Power converter for led large area light source lamp

• US 7,554,822 B2
• Filed: 09/27/2005
• Issued: 06/30/2009
• Est. Priority Date: 10/01/2004
• Status: Expired due to Fees

• Current Assignee: Philips Lighting BV (Koninklijke Philips N.V.)
• Original Assignee: Koninklijke Philips Electronics N.V. (Koninklijke Philips N.V.)
• Inventors: Waffenschmidt, Eberhard, Neubert, Tom
• Primary Examiner(s): VO, TUYET THI
• Application Number:
  US11/576,283
• Publication Number:
  US 20080084167A1
• Time in Patent Office: 1,372 Days
• Field of Search: 363/21.02, 363/21.01, 363/21.03, 363/21.04, 363/21.08, 363/21.14, 363/21.15, 363/21.16, 363/23, 363/25, 363/39, 363/40, 363/15, 363/16, 315274-289, 315/224, 315/225, 315/209.R, 315/247, 315/246, 315312-326, 361/688, 361/704, 361/709, 361/748, 361/761, 361/764, 361/600
• US Class Current: 363/21.16
• CPC Class Codes: H02M 3/01 Resonant DC/DC converters
• CPC Class Codes: H02M 3/33571 Half-bridge at primary side of an isolation transformer
• CPC Class Codes: H02M 3/3376 with automatic control of output voltage or current
• CPC Class Codes: H05B 45/3725 Switched mode power supply [SMPS]
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]
• 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

Power converter for receiving an input current at an input voltage and for providing an output current at an output voltage. The power converter comprises a transformer (133) having a primary (136) and at least one secondary (138) side, wherein the transformer shows a mutual inductivity L_s. The power converter further comprises at least one switching device (124a, 124b) being operated at an operating frequency f_op at the primary side of said transformer, and a capacitor C_S at the primary side of the transformer. The capacitor forms a resonant circuit with the leakage inductivity L_S of said transformer, wherein said operating frequency, said capacitor C_s, said mutual inductivity L_m and said leakage inductivity L_S are matched such that the effective value of the output current is substantially constant with respect to variations of a load being traversed by said output current by using resonance principles and operating the power converter in a current source mode.

Claims

1. Power converter for receiving an input current at an input voltage and for providing an output current at an output voltage, said power converter comprising:

a transformer having a primary winding and at least one secondary winding, wherein the primary and secondary windings are integrated in a printed circuit board (PCB) in a planar manner, wherein the PCB is mounted to a first side of a heat sink, the transformer showing a mutual inductivity L_m and a leakage inductivity L_si at least one switching device being operated at an operating frequency f_op at the primary side of said transformer; and

a capacitor C_s at the primary side of said transformer, said capacitor forming a resonant circuit with said leakage inductivity L_s of said transformer, wherein said operating frequency, said capacitor C_s, said mutual inductivity L_m and said leakage inductivity L_s are matched such that the effective value of the output current is substantially constant with respect to variations of a load being traversed by said output current, and

wherein the PCB is thermally coupled to the first side of the heat sink, and a load of the power converter includes a plurality of light emitting diodes thermally coupled to a second side of the heat sink.

2. Power converter according to claim 1, wherein said operating frequency f_op, said capacitor C_s, and said leakage inductivity L_s are matched according to a lower bound for the operating frequency being a basic resonance frequency defined by the series capacitor and the sum of the mutual inductivity L_m and the leakage inductivity L_s, such that

$f_{\mathrm{op}}>$

1 2 ⁢

⁢

π

⁢

1 ( L m + L s ) ⁢

C s .

3. Power converter according to claim 1, wherein said operating frequency f_op, said capacitor C_s, and said leakage inductivity L_s matched according to an upper bound for said operating frequency at which an output impedance of said resonant circuit is substantially matched to said load.

4. Power converter according to claim 1, wherein said operating frequency f_op, said capacitor C_s, and said leakage inductivity L_s are matched according to an upper bound for said operating frequency, such that

$f_{\mathrm{op}}<$

1 2 ⁢

⁢

π

⁢

1 L s ⁢

C s .

5. Power converter according to claim 1, wherein said leakage inductivity L_s is realized by different dimensions of a primary and a secondary spiral winding of said transformer.

6. Power converter according to claim 1, wherein said power converter is mounted in a groove formed at the first side of the heat sink.

7. Large Area Light Source (LALS) lamp comprising a power converter according to claim 1.

8. Power converter according to claim 1, wherein the operating frequency is chosen substantially higher than a series resonance frequency defined by the series capacitor and the leakage inductivity L_s as

$f_s=\frac{1}{2}$

⁢

π

⁢

1 L s ⁢

C s ,

such that the leakage inductivity L_s limits said output current.

9. Power converter according to claim 8, wherein said operating frequency f_op, said capacitor C_s, and said leakage inductivity L_s are matched such that an input impedance of said resonant circuit presents an inductive character.

10. Power converter according to claim 1, wherein said transformer is a planar transformer.

11. Power converter according to claim 10, wherein said leakage inductivity L_s is realized by shifting the center of a spiral primary winding of said transformer with respect to the center of a spiral secondary winding of said transformer.

12. Power converter according to claim 10, wherein said leakage inductivity L_s is realized as a combination of shifting the centers of a primary and a secondary winding with respect to each other, and of different dimensioning of said primary and secondary windings.

13. Power converter according to claim 1, further comprising

a first AC-to-DC rectifier connectable to an AC mains supply;

a second AC-to-DC rectifier connectable to an electric consumer.

14. Power converter according to claim 13, wherein said first AC-to-DC rectifier produces a rectified voltage and a superposed ripple voltage, said ripple voltage having a frequency that is the double of the frequency of the voltage of said AC mains supply.

15. Power converter according to 13, wherein the current drawn by said first AC-to-DC rectifier from said AC mains supply is substantially sinusoidal with a frequency equal to the frequency of the voltage of said AC mains supply.

16. Power converter according to claim 13, wherein said electric consumer has a diode-like current-voltage characteristic.

17. Power converter according to claim 1, wherein a solid PCB layer is disposed between said primary and secondary windings.

18. Power converter according to claim 17, wherein said capacitor C_s is integrated in the PCB.

19. Power converter according to claim 17, wherein said PCB is mounted directly to said heat sink.

20. Power converter according to 17, wherein said PCB is made from a thermally highly conducting material.

21. Power converter according to claim 17, wherein capacitors having high nominal values are avoided.

22. Power converter according to claim 17, wherein planar magnetic cores are disposed adjacent to the flat side of the arrangement consisting of primary windings, solid PCB layer, and secondary winding.

23. Power converter according to claim 22, wherein said planar magnetic cores consist of ferrite tiles.

24. Power converter according to claim 22, wherein said magnetic cores are made from amorphous iron.

25. Power converter according to claim 22, wherein said magnetic cores are made from nanocrystalline iron.

26. Power converter according to claim 22, wherein the magnetic cores are structured by providing slots in the magnetic cores, said slots being parallel to magnetic field lines guided within the magnetic cores.

27. Power converter according to claim 22, wherein said magnetic cores are formed by highly permeable metal foil.

28. Power converter according to claim 27, wherein said highly permeable metal foil is made of NiFe or a mu-metal.

29. Large area light source comprising light emitting diodes as illuminants and comprising a power converter for receiving an input current at an input voltage and for providing an output current at an output voltage, said power converter comprising:

a transformer having a primary winding and at least one secondary winding, wherein the primary and secondary windings are integrated in a printed circuit board (PCB) in a planar manner, wherein the PCB is mounted to a first side of a heat sink, the transformer showing a mutual inductivity L_m and a leakage inductivity L_s; and

a least one switching device being operated at an operating frequency f_op at the primary side of said transformer; and

a capacitor Cs at the primary side of said transformer, said capacitor forming a resonant circuit with the leakage inductivity Ls of said transformer,

wherein the PCB is thermally coupled to the first side of the heat sink, and wherein a load of the power converter includes the light emitting diodes, the load thermally coupled to a second side of the heat sink.

30. Large area light source according to claim 29, wherein said capacitor Cs is integrated in the PCB.

31. Large area light source according to claim 29, wherein said power converter is mounted in a groove formed at the first side of the heat sink.

32. Large area light source according to claim 31, wherein said PCB is mounted directly to said heat sink.

33. Large area light source according to claim 29, wherein said transformer is a planar transformer.

34. Large area light source according to claim 33, wherein a solid PCB layer is disposed between said primary and secondary windings.

35. Large area light source according to claim 34, wherein planar magnetic cores are disposed adjacent to the flat side of the arrangement consisting of primary winding, PCB and secondary winding.