IP Library › Granted Patent US 11,411,510
Granted Patent B2
US 11,411,510 · App. 16/751,775 · Granted Aug 9, 2022

DC/AC inverter resonance topology

Inventors: Seba Alnajjar (Southfield, MI); Tayler Jouja (Southfield, MI); Theodore Atanassov (Southfield, MI); David A. Hein (Sterling Heights, MI)
Assignee: LEAR CORPORATION
H02M7/4807H02M3/337H02M3/3376H02M3/33569H02M7/48H02M1/0058H02M1/0083H02M7/4815
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Quick Facts
Patent No.
US 11,411,510
App. No.
16/751,775
Granted
Aug 9, 2022
Kind
B2
Abstract

A direct current/alternating current (DC/AC) inverter system includes a primary DC-DC converter that receives an input DC voltage and a secondary DC/AC inverter. The primary DC-DC converter includes a plurality of switching networks and a plurality of transformers having a plurality of primary windings and a plurality of secondary windings. Characteristically, the plurality of secondary windings is arranged in series to provide a first output and a second output. A resonant LC circuit is connected in series with the first output and the second output. A rectifier rectifies an AC voltage between the first output and the second output to form a first rectified output. The secondary DC/AC inverter receives the first rectified output or filtered output thereof and provides a high voltage AC output. A controller mediates switching of the plurality of switching networks.

Claims (29)

1. A direct current/alternating current (DC/AC) inverter system comprising:

a primary DC-DC converter that receives an input DC voltage and includes:

a plurality of switching networks, wherein each switching network includes one or more transistor switches;

a plurality of transformers having a plurality of primary windings and a plurality of secondary windings, each transformer having an associated primary winding of the plurality of primary windings and an associated secondary winding of the plurality of secondary windings, each transformer configured to be activated by switching of an associated switching network of the plurality of switching networks, each associated switching network of the plurality of switching networks configured to alternate the input DC voltage across the associated primary winding of the plurality of primary windings, wherein the plurality of secondary windings are arranged in series to provide a first output and a second output;

a resonant LC circuit connected in series with the first output and the second output; and

a rectifier that rectifies an AC voltage between the first output and the second output to form a first rectified output;

a secondary DC/AC inverter that receives the first rectified output or filtered output thereof and provides an AC output; and

a controller that controls switching of the plurality of switching networks, wherein the plurality of switching networks are switched with zero current switching at a frequency from 40 kHz to 100 kHz, the DC/AC inverter system being configured to operate without a cooling fan, wherein the resonant LC circuit includes a leakage inductance of the plurality of secondary windings in series with a capacitor.

2. The DC/AC inverter system of claim 1 wherein the primary DC-DC converter includes 2n push-pull converters where n is an integer equal to or greater than 2.

3. The DC/AC inverter system of claim 1 wherein the primary DC-DC converter includes 2n flyback converters where n is an integer equal to or greater than 2.

4. The DC/AC inverter system of claim 1 wherein the primary DC-DC converter includes 2n H-bridge converters where n is an integer equal to or greater than 2.

5. The DC/AC inverter system of claim 1 wherein the AC output has an RMS voltage from about 80 to 250 volts.

6. The DC/AC inverter system of claim 1 wherein the resonant LC circuit includes the capacitor in series with an inductor.

7. The DC/AC inverter system of claim 1 wherein the input DC voltage is from 11 to 16 volts.

8. The DC/AC inverter system of claim 1 wherein the first rectified output is a DC output or filtered output thereof.

9. The DC/AC inverter system of claim 1 wherein the first rectified output has an average voltage magnitude from about 80 to 400 volts.

10. A direct current/alternating current (DC/AC) inverter system comprising:

a first push-pull converter including a first switching network and a first isolation transformer, the first isolation transformer includes a first plurality of primary windings and a first plurality of secondary windings, the first switching network configured to alternate an input DC voltage across the first plurality of primary windings;

a second push-pull converter including a second switching network and a second isolation transformer, the second isolation transformer including a second plurality of primary windings and a second plurality of secondary windings, the second switching network also configured to alternate the input DC voltage across the second plurality of primary windings, the first plurality of secondary windings and the second plurality of secondary windings being connected in series to output a first output and a second output;

a resonant LC circuit connected in series with the first output and the second output;

a rectifier that rectifies an AC voltage between the first output and the second output to form a first rectified output;

a controller that controls switching of the first switching network and the second switching network, wherein the first switching network and the second switching network are switched with zero current switching at a frequency from 40 kHz to 100 kHz, wherein the DC/AC inverter system is configured to operate without a cooling fan; and

a DC/AC converter that receives the first rectified output or filtered output thereof and provides a high voltage AC output, wherein the resonant LC circuit includes a leakage inductance of the first plurality of secondary windings and the second plurality of secondary windings in series with a capacitor.

11. The DC/AC inverter system of claim 10 wherein the high voltage AC output has an RMS voltage from about 80 to 250 volts.

12. The DC/AC inverter system of claim 10 wherein the first isolation transformer and the second isolation transformer are each independently configured with a two-switch topology.

13. The DC/AC inverter system of claim 12 wherein the first isolation transformer and the second isolation transformer are each independently configured with a split primary winding.

14. The DC/AC inverter system of claim 12 wherein the first isolation transformer includes a first switch attached to a first terminal of the first isolation transformer and a second switch in electrical communication with a second terminal of the first isolation transformer.

15. The DC/AC inverter system of claim 10 wherein the resonant LC circuit is connected in series with the first plurality of secondary windings and the second plurality of secondary windings, the resonant LC circuit includes the capacitor in series with an inductor.

16. The DC/AC inverter system of claim 10 wherein the input DC voltage is from 11 to 16 volts and the first rectified output has an average voltage magnitude from about 80 to 400 volts.

Assignments (2)
CORRECTIVE ASSIGNMENT TO CORRECT THE TO REMOVE THE 4TH, 5TH AND THE 6TH INVENTOR PREVIOUSLY RECORDED AT REEL: 051610 FRAME: 0679. ASSIGNOR(S) HEREBY CONFIRMS THE ASSIGNMENT. Recorded May 9, 2022
From: ALNAJJAR, SEBA; JOUJA, TAYLER; ATANASSOV, THEODORE; HEIN, DAVID A.
To: LEAR CORPORATION
Reel/Frame 059911/0429 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 24, 2020
From: ALNAJJAR, SEBA; JOUJA, TAYLER; ATANASSOV, THEODORE; TARMOON, EHAB; NIRANJAN, CHARLES; VADLAMUDI, VENKATA; HEIN, DAVID A.
To: LEAR CORPORATION
Reel/Frame 051610/0679 →
Continuity (1)
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