Dc/dc power processor with distributed rectifier stage

Information

  • Patent Grant
  • 6388898
  • Patent Number
    6,388,898
  • Date Filed
    Monday, January 22, 2001
    24 years ago
  • Date Issued
    Tuesday, May 14, 2002
    22 years ago
Abstract
A technique, which substantially reduces the number of power-stage and control circuit components in an isolated DC/DC converter with parallel current-doubler rectifier stages, includes on the primary side transformers with serially connected primary windings each having a corresponding secondary winding coupled to one of the voltage-doubler stages. In one embodiment, the primary and secondary windings and filter inductors of the current-doubler rectifier stages are provided on an integrated magnetic core. The filter inductors in each current-doubler rectifier stage can be provided as coupled inductors. In one embodiment, an X-shaped magnetic core is provided to achieve coupled or uncoupled filter inductors.
Description




BACKGROUND OF THE INVENTION




1. Field of the Invention




This invention relates to isolated dc/dc converters. In particular, this invention relates to low output voltage, high output current, isolated dc/dc converters that has multiple rectifier stages connected in parallel.




2. Discussion of the Related Art




In a high-power application, by connecting several substantially identical converter power stages in a parallel configuration to share the total power processed, one can often achieve a desired output power using smaller, lower-rated magnetic and semiconductor components. With several power stages connected in parallel, the power losses and thermal stresses on the magnetic and semiconductor components are distributed among the parallel power stages, thus improving conversion efficiency and eliminating “hot spots”. In addition, because lower-power, faster semiconductor switches can be used to implement the parallel power stages, the parallel power stages may be operated at a higher switching frequency than that of a corresponding single high-power stage. Consequently, the parallel configuration reduces the required sizes of the magnetic components and increases conversion power density. In addition, because the parallel power stages can be operated at a higher switching frequency, this approach can be used to optimize the transient response of a power supply.





FIG. 1

shows converter


100


with two forward-converter power stages


101


and


102


connected in parallel. Generally, a power supply with parallel power stages requires more power stage and control circuit components. However, if the parallel converters share the same output filter, the number of power stage components can be reduced, such as illustrated by converter


200


of FIG.


2


. Similarly, if transformer secondary windings are provided directly in parallel, required power stage components can also be reduced, such as illustrated by converter


300


of FIG.


3


. Converters


200


and


300


of

FIGS. 2 and 3

are discussed in “Analysis, Design, and Evaluation of Forward Converter with Distributed Magnetics—Interleaving and Transformer Paralleling,” (“Zhang”) by M. T. Zhang, M. M. Jovanovic and F. C. Lee, published in


IEEE Applied Power Electronics Conf


. (


APEC


)


Proc


., pp. 315-321, 1995.




Regardless of the approach used in connecting power stages in parallel, ensuring that an acceptable load current (hence, power) is shared among the parallel modules is the main design challenge of such an approach. In fact, without an acceptable current-sharing mechanism, the load current can be unevenly distributed among the parallel modules. As a result, the modules that carry higher currents are electrically and thermally stressed more than the other modules, thus reducing the reliability of the power supply. Moreover, when the current of a parallel module exceeds its current limit, such as may occur when the converter current is unevenly distributed, the entire power supply may need to be shut off. Therefore, many current-sharing techniques of different complexities and performance are developed to ensure a relatively even current distribution among parallel modules. A discussion of some of these techniques is found in “A Classification and Evaluation of Paralleling Methods for Power Supply Modules,” by S. Luo, Z. Ye, R. L. Lin, and F. C. Lee, published in


IEEE Power Electronics Specialists' Conf. Rec


., pp. 901-908, 1999. For example, relatively even current sharing in converters


100


and


200


in

FIGS. 1 and 2

can be achieved by equalizing the peak values of primary currents in the modules. Furthermore, the performance of converter


100


and


200


of

FIGS. 1 and 2

can be further improved by interleaving (i.e., operating the primary switches in each converter with 180° phase shift). Generally, as discussed by Zhang above, interleaving provides some input current and output current ripple cancellation, thus reducing the size of the input and output filters.




Referring to

FIG. 3

, steady-state current sharing among parallel transformers


301


and


302


of converter


300


is determined by the winding resistances of transformers


301


and


302


. Because winding resistance is usually comparable with the layout resistance, the current sharing performance of parallel transformers is sensitive to circuit layout. Sensitivity to layout resistance can be reduced by including a rectifier in the secondary side of each transformer, such as shown in converter


400


of FIG.


4


. In converter


400


, current sharing is determined by the on-resistances of rectifiers


401


and


402


, as a rectifier's resistance is usually larger than that of a printed circuit board (PCB) trace resistance. However, because the on-resistance of silicon rectifiers has a negative temperature coefficient (i.e., the rectifier's resistance decreases as the temperature of the rectifier increases), a current runaway condition may exist. In a runaway condition, all the secondary current flows through one of the rectifiers and the associated transformer secondary windings. The runaway condition in converter


400


can be avoided if low on-resistance MOSFETs (which have positive on-resistance temperature coefficients) are used instead of the diode rectifiers, as it is routinely done in low-voltage high-current applications.




In a low output voltage (e.g., below 3.3 V), high output current (e.g., above 50 A) application that requires transformer isolation, secondary-side conduction loss dominates total loss and limits conversion efficiency. Therefore, to increase conversion efficiency, rectification and transformer winding losses must be reduced. Rectification loss can be reduced, for example, by replacing Schottky rectifiers with MOSFET synchronous rectifiers. Reduction of transformer winding loss can be achieved by reducing winding resistance and the root-mean-square (rms) current in the winding, respectively, by properly selecting the winding geometry and transformer structure, and by employing a current-doubler topology. These techniques are discussed for example in “Design and Performance Evaluation of Low-Voltage/High-Current Dc/Dc On-Board Modules,” (“Panov”) by Y. Panov, M. M. Jovanovic, published in


IEEE Applied Power Electronics Conf


. (


APEC


)


Proc


., pp. 545-552, 1999, and in “The Performance of the Current Doubler Rectifier with Synchronous Rectification,” by L. Balogh, published in


High Frequency Power Conversion Conf. Proc


., pp. 216-225, 1995.





FIG. 5

shows an example of a 1.45-volt, 70-ampere dc/dc converter


500


that employs a current-doubler topology implemented with synchronous rectifiers. (Converter


500


is discussed in the Panov reference mentioned above). In converter


500


, synchronous rectifier


501


and


502


are each implemented by connecting three low on-resistance MOSFETs in parallel. The technique used in converter


500


, however, cannot be extended to higher current levels by simply adding more synchronous rectifier MOSFETs, because the incremental reduction in conduction losses is less than the incremental increase of switching losses due to charging and discharging of MOSFETs' relatively large intrinsic terminal capacitances. If the switching frequency were not reduced, conversion efficiency would be reduced. However, reduction of switching frequency requires an undesirable increase in the sizes of magnetic components. In addition, the packaging of a large number of paralleled synchronous rectifiers is also difficult.




The output current of converter


500


of

FIG. 5

can be increased without efficiency degradation by connecting in parallel two or more power stages, as illustrated in converter


600


of FIG.


6


. However, converter


600


requires significantly more power-stage and control circuit components to achieve even current (hence, power) sharing among the parallel modules. The additional components increase both the size and the cost of the converter.




SUMMARY OF THE INVENTION




According to the present invention, a parallel technique, which substantially reduces the number of power-stage and control-circuit components in an isolated dc/dc converter with a current-doubler rectifier and provides automatic current sharing is described. Using a common primary side inverter, and by providing in parallel only the secondary-side current-doubler rectifiers that are driven through separate isolation transformers, component count reduction is achieved. Current sharing among the parallel rectifier stages is achieved by connecting the primary windings of the transformers in series, thus forcing the same current through the transformers' secondary windings and the rectifiers. Additional component count reduction is achieved using integrated magnetic components. The technique of the present invention can be extended to an arbitrary number of rectifier stages, as well as to any rectifier topology.




The present invention is better understood upon consideration of the following detailed description and the accompanying drawings.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

shows prior art converter


100


having two forward converter stages


101


and


102


connected in parallel.





FIG. 2

shows prior art converter


200


having two forward converter stages


201


and


202


connected in parallel and sharing a common output filter.





FIG. 3

shows prior art forward converter


300


having transformers


301


and


302


connected in parallel upstream to rectifier


303


.





FIG. 4

shows prior art forward converter


400


having transformers


403


and


404


connected in parallel downstream from rectifiers


401


and


402


.





FIG. 5

shows prior art half-bridge converter


500


having a current-doubler output stage implemented by synchronous rectifiers


501


and


502


.





FIG. 6

shows prior art half-bridge converters


601


and


602


, each having a current-doubler rectifier, connected in parallel.





FIG. 7

shows, schematically, dc/dc converter


700


, having an arbitrary number N of parallel rectifier stages, according to one embodiment of the invention.





FIG. 8

shows key waveforms of converter


700


of

FIG. 7

, including (a) output voltage V


inv


of inverter


701


; (b) secondary voltage V


si


, representative of a secondary voltage at one of transformers


709


-


1


to


709


-N; (c) voltage V


L1i


, representative of a voltage across one of filter inductors


703


-


1


to


703


-N; (d) voltage V


L2i


, representative of a voltage across one of filter inductors


704


-


1


to


704


-N; (e) primary current i


PRIM


; (f) currents i


L1i


and i


L2i


, representative of the respective currents in one of filter inductors


703


-


1


to


703


-N and in one of filter inductors


704


-


1


to


704


-N; (g) current i


D1i


, representative of a current in one of rectifiers


705


-


1


to


705


-N; (h) current i


D2i


, representative of a current in one of rectifiers


706


-


1


to


706


-N.





FIG. 9

shows converter


900


using magnetic coupling of output filters, in accordance with a second embodiment of the present invention.





FIG. 10

shows an implementation of converter


900


of

FIG. 9

, using integrated magnetic components that has no magnetic coupling between filter inductors of the same rectifier stage.





FIG. 11

shows another implementation of converter


900


of

FIG. 9

, using integrated magnetic components that has magnetic coupling between filter inductors of the same rectifier stage.





FIG. 12

shows converter


1200


with rectifiers


1201


and


1202


, having integrated magnetic components on a single magnetic core (separation of core halves


1203


-


1


and


1203


-


2


is exaggerated for clarity).





FIG. 13

shows a model of the magnetic reluctance circuit of converter


1200


of FIG.


12


.





FIG. 14

shows converter


1300


, which is an alternative implementation of converter


1200


of

FIG. 12

, using opposite winding orientations to reduce the magnetic flux through center post


1203


-


3


. Note that the orientation of windings (dot positions) on legs


2


and


3


are opposite to the orientation of the corresponding windings in FIG.


12


.











DETAILED DESCRIPTION OF THE INVENTION




In the detailed description below, to facilitate illustration and correspondence between figures, like elements are provided like reference numerals.





FIG. 7

shows, schematically, dc/dc converter


700


that has an arbitrary number N of parallel rectifier stages


707


-


1


to


707


-N, according to one embodiment of the invention. Dc/dc converter


700


uses inverter


701


to convert the dc input signal into a bipolar high-frequency square-wave signal that is applied across the series connection of primary windings


702


-


1


to


702


-N of transformers


709


-


1


to


709


-N. Inverter


701


can be implemented by virtually any converter topology, such as a forward converter, a two-switch forward converter, a half-bridge converter, or a full-bridge converter. As shown in

FIG. 7

, converter


700


has secondary windings


708


-


1


to


708


-N of transformers


709


-


1


to


709


-N each coupled to a respective one of current-doubler rectifiers


707


-


1


to


707


-N. Current-doubler rectifiers


707


-


1


to


707


-N are connected in parallel at the output terminals of converter


700


. Of course, rectifiers


705


-


1


to


705


-N and


706


-


1


to


706


-N can be implemented by synchronous rectifiers, such as those discussed above with respect to FIG.


5


.




Because primary windings


702


-


1


to


702


-N of transformers


709


-


1


to


709


-N are connected in series, a common current i


PRIM


flows in all primary windings


702


-


1


to


702


-N (assuming that the primary windings of transformers


709


-


1


to


709


-N have identical magnetizing inductances). Consequently, if each pair of corresponding primary and secondary windings has the same turns ratio, secondary currents i


SEC


in each of secondary windings


708


-


1


to


708


-N are also the same, which ensures a perfect current (hence, power) sharing among rectifier stages


707


-


1


to


707


-N. However, if the magnetizing inductances are different, secondary currents i


SEC


will also be different. Because the variation of magnetizing inductance can be easily kept within a narrow range, variations in magnetizing inductances do not significantly affect current sharing.





FIG. 8

shows representative key waveforms of converter


700


of FIG.


7


. It should be noted that in

FIG. 8

the symmetrical bipolar high-frequency voltage waveform at the output of the inverter implies that a symmetrical inverter topology (bridge-type topology) is assumed in the analysis that follows.




Ideally, when all components of rectifier stages


707


-


1


to


707


-N are identical, the waveforms of signals in rectifier stages


707


-


1


to


707


-N are identical. Thus, under ideal conditions, perfect current sharing is achieved, so that each rectifier stage carries 1/N of total load current i


LOAD


. Under ideal conditions, primary voltage V


pi


across each of primary windings


702


-


1


to


702


-N is


1


/N input voltage V, or:






V


P1


=V


P2


= . . . =V


Pn


=V/N






Initially, as shown in

FIG. 8

between time t


0


to t


1


, voltage V


INV


of inverter


701


(magnitude V) is applied equally across each of primary windings


702


-


1


to


702


-N, thus inducing positive voltage V


si


=n*V/N across each of secondary windings


708


-


1


to


708


-N, where n is the turns ratio across each corresponding pair of primary and secondary windings. (FIGS.


8


(


a


),


8


(


b


)) Consequently, rectifiers


705


-


1


to


705


-N are each in an “off” state (FIG.


8


(


g


)), carrying no appreciable current. At the same time, a positive voltage V


L1i


develops across each of inductors


703


-


1


to


703


-N (FIG.


8


(


c


)), thus increasing inductor current i


L1i


(FIG.


8


(


f


)), which flows in the loop consisting of corresponding secondary windings


708


-


1


to


708


-N, rectifier


706


-


1


to


706


-N and filter capacitor


710


-


1


to


710


-N. Because rectifiers


706


-


1


to


706


-N conduct (FIG.


8


(


h


)), voltage V


L2i


across inductors


704


-


1


to


704


-N is negative and equals in magnitude to output voltage V


o


(FIG.


8


(


d


)). As a result, inductor current i


L2i


in each of inductor


704


-


1


to


704


-N is linearly decreasing (FIG.


8


(


f


)).




Between time t


1


and t


2


(i.e., time interval [t


1


, t


2


]), voltage V


INV


of inverter


701


is zero (FIG.


8


(


a


)), inductor current i


L1i


in each of inductors


703


-


1


to


703


-N, which was flowing during time interval [t


0


, t


1


] through corresponding secondary windings


708


-


1


to


708


-N, continues to flow through rectifiers


705


-


1


to


705


-N (FIGS.


8


(


f


) and


8


(


g


)). During time interval [t


1


, t


2


], voltage V


L1i


or V


L2i


(FIGS.


8


(


c


) and


8


(


d


)) across each inductor—i.e., any of inductors


703


-


1


to


703


-N and


704


-


1


to


704


-N—is negative and equal to output voltage V


o


. Consequently, current i


L1i


or i


L2i


in each inductor is decreasing linearly at the same rate (FIG.


8


(


f


)).




During time intervals [t


2


, t


3


] and [t


3


and t


4


], the output voltage V


INV


of inverter


701


is negative and zero, respectively. During these time intervals, the operations of converter


700


are identical to those of time intervals [t


0


, t


1


] and time intervals [t


1


, t


2


], except that the roles of inductors


703


-


1


to


703


-N and rectifiers


705


-


1


to


705


-N are exchanged with those of inductors


704


-


1


to


704


-N and rectifiers


706


-


1


to


706


-N.




In rectifier stages


707


-


1


to


707


-N, because voltage V


L1i


across each of inductors


703


-


1


to


703


-N is the same, inductors


703


-


1


to


703


-N can be coupled, such as illustrated by coupled inductor


901


of converter


900


in FIG.


9


. (Similarly, because voltage V


L2i


across each of inductors


704


-


1


to


704


-N is the same, inductors


704


-


1


to


704


-N can be coupled, such as also illustrated by coupled inductor


902


of converter


900


in

FIG. 9

) Using coupled inductors


901


and


902


, the number of magnetic cores required to implement output filtering is reduced to two. Further reduction of the magnetic core count can be achieved by integrating coupled inductors


901


and


902


of

FIG. 9

onto a single magnetic core, such as illustrated in

FIG. 10

for converter


1000


with two converter stages. Of course, the same concept can be extended to any number of rectifier stages. In the integrated magnetic implementation of converter


1000


in

FIG. 10

, outer legs of EE core


1003


are gapped where the windings of coupled inductors


901


and


902


are placed. As shown in

FIG. 10

, the center leg of EE core


1003


has no gap and, therefore, has a much lower reluctance than the gapped outer legs. As a result, any flux generated in either of the outer legs is closed through the center leg (i.e., no coupling exists between opposite windings, so that there is no interaction between inductors


703


-


1


and


703


-


2


on one outer leg of EE core


1003


with inductors


704


-


1


and


704


-


2


on the other outer leg of EE core


1003


).




Alternatively, the magnetic integration of output filters can be also implemented by allowing a certain degree of coupling between filter inductors


703


-


1


and


703


-


2


wound on one leg of an EE core, and filter inductors


704


-


1


and


704


-


2


wound on the other leg of the EE core, as illustrated by EE core


1101


of converter


1100


, shown in FIG.


11


. In

FIG. 11

, the coupling between inductors


703


-


1


,


703


-


2


and inductors


704


-


1


and


704


-


2


wound on two outside legs of EE core


1101


is achieved by gapping the middle leg of EE core


1101


. Due to an increased reluctance of the gapped middle leg of EE core


1101


, relative to EE core


1003


of

FIG. 10

, some flux that is generated in one outer leg of EE core


1101


is forced to flow in the other outer leg of EE core


1101


, thus coupling all windings of inductors


703


-


1


,


703


-


2


.


704


-


1


and


704


-


2


. When a proper amount of coupling is provided, the ripple in filter inductors


703


-


1


,


703


-


2


,


704


-


1


and


704


-


2


of converter


1100


is less than the corresponding filter inductors in converter


1000


of

FIG. 10

, thus improving converter performance.




Converter


900


of

FIG. 9

can also be implemented using a single magnetic core, such as illustrated by converter


1200


of FIG.


12


. In converter


1200


, 4-legged X-type magnetic core


1203


is used. Note that, for illustrative purpose, core halves


1203


-


1


and


1203


-


2


are shown in

FIG. 12

with an exaggerated separation. Actual separation between core halves


1203


-


1


and


1203


-


2


is typically a few millimeters, or less. In

FIG. 12

, core halves


1203


-


1


and


1203


-


2


implement coupled filter inductors


703


-


1


,


703


-


2


,


704


-


1


, and


704


-


2


in the legs labeled “


1


” and “


2


”. Transformer windings


702


-


1


,


702


-


2


,


708


-


1


and


708


-


2


are implemented on the legs labeled “


3


” and “


4


”. To ensure correct operation of converter


1200


, magnetic core


1203


is properly gapped, so that the fluxes created by the transformer windings are provided in the desired magnetic paths. To illustrate the gapping requirements,

FIG. 13

shows reluctance circuit


1300


that models the magnetic structure of core


1203


of FIG.


12


.




Generally, in an implementation such as converter


1200


of

FIG. 12

, a magnetic coupling between the transformers and the filter inductors is not desired. Because filter inductors are intended to store energy, legs


1


and


2


of EE core


1203


are gapped to create relatively large reluctances R


1


and R


2


, which are represented in

FIG. 13

by respective reluctances


1303


and


1306


. In

FIG. 13

, inductors


703


-


1


and


703


-


2


in leg


1


of EE core


1203


are represented by voltage sources


1301


and


1302


, respectively. Similarly, inductors


704


-


1


and


704


-


2


in leg


2


of core


1203


are represented in

FIG. 13

by voltage sources


1305


and


1304


. Because the transformers in converter


1200


are not intended to store energy, legs


3


and


4


need not be gapped. Reluctances in legs


3


and


4


are represented in

FIG. 13

by reluctances


1312


and


1309


, respectively. However, without a gap, reluctances R


3


and R


4


are relatively small (i.e., reluctance R


3


and R


4


would each be comparable to reluctance R


c


of non-gapped center post


1203


-


3


, which is represented in

FIG. 13

by reluctance


1313


). Primary windings


702


-


1


and


702


-


2


are represented in

FIG. 13

by voltage sources


1307


and


1310


, respectively. Similarly, secondary windings


708


-


1


and


708


-


2


are represented in

FIG. 13

by voltage sources


1308


and


1311


. As a result of the relative reluctances of the transformers to those of the inductors, a part of fluxes Φ


1


and Φ


2


produced by inductor currents in legs


1


and


2


of core


1203


would flow through legs


3


and


4


, in addition to the part of fluxes Φ


1


and Φ


2


flowing through center post


1203


-


3


. The amount of this flux coupling between the transformer legs and the inductor legs depends on the ratio of reluctance R


3


or reluctance R


4


to center-post reluctance R


c


. To minimize this coupling, reluctances R


3


and R


4


should be made much larger than reluctance R


c


by not having a gap in center post


1203


-


3


, and by introducing small gaps in legs


3


and


4


. The gaps in legs


3


and


4


are generally much smaller than the gaps in legs


1


and


2


. In addition, when the air gaps are designed to achieve R


c


<<R


3


=R


4


<<R


1


=R


2


, flux linkage between legs


3


and


4


is also minimized (i.e., Φ


3


and Φ


4


corresponding to currents in legs


3


and


4


are coupled to low-reluctance center post


1203


-


3


). As a result, currents in secondary windings


708


-


1


and


708


-


2


are each proportional to the respective current in primary windings


702


-


1


and


702


-


2


(i.e., the parallel current-doubler rectifiers


707


-


1


and


707


-


2


share load current I


LOAD


equally). Otherwise, i.e., when fluxes Φ


3


and Φ


4


in legs


3


and


4


are coupled, the currents in secondary windings


708


-


1


and


708


-


2


are not equal, even though the primary currents in


702


-


1


and


702


-


2


are the same, due to the internal impedance of each secondary circuit.




The flux in low-reluctance center post


1203


-


3


, which is shown in

FIG. 13

as being equal to the sum of the fluxes of legs


1


-


4


, can be reduced by having opposite winding orientations in the windings of transformers in legs


3


and


4


, and in the filter-inductor legs


1


and


2


.

FIG. 14

shows such a configuration in converter


1400


. (Note the difference between the dot positions of the windings in

FIGS. 12 and 14

.) With opposite winding orientations, both fluxes Φ


3


and Φ


4


and fluxes Φ


1


and Φ


2


flow in opposite directions through center post


1203


-


3


. As a result, the total flux Φ


c


in un-gapped center post


1203


-


3


is reduced, thus relieving reducing the area in center post


1203


-


3


necessary to prevent saturation.




The integrated magnetic approach in

FIGS. 10

,


11


,


12


, and


14


can be applied to any number of rectifier stages, although the integrated magnetic components in

FIGS. 12 and 14

may require custom-designed magnetic cores when more than two parallel rectifier stages are present, because each additional rectifier stage requires an additional leg. For an even number of rectifier stages, the converter can be implemented with a number of x-type cores, using an x-core to integrate each pair of rectifiers, as illustrated by converters


1200


and


1400


of

FIGS. 12 and 14

. Finally, converters


700


,


900


,


1000


,


1100


,


1200


, and


1400


of

FIGS. 7

,


9


,


10


,


11


,


12


, and


14


can be implemented using synchronous rectifiers, rather than diode rectifiers.




The current-sharing performance of each of converters


700


,


900


and


1000


was verified experimentally on a 200 kHz, 100 A/2.5 V prototype designed to operate from a 48-volt input. The prototype was implemented with a half-bridge inverter and two current-doubler rectifier stages. The measured full-load current-sharing performance and conversion efficiency are summarized in Table I.












TABLE I











Measured current-sharing performance and






conversion efficiency of a 100-A/5-V prototype with






two paralleled rectifier stages















First rectifier




Second rectifier








(i.e., rectifier




(i.e., rectifier








707-1) output




707-2) output







Implementation




current (A)




current (A)




Efficiency (%)

















Non-coupled




48.1




48.6




73.7






inductors (e.g.,






converter 700 of






FIG. 7)






Coupled




48.7




47.8




73.7






inductors (e.g.,






converter 900 of






FIG. 9)






Integrated




49.3




48.1




73.6






Magnetics (e.g.,






converter 1000






of FIG. 10)














The detailed description above is provided to illustrate specific embodiments of the present invention and is not intended to be limiting. Numerous variations and modifications within the scope of the present invention are possible. The present invention is set forth in the following claims.



Claims
  • 1. An isolated DC/DC converter, comprising:an inverter stage including a plurality of transformers having their primary windings connected in series; and a plurality of parallel rectifier stages each including a filter inductor and each connected to a secondary winding of said transformer, wherein each said secondary winding corresponds to a respective one of said primary windings and wherein each filter inductor of said plurality of parallel rectifier stages is coupled to another filter inductor of said plurality of parallel rectifier stages.
  • 2. An isolated DC/DC converter as in claim 1, wherein each of said rectifier stages comprises a current doubler.
  • 3. An isolated DC/DC converter as in claim 1, wherein each of said secondary winding is related to said respective primary winding by a predetermined turns ratio.
  • 4. An isolated DC/DC converter as in claim 2, wherein each parallel rectifier stage further comprises a second filter inductor.
  • 5. An isolated DC/DC converter as in claim 4, further comprising a magnetic core wherein said first filter inductors of said parallel rectifier stages are coupled to each other, and wherein said second filter inductors of said parallel rectifiers stages are coupled to each other.
  • 6. An isolated DC/DC converter as in claim 4, wherein said first and second filter inductors of said parallel rectifier stages are coupled to each other.
  • 7. An isolated DC/DC converter as in claim 5, wherein said first and second filter inductors of said parallel rectifier stages are coupled to each other by virtue of the structure of said magnetic core.
  • 8. An isolated DC/DC converter as in claim 4, wherein said first and second filter inductors of said parallel rectifier stages are isolated from each other.
  • 9. An isolated DC/DC converter as in claim 4, wherein said first and second filter inductors of said parallel rectifier stages are isolated from each other by virtue of said magnetic core.
  • 10. An isolated DC/DC converter as in claim 1, wherein said filter inductors and said primary and secondary windings of said transformer are provided on an integrated magnetic core.
  • 11. An isolated DC/DC converter as in claim 10, wherein said integrated magnetic core comprises a center post.
  • 12. An isolated DC/DC converter as in claim 11, wherein said center post of said integrated magnetic core is ungapped.
  • 13. An isolated DC/DC converter as in claim 12, wherein said primary and secondary windings of each transformer are placed on a corresponding leg of said integrated magnetic core having a first air gap, and wherein said first and second inductors of each rectifier stage are placed on corresponding legs of said integrated magnetic core having a second air gap, said first air gap being smaller than said second air gap.
  • 14. An isolated DC/DC converter as in claim 10, whereto said integrated magnetic core comprises of an X-shaped magnetic core.
  • 15. An isolated DC/DC converter as in claim 13, wherein substantially equal number of said rectifier stages have the winding orientation of said transformer and inductor windings in the opposite directions to reduce the flux in said center post of said integrated magnetic core.
  • 16. An isolated DC/DC converter as in claim 14, wherein said first rectifier stage has the opposite winding orientation of said transformer and inductor windings from the winding orientation of the corresponding windings of said second rectifier stage so that the flux in said center post of said integrated magnetic core is substantially reduced.
US Referenced Citations (7)
Number Name Date Kind
3654537 Coffey Apr 1972 A
4445166 Berglund Apr 1984 A
4673888 Englemanns et al. Jun 1987 A
5500791 Kheraluwala et al. Mar 1996 A
5541827 Allfather Jul 1996 A
6118679 Smith Sep 2000 A
6272027 Fraidlin et al. Aug 2001 B1