Zero voltage switching half-bridge converters

• US 9,991,742 B2
• Filed: 08/25/2015
• Issued: 06/05/2018
• Est. Priority Date: 08/25/2014
• Status: Active Grant

• Current Assignee: Quanten Technologies Limited
• Original Assignee: NuVolta Technologies, Inc.
• Inventors: Mao, Hengchun
• Primary Examiner(s): Nguyen, Long
• Application Number:
  US14/835,537
• Publication Number:
  US 20160056640A1
• Time in Patent Office: 1,015 Days
• Field of Search: None
• CPC Class Codes: H02J 50/10 using inductive coupling
• CPC Class Codes: H02J 50/12 of the resonant type
• CPC Class Codes: H02J 50/80 involving the exchange of data, concerning supply or distribution of electric power, between transmitting devices and receiving devices

Abstract

A power converter comprises a primary switch network coupled to a power source, wherein the primary switch network comprises a plurality of power switches, a controller configured to generate gate drive signals for the plurality of power switches, a secondary rectifier coupled to an output, a first transformer having a first winding coupled to the primary switch network, a second winding coupled to the secondary rectifier and a third winding coupled to the controller and a second transformer having a fourth winding coupled to the primary switch network, a fifth winding coupled to the secondary rectifier and a sixth winding coupled to the controller, wherein a voltage signal from the third winding and/or the sixth winding is processed to provide a feedback of a voltage at the output.

Claims

1. A converter comprising:

a primary switch network coupled to a power source, wherein the primary switch network comprises a plurality of power switches;

a controller configured to generate gate drive signals for the plurality of power switches;

a secondary rectifier coupled to an output;

a first transformer having a first winding coupled to the primary switch network, a second winding coupled to the secondary rectifier and a third winding coupled to the controller; and

a second transformer having a fourth winding coupled to the primary switch network, a fifth winding coupled to the secondary rectifier and a sixth winding coupled to the controller, wherein a voltage signal from the third winding or the sixth winding is processed to provide a feedback of a voltage at the output, and wherein the secondary rectifier comprises a first diode and a second diode, and wherein the second winding is connected in series with the first diode and the fifth winding is connected in series with the second diode.

2. The converter of claim 1, wherein:

a first switch and a second switch of the plurality of power switches are connected in series across two terminals of the power source, and a capacitor is coupled between one of the first transformer and the second transformer, and the power source.

3. The converter of claim 2, wherein:

the first winding and the fourth winding are connected in series between a common node of the first switch and the second switch, and the capacitor.

4. The converter of claim 1, wherein:

the controller is configured to regulate the voltage at the output through complementary control of the plurality of power switches, and a switch of the plurality of power switches is turned on with zero voltage switching during normal operation.

5. The converter of claim 4, wherein:

a switching frequency of the plurality of power switches is adjusted to improve the zero voltage switching of the switch.

6. The converter of claim 1, wherein:

the first transformer and the second transformer form an integrated magnetic device.

7. A power apparatus comprising:

a primary side circuit of a half-bridge converter having two primary switches and two capacitors;

a secondary side circuit of the half-bridge converter having a first leg coupled to the primary side circuit of the half-bridge converter through a first transformer and a second leg coupled to the primary side circuit of the half-bridge converter through a second transformer, wherein a first winding of the first transformer and a first winding of the second transformer are connected in series between a common node of the two primary switches and a common node of the two capacitors; and

a controller configured to generate gate drive signals for the two primary switches based upon a voltage signal detected from an auxiliary winding of one of the first transformer and the second transformer through a magnetic coupling between the auxiliary winding and the secondary side circuit of the half-bridge converter.

8. The power apparatus of claim 7, wherein:

the controller is configured to regulate a voltage at an output of the power apparatus through a duty cycle of one primary switch.

9. The power apparatus of claim 8, wherein:

the first transformer and the second transformer form an integrated magnetic device comprising a first magnetic leg having a first air gap, a second magnetic leg having a second air gap and a third magnetic leg, wherein;

the first transformer is implemented around the first magnetic leg;

the second transformer is implemented around the second magnetic leg; and

the third magnetic leg provides a shared magnetic flux path for the first transformer and the second transformer.

10. The power apparatus of claim 9, wherein:

the third magnetic leg has a third air gap.

11. A method comprising:

providing a power converter comprising a primary side circuit having primary switches and a secondary side circuit having a first leg coupled to the primary side circuit through a first transformer and a second leg coupled to the primary side circuit through a second transformer, wherein the first transformer and the second transformer are coupled to an output, and a primary winding of the first transformer and a primary winding of the second transformer are connected in series between a common node of the primary switches and a common node of input capacitors of the power converter; and

configuring a controller to sense an output voltage of the power converter through an auxiliary winding of one of the first transformer and the second transformer, wherein the auxiliary winding is electrically isolated from the secondary side circuit.

12. The method of claim 11, further comprising:

configuring the power converter so that an input voltage and the output voltage of the power converter satisfy;

13. The method of claim 12, further comprising:

configuring the power converter to operate in a manner similar to a forward converter during a first operating mode.

14. The method of claim 11, further comprising:

configuring the power converter to operate in a manner similar to an asymmetric half-bridge converter during a second operating mode.

15. The method of claim 11, further comprising:

configuring the power converter to operate in a discontinuous mode in a manner similar to a flyback converter during a third operating mode, wherein the primary switches are not controlled in a complementary manner.

16. The method of claim 11, further comprising:

during an ultra-light load mode, configuring the power converter such that;

a primary switch of the primary switches is controlled with a duty cycle; and

at least one primary switch of the primary switches are not turned on by dedicated gate signals during some switching cycles.

17. The method of claim 16, further comprising:

controlling the primary switches so that one of the primary switches is turned on with zero voltage switching when both the primary switches are switched during a switching cycle.

18. The method of claim 16, wherein:

one of the transformers stops transferring energy to the output.

19. The method of claim 11, further comprising:

detecting the output voltage of the power converter through voltage signals across the auxiliary winding of one of the first transformer and the second transformer; and

regulating the output voltage of the power converter based upon the detected output voltage.