising a communications controller coupled to the controller for transmitting signals to the controller to enable remote operation of the switched capacitor device.

6. The apparatus of claim 1, further comprising a hold capacitor coupled to the buck converter.

7. The apparatus of claim 1, further comprising a full-wave bridge rectifier circuit coupled to the input switch for receiving the input signal from the power source and delivering a rectified power signal to the switched capacitor device.

8. The apparatus of claim 1, wherein the semiconductor chip includes a substrate material including at least one of low Ohmic silicon, polysilicon, gallium nitride, gallium arsenide, silicon germanium, silicon carbide and indium phosphide.

9. An electrical circuit for providing electrical power for use in powering electronic devices, comprising:

a power delivery circuit including;

a switched capacitor device adapted to be coupled to a power source, the switched capacitor device including an input switch for receiving an input power signal from the power source, a capacitor coupled to the input switch, and a pair of output switches including a first output switch coupled to a top plate of the capacitor and a second output switch coupled to a bottom plate of the capacitor and to ground;

a buck converter coupled to the switched capacitor device; and

a transformer coupled to the buck converter for receiving a modified power signal from the buck converter and delivering an output power signal to an electrical device;

a controller coupled to the switched capacitor device and configured to regulate the switched capacitor device as a function of a voltage level of the output power signal; and

a startup circuit including a low power regulator circuit that is connected to the power source for providing start-up power to the controller;

wherein the controller is configured to;

detect the input power signal being received from the power source;

initiate a start-up routine including detecting a current draw of the electrical device upon detecting the input power signal;

initiate a sleep mode if the current draw of the electrical device is not detected including initiating a predefined sleep period and reinitiating the start-up routing upon expiration of the predefined sleep period; and

initiate a charging routine if the current draw of the electrical device is detected, the charging routing including sensing the input voltage level and transmitting control signals to the switched capacitor device to regulate the switched capacitor device as a function of the sensed input voltage level.

10. The electrical circuit of claim 9, further comprising:

a vampire load subsystem coupled to the low power regulator circuit and configured to disable the power delivery circuit if a current level of the DC output power signal is lower than a threshold current level, and to subsequently enable the power delivery circuit when the current level of the DC output power signal is higher than the threshold current level.

11. The electrical circuit of claim 9, wherein the controller is configured to regulate the switched capacitor device as a function of a current level of the output power signal.

12. The electrical circuit of claim 11, wherein the controller is configured to regulate the buck converter to increase the current level of the output power signal.

13. The electrical circuit of claim 9, further comprising a communications controller coupled to the controller for transmitting signals to the controller to enable remote operation of the switched capacitor device.

14. The electrical circuit of claim 9, further comprising a hold capacitor coupled to the buck converter.

15. The electrical circuit of claim 9, further comprising a full-wave bridge rectifier circuit coupled to the input switch for receiving the input signal from the power source and delivering a rectified power signal to the switched capacitor device.

16. A method of assembling an electrical circuit, comprising the steps of:

forming a buck converter on a semiconductor chip;

coupling a switched capacitor device to the buck converter, the switched capacitor device including a input switch for receiving an input power signal from a power source, a capacitor coupled to the input switch, and a pair of output switches including a first output switch coupled to a top plate of the capacitor and a second output switch coupled to a bottom plate of the capacitor and to ground, the input switch and the pair of output switches being formed on the semiconductor chip;

coupling a transformer to the buck converter for receiving a modified power signal from the buck converter and delivering an output power signal to an electrical device;

coupling a controller to the switched capacitor device, the controller configured to regulate the switched capacitor device as a function of a voltage level of the output power signal; and

coupling a startup circuit to the controller, the startup circuit including a low power regulator circuit that is connected to the power source for providing start-up power to the controller;

wherein the controller is configured to;

detect the input power signal being received from the power source;

initiate a start-up routine including detecting a current draw of the electrical device upon detecting the input power signal;

initiate a sleep mode if the current draw of the electrical device is not detected including initiating a predefined sleep period and reinitiating the start-up routing upon expiration of the predefined sleep period; and

initiate a charging routine if the current draw of the electrical device is detected, the charging routing including sensing the input voltage level and transmitting control signals to the switched capacitor device to regulate the switched capacitor device as a function of the sensed input voltage level.