Ulllted States Patent [19]
`Lanni
`
`US005838554A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,838,554
`*N0v. 17, 1998
`
`[54] SMALL FORM FACTOR POWER SUPPLY
`
`[75] Inventor: Thomas W- Lanni, Laguna Niguel,
`Calif
`
`4,307,441 12/1981 Bello ....................................... .. 363/25
`4,622,627 11/1986 Rodriguez et al. .
`363/37
`4,734,839
`3/1988 Barthold ....... ..
`363/16
`4,885,674 12/1989 Varga 618.1.
`363/21
`
`_
`
`_
`
`_
`
`[73] Ass1gnee: Cornarco Wireless Technologies, Inc.,
`Irvlne> Cahf-
`
`4,890,214 12/1989 Yamamoto ....... ..
`
`5,019,954
`5,146,394
`
`5/1991 Bourgeault et a1‘
`9/1992 Ishii et a1. ......... ..
`
`363/49
`
`363/21
`363/16
`
`363/25
`
`.
`
`[*1 Nome‘
`
`.
`
`ghe teéntlhof thls. pfltentdstiau If“); ixtgld
`563211106 explra 10“ H O
`a‘
`0'
`
`5,177,675
`
`5,184,291
`5,309,348
`
`1/1993 Archer ...... ..
`
`2/1993 Crowe et a1. ........................... .. 363/77
`5/1994 Leu ......................................... .. 363/71
`
`’
`
`’
`
`'
`
`[21] Appl. No.: 994,905
`
`5,479,331 12/1995
`.. 363/21
`5,636,110
`6/1997 LaIlIll ...................................... .. 363/21
`
`[22] Flled:
`
`Dec' 19’ 1997
`Related US Application Data
`
`Primary Examiner—Adolf Berhane
`Attorney, Agent, or Firm—Pillsbury Madison & Sutro LLP
`
`[63] Continuation-in-part of Ser. No. 767,307, Dec. 16, 1996,
`abandoned, which is a continuation-in-part of Ser. No.
`567,369, Dec. 4, 1995, Pat. NO. 3,636,110, which is a
`continuation-in-part of Ser. No. 233,121,Apr. 26, 1994, Pat.
`NO‘ 5’479’331'
`Int. Cl.6 .................................................. .. H02M 3/335
`[51]
`[52] US. Cl. ............................ .. 363/21; 363/97; 363/144;
`363/147
`20, 21,
`of Search ................................ ..
`363/24> 25> 78> 79> 80> 97> 98> 132> 141>
`144; 323/212
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`[57]
`
`ABSTRACT
`
`_
`_
`A new, Small form factor Power Supply 15 (1156105601 that
`provides a regulated DC power supply in a package that
`radiates relatively little heat and that occupies 2.85><5.0><
`0.436 inches. The secondary coil of the transformer is
`positioned at the summing node of the ?ux of the primary
`coils and the phase of the drive signals provided to the
`Secondary Coils is regulated to Control the Current and
`voltage provided by the secondary circuit. Preferably, all
`circuit components are surface mount devices and the trans
`former cores are E block planar cores mounted on the
`printed circuit board.
`
`4,257,080
`
`3/1981 Ravis ...................................... .. 363/25
`
`36 Claims, 39 Drawing Sheets
`
`[ 3000
`
`Prong, Inc. Exh. 1007 p. 1
`
`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 1 0f 39
`
`5,838,554
`
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`Prong, Inc. Exh. 1007 p. 2
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`US. Patent
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`Nov. 17, 1998
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`US. Patent
`
`Nov. 17,1998
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`Sheet 3 0f 39
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`5,838,554
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`Prong, Inc. Exh. 1007 p. 4
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`Prong, Inc. Exh. 1007 p. 4
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`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 4 0f 39
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`5,838,554
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`

`

`US. Patent
`
`Nov. 17,1998
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`Sheet 5 0f 39
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`5,838,554
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`Prong, Inc. Exh. 1007 p. 6
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`Prong, Inc. Exh. 1007 p. 6
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`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 6 0f 39
`
`5,838,554
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`Prong, Inc. Exh. 1007 p. 7
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`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 7 0f 39
`
`5,838,554
`
`4/‘ L318
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`Prong, Inc. Exh. 1007 p. 8
`
`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 8 0f 39
`
`5,838,554
`
`FIG. 6
`
`Prong, Inc. Exh. 1007 p. 9
`
`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 9 0f 39
`
`5,838,554
`
`\DCO NCO
`
`Prong, Inc. Exh. 1007 p. 10
`
`

`

`U.S. Patent
`
`Nov. 17,1998
`
`Sheet 10 0f 39
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`5,838,554
`
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`U.S. Patent
`
`Nov. 17,1998
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`Sheet 11 0f 39
`
`5,838,554
`
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`
`Prong, Inc. Exh. 1007 p. 12
`
`

`

`US. Patent
`
`Nov. 17, 1998
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`Sheet12 0f39
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`5,838,554
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`

`U.S. Patent
`
`Nov. 17, 1998
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`U.S. Patent
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`Nov. 17,1998
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`US. Patent
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`Nov. 17,1998
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`U.S. Patent
`
`Nov. 17,1998
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`Sheet 16 0f 39
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`U.S. Patent
`
`Nov. 17, 1998
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`Sheet 17 0f 39
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`

`U.S. Patent
`
`Nov. 17,1998
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`Sheet 18 0f 39
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`
`Prong, Inc. Exh. 1007 p. 19
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`

`

`US. Patent
`
`Nov. 17,1998
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`US. Patent
`
`Nov.
`
`17,1998
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`Sheet 20 0f 39
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`5,838,554
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`Prong, Inc. Exh. 1007 p. 21
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`

`

`US. Patent
`
`Nov. 17,1998
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`Sheet 21 0139
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`Prong, Inc. Exh. 1007 p. 22
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`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 23 0f 39
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`5,838,554
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`Prong, Inc. Exh. 1007 p. 24
`
`Prong, Inc. Exh. 1007 p. 24
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 24 0f 39
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`5,838,554
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`Prong, Inc. Exh. 1007 p. 25
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`Prong, Inc. Exh. 1007 p. 25
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`

`

`US. Patent
`
`Nov. 17, 1998
`
`Sheet 25 0f 39
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`US. Patent
`
`Nov. 17,1998
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`US. Patent
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`Nov. 17,1998
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`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 28 0f 39
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`5,838,554
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`US. Patent
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`Nov. 17, 1998
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`Prong, Inc. Exh. 1007 p. 30
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 30 0f 39
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`“4
`
`1536
`
`1536
`
`FIG.38(b)
`
`FlG.38(a)
`
`FlG.38(c)
`
`Prong, Inc. Exh. 1007 p. 31
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 31 0139
`
`5,838,554
`
`5541
`
`FIG. 39((b)
`
`|—)l/l§36-'0
`
`1 536
`
`'234
`FIG. 39(c
`
`1 554
`
`1 552
`
`F NC
`FIG. 39(0
`
`1558
`
`1536
`
`1535
`
`FIG. 40(b
`
`FIG.40(a)
`
`FIG.40(c)
`
`Prong, Inc. Exh. 1007 p. 32
`
`

`

`US. Patent
`
`Nov. 17, 1998
`
`Sheet 32 0f 39
`
`5,838,554
`
`
`
`h. 1007 p.33
`
`Prong, Inc. Exh. 1007 p. 33
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 33 0f 39
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`5,838,554
`
`’/ 3000
`
`
`
`Prong, Inc. Exh. 1007 p. 34
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 34 0f 39
`
`5,838,554
`
`
`
`Prong, Inc. Exh. 1007 p. 35
`
`Prong, Inc. Exh. 1007 p. 35
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 35 0f 39
`
`5,838,554
`
`3000
`
`
`302]
`3018
`3020
`
`FIG.45
`
`
`
`Prong, Inc. Exh. 1007 p. 36
`
`Prong, Inc. Exh. 1007 p. 36
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 36 0f 39
`
`5,838,554
`
`
`
`Prong, Inc. Exh. 1007 p. 37
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 37 0f 39
`
`5,838,554
`
`FIG.48
`
`Prong, Inc. Exh. 1007 p. 38
`
`Prong, Inc. Exh. 1007 p. 38
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 38 0f 39
`
`5,838,554
`
`4000
`
`FIG.49
`
`Prong, Inc. Exh. 1007 p. 39
`
`Prong, Inc. Exh. 1007 p. 39
`
`

`

`US. Patent
`
`Nov. 17,1998
`
`Sheet 39 0f 39
`
`5,838,554
`
`
`
`Prong, Inc. Exh. 1007 p. 40
`
`Prong, Inc. Exh. 1007 p. 40
`
`

`

`5,838,554
`
`1
`SMALL FORM FACTOR POWER SUPPLY
`
`RELATED APPLICATIONS
`
`This application is a continuation-in-part application of
`utility application Ser. No. 08/767,307 filed Dec. 16, 1996,
`now abandoned, which is a continuation-in-part application
`of utility application Ser. No. 08/567,369 filed Dec. 4, 1995,
`now US. Pat. No. 3,636,110, and claims priority of provi-
`sional application Ser. No. 60/002,488 filed Aug. 17, 1995,
`and is also a continuation-in-part application of utility
`application Ser. No. 08/233,121 filed Apr. 26, 1994, now
`US. Pat. No. 5,479,331 issued Dec. 26, 1995.
`NOTICE OF COPYRIGHTS
`
`A portion of the disclosure of this patent document
`contains material which is subject to copyright protection.
`The copyright owner has no objection to the facsimile
`reproduction by anyone of the patent disclosure, as it
`appears in the United States Patent and Trademark Office
`patent files or records, but otherwise reserves all copyright
`rights whatsoever.
`BACKGROUND OF THE INVENTION
`
`1. Field of the Invention
`
`This invention relates to power supplies and in particular
`relates to small form factor power supplies for use with a
`variety of different devices.
`2. Background of the Invention
`Prior art power supplies include a variety of techniques,
`particularly those used for powering microelectronics such
`as the class of computers commonly known as “notebook”
`computers such as the Powerbook Series available from
`Apple Computer of Cupertino, Calif. and the Thinkpad
`Series available from International Business Machines
`
`(IBM) of Armonk, NY. More recently, even smaller per-
`sonal computers referred to as “sub-notebooks” have also
`been developed by various companies such as Hewlett-
`Packard’s Omnibook. The goal of these notebooks and
`sub-notebooks designs is to reduce the size and weight of the
`product. Currently, notebooks typically weigh about six
`pounds and sub-notebooks weigh slightly less than four
`pounds.
`Many of these notebook and sub-notebook computers
`have a battery that must be recharged. Also, typically the
`computers are designed to be operated from external power
`sources such as line current and the electrical power system
`of automobiles.
`
`To power these computers, the manufacturer typically
`provides an external power source. The external power
`source may be a switching power supply that may weigh
`close to a pound and may be about eight inches long, four
`inches wide and about four inches high. Smaller power
`supplies do exist but frequently they lack sufficient power to
`charge new batteries such as nickel hydride batteries.
`Such external power supplies therefore contribute sub-
`stantial additional weight that the user of the computer must
`carry with him or her to permit battery charging and/or
`operation from an electrical socket. Further,
`the external
`power supply is bulky and may not be readily carried in
`typical cases for such notebook and sub-notebook comput-
`ers. In addition, conventional power supplies often have
`difficulty providing the necessary power curve to recharge
`batteries that have been thoroughly discharged. Also, a
`power supply is needed for each peripheral device, such as
`a printer, drive or the like. Thus, a user needs multiple power
`supplies.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
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`55
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`60
`
`65
`
`2
`While it has long been known to be desirable to reduce the
`size and weight of the power supply,
`this has not been
`readily accomplished. Many of the components such as the
`transformer core are bulky and have significant weight.
`Further, such power supplies may need to be able to provide
`DC power of up to seventy-five watts, thereby generating
`substantial heat. Due to the inherent inefficiencies of power
`supplies,
`this results in substantial heat being generated
`within the power supply. Reduction of the volume, weight
`and heat are all critical considerations for a power supply in
`this type of application and cannot be readily accomplished.
`In particular, it is believed to be desirable to have a package
`as thin as possible and designed to fit within a standard
`pocket on a shirt or a standard calculator pocket on a brief
`case. In addition, conventional power supplies are device
`specific and each device requires its own power supply.
`Therefore, users need multiple power supplies, which con-
`sumes space and increases unnecessary weight.
`Cellular telephones are also extensive users of batteries.
`Typically, cellular telephone battery chargers have been
`bulky and are not readily transportable. Moreover, cellular
`telephone battery chargers often take several hours, or more,
`to charge a cellular telephone battery.
`
`SUMMARY OF THE INVENTION
`
`It is an object of an embodiment of the present invention
`to provide an improved small form factor power supply that
`is resistant to liquids and/or is programmable to supply
`power for a variety of different devices, which obviates for
`practical purposes, the above mentioned limitations.
`These and other objects are accomplished through novel
`embodiments of a power supply having a transformer. The
`primary portion includes a primary rectifier circuit, a
`controller, first and secondary primary drive circuits each
`coupled magnetically by a coil to the core and a primary
`feedback circuit magnetically coupled by a separate core.
`The secondary portion includes a secondary output circuit
`magnetically coupled by a coil to the core that provides the
`regulated DC output and a secondary feedback back circuit
`magnetically coupled to the second core to provide a signal
`to the primary feedback circuit. In alternative embodiments,
`different transformer topologies may be used.
`The controller provides a separate square wave signal to
`each of the two primary circuits and the phase of the square
`wave signals may be altered relative to each other as
`determined by the controller. The secondary circuit is posi-
`tioned on the core relative to the two primary circuits so that
`the secondary circuit coil is positioned at a summing point
`on the core of the first and second primary circuit coils. The
`DC voltage and current levels produced at the output of the
`secondary circuit are monitored by the secondary feedback
`circuit to provide, through a secondary feedback coil and a
`primary feedback coil, a signal to the controller. The con-
`troller alters the phase between the signals driving the two
`coils to produce the desired output DC voltage and current
`at the secondary coils. This results in providing a regulated
`DC power supply with high efficiency.
`By mounting all of the components on a printed circuit
`board using planar or low profile cores and surface mounted
`integrated circuits, a small form factor power supply can be
`attained. Given the high efficiency of the conversion and
`regulation, the system minimizes dissipation of heat permit-
`ting the entire power supply to be mounted within a high
`impact plastic container dimensioned, for example, as a right
`parallelepiped of approximately 2.85><5.0><0.436 inches,
`thereby providing a power supply that can readily be carried
`
`Prong, Inc. Exh. 1007 p. 41
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`Prong, Inc. Exh. 1007 p. 41
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`

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`5,838,554
`
`3
`in a shirt pocket. It should be understood that changes in the
`overall dimensions may be made without departing from the
`spirit and scope of the present invention. Making a relatively
`thin package having relatively large top and bottom surface
`areas relative to the thickness of the package provides
`adequate heat dissipation.
`Particular embodiments of the present invention utilize an
`improved transformer core that, by moving the relative
`position of the transformer legs, maximizes a ratio of the
`cross-sectional area of the transformer legs to the windings,
`thereby requiring less windings for the same magnetic
`coupling. Fewer windings means less area of a layer of a
`circuit board may be used so that the number of layers on the
`circuit board may be minimized. The improved transformer
`core also provides this maximized ratio while maintaining
`the ratio of the secondary and primary windings at a constant
`value.
`In alternative embodiments, different
`transformer
`topologies may be used.
`Also, the power supplies may be configured to be pro-
`grammable to support a variety of different devices and/or
`more than one device at a time. This may be accomplished
`with an onboard processor or by using external cables to
`provide the programming. Further embodiments utilize a
`sealed heat sink and louver system to dissipate heat and still
`maintain resistance to the penetration of liquids into the
`power supply.
`Other features and advantages of the invention will
`become apparent from the following detailed description,
`taken in conjunction with the accompanying drawings which
`illustrate, by way of example, various features of embodi-
`ments of the invention.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`A detailed description of embodiments of the invention
`will be made with reference to the accompanying drawings,
`wherein like numerals designate corresponding parts in the
`several figures.
`FIG. 1 is a block diagram of a first embodiment of the
`disclosed invention.
`FIG. 2 is a sectional view of the E core for use in the
`embodiments of FIG. 1.
`FIGS. 3A and 3B are a detailed circuit schematic of the
`embodiment of FIG. 1.
`
`FIG. 4 is a top planar view of a printed circuit board
`containing the circuit of FIG. 3.
`FIG. 5A is a top planar view of a case or housing for an
`additional embodiment of the for an invention where the
`
`case houses the other components.
`FIG. 5B is a partial cross-section of the louvers and
`openings of the case top as shown in FIG. 5A.
`FIG. 5C is a partial cross-section of another embodiment
`of the louvers formed from raised ridges and depressions on
`the case top.
`FIG. 6 is a top planar view of one of two heat sinks for
`the additional embodiment of the invention that sandwich a
`
`printed circuit board containing the circuitry for the addi-
`tional embodiment.
`
`FIGS. 7A and 7B are a schematic diagram of the addi-
`tional embodiment of the invention.
`
`FIG. 8 is a timing diagram for the circuit shown in FIG.
`
`7
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`FIG. 9 is a block diagram of the U1 integrated circuit
`shown in FIG. 7.
`
`65
`
`FIGS. 10A and B are timing diagrams for the block
`diagram shown in FIG. 9.
`
`4
`FIG. 11 is a power versus output current curve and an
`output voltage versus current curve of a power supply in
`accordance with an embodiment of the present invention.
`FIGS. 12A—12C are a top plan view and two side plan
`views of a transformer core in accordance with another
`
`embodiment of the present invention.
`FIGS. 13A—13C are a top plan view and two side plan
`views of a transformer cap for use with the transformer core
`shown in FIGS. 12A—12C.
`
`FIG. 14 is a top plan view of a printed circuit board layer,
`without winding patterns, to be coupled with the transformer
`core shown in FIGS. 12A—12C.
`
`10
`
`FIG. 15 is a top plan view of another printed circuit board
`layer showing a secondary winding pattern to be coupled
`with to the transformer core shown in FIGS. 12A—12C.
`
`15
`
`FIG. 16 is a top plan view of another printed circuit board
`layer showing a primary winding pattern to be coupled with
`the transformer core shown in FIGS. 12A—12C.
`
`20
`
`25
`
`FIGS. 17A—17C are a top plan view and two side plan
`views of a transformer core in accordance with an alterna-
`
`tive embodiment of the present invention.
`FIGS. ISA—18C are a top plan view and two side plan
`views of a transformer cap for use with the transformer core
`shown in FIGS. 17A—17C.
`
`FIG. 19 is a top plan view of a printed circuit board layer
`with a secondary winding pattern to be coupled with the
`transformer core shown in FIGS. 17A—17C.
`
`30
`
`FIG. 20 is a top plan view of another printed circuit board
`layer showing primary winding patterns to be coupled with
`the transformer core shown in FIGS. 17A—17C.
`
`FIG. 21 is a top plan view of another printed circuit board
`layer showing additional primary winding patterns to be
`coupled with the transformer core shown in FIGS.
`17A—17C.
`
`FIG. 22 is a top plan view of another printed circuit board
`layer showing a another secondary winding pattern to be
`coupled with the transformer core shown in FIGS.
`17A—17C.
`FIG. 23 is a schematic of a control circuit in accordance
`
`with an embodiment of the present invention.
`FIG. 24 is a schematic of a programing circuit in accor-
`dance with an embodiment of the present invention that is
`used to digitally program the power supply to produce
`between 0 and 16 volts.
`
`FIG. 25 is a schematic of another programing circuit in
`accordance with an embodiment of the present invention
`that is used to digitally program the power supply to produce
`between 16 and 18 volts.
`FIG. 26 is an end view of a connector that mates with the
`
`small form factor power supply and is useable to program
`the small form factor power supply.
`FIGS. 27(a)—34(c) show various cables with connectors
`in accordance with embodiments of the present invention
`that program the small form factor power supply for sup-
`plying power to different devices.
`FIGS. 35(a)—40(c) show various connector adapters four
`use with the cable shown above in FIGS. 34(a)—34(c).
`FIGS. 41(a) and 41(b) illustrate a block diagram and a
`schematic of an interface for providing power to more than
`one device at a time.
`
`FIG. 42 shows a top and rear perspective view of a small
`form factor power supply for use with portable telephone
`equipment.
`FIG. 43 shows a top and front perspective view of the
`small form factor power supply shown in FIG. 42.
`
`Prong, Inc. Exh. 1007 p. 42
`
`Prong, Inc. Exh. 1007 p. 42
`
`

`

`5,838,554
`
`5
`FIG. 44 shows a bottom and front perspective view of the
`small form factor power supply shown in FIG. 42.
`FIG. 45 shows a side perspective view of the small form
`factor power supply shown in FIGS. 42—44 connected to a
`cellular telephone battery and telephone.
`FIG. 46 shows a top front perspective view of the small
`form factor power supply shown in FIGS. 42—44 connected
`to a cellular telephone battery and telephone.
`FIG. 47 shows a top and front perspective view of a small
`form factor power supply adapter connector for use with
`portable telephone equipment.
`FIG. 48 shows a top perspective view of the adapter
`connector shown in FIG. 47.
`
`FIG. 49 shows a bottom perspective view of the adapter
`connector shown in FIG. 47
`
`FIG. 50 shows a right side view of the adapter connector
`shown in FIG. 47.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`As shown in the drawings for purposes of illustration, the
`invention is embodied in an improved small form factor
`power supply.
`In preferred embodiments of the present
`invention, the small form factor power supply is packaged in
`a small volume and produces over 75 watts of power with
`temperatures below 140° F. Preferred embodiments are used
`to power portable computers. However, it will be recognized
`that further embodiments of the invention may be used with
`other electronic devices, such as computer peripherals, audio
`and video electronics, portable telephone equipment and the
`like.
`
`FIG. 1 shows a block diagram of the power supply
`according to the invention. All components on the left side
`of a magnetic core 20 are part of the primary portion 100 and
`all portions on the right hand side are part of the secondary
`portion 200 of the power supply.
`The primary portion 100 includes a primary rectifier and
`input circuit 110, a first primary and drive circuit 120, a
`second primary and drive circuit 130, a primary feedback
`circuit 140 and a controller 150. The secondary portion 200
`includes a secondary output circuit 210 and a secondary
`feedback circuit 240.
`
`The function of the primary rectifier and input circuit 110
`is to couple the embodiment 10 to the line voltage (for
`example 110 volt, 60 Hz), to rectify that voltage and provide
`DC power for the remainder of the primary portion 100 and
`a ground path for the primary circuits 120 and 130. The
`controller 150, which may be a Unitrode 3875 provides two
`square wave driver signals 152 and 154 having alterable
`phases to the first and the second primary circuits 120 and
`130. The first and second primary circuits are resonant
`circuits that are resonant at about the frequency of the driver
`signals and include coils that are coupled to the core 20,
`which may be a planar or low profile “E” type core, which
`may be any low loss material, as is shown in a sectional view
`in FIG. 2. Hence, the driver signals are magnetically coupled
`to the core 20 by first and second primary coils contained
`within the circuits 120, 130.
`The coil 212 in the secondary circuit 210 is preferably
`positioned relative to the coils of the two primary cores so
`that the coil in the secondary circuit is at a summing point
`of the magnetic flux from the primary circuit coils. If a
`planar or low profile “E” type core as shown in FIG. 2 is
`used, the coil 212 for the secondary circuit 210 is positioned
`about the central leg 22. The coil for the feedback circuits
`
`10
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`15
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`20
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`25
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`30
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`35
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`40
`
`45
`
`50
`
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`
`60
`
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`
`6
`140 is positioned on one of the outer legs 24, 26. As a result,
`the magnetic flux from the two primary coils of the primary
`circuits 120, 130 are summed at the position where the
`secondary coil 212 for the secondary circuit 210 is posi-
`tioned. (This positioning of the coils is shown in FIG. 1 by
`using the double line to indicate the central leg 22 and a
`single line to represent the outer legs 24, 26).
`The amplitude of the DC voltage and current produced by
`the secondary circuit 210 are monitored by the secondary
`feedback circuit 230. The primary feedback circuit 140 and
`the secondary feedback circuit 230 are magnetically coupled
`by coils positioned on another core 23 to provide a feedback
`signal to the controller 150. In response to the feedback
`signal, the controller alters the relative phase between the
`two driver signals 152 and 154 to obtain the desired mag-
`nitude of the voltage and current. Since the secondary coil
`212 is located at a summing point on the core of the flux
`from the two primary coils, as the phase between the driving
`signals 152 and 154 to the two primary coils alters, the
`magnitude of the current and voltage induced in the sec-
`ondary coil will vary. This will permit control of the sec-
`ondary circuit 210 output voltage and current,
`thereby
`providing a readily controlled output voltage.
`FIG. 3 shows a more detailed schematic of an embodi-
`
`ment of the invention. A standard AC plug may be coupled
`to input nodes 111, 112 to a first filter coil L1 that is coupled
`to a full wave rectifier bridge 113, which may be a
`MDA106G. Filtering capacitors C1, C2, C7, C8 are also
`coupled to the bridge 113 and one side of the bridge is
`coupled to AC ground.
`The other side of the bridge is coupled to the primary coils
`122 and 132 of the first and second primary circuits 120, 130
`respectively. The other terminal of the primary coils 122,
`132 are coupled to the remainder of the primary circuits 120
`and 130. Each of these primary circuits 120, 130 also
`comprise a drive field effect 124, 134, which may be a
`MTP6N60 and a capacitor 126, 136. The coils 122, 132,
`transistors 124, 134 and capacitors 126, 136 are selected so
`that the resonant frequency of the circuits 120, 130 is at
`about the frequency of the drive signals 152, 154 to maXi-
`mize the efficiency of the power supply. In this embodiment,
`the drive signal frequency is about one megahertz, though
`other frequencies may be used.
`The drive signals 152 and 154 are supplied by a controller
`150 such as a Unitrode UC3875QP or other similar product.
`The controller 150 receives the biasing power at pins 28 and
`1 from the primary power supply circuit 160.
`Each of the coils 122 and 132 induce a varying magnetic
`field in the outer legs of the core 20. The secondary coil 212,
`which has a center tap 213, is coupled to a half wave rectifier
`bridge 214, which may comprise an MBRD660CT, and then
`is coupled to a filtering circuit 216 comprised of a capacitor
`218, an inductor 220, and capacitors 222 and 224 to provide
`a DC regulated output 226.
`The regulation is provided by feeding back to the con-
`troller 150 a signal modulated by a current sensing amplifier
`circuit 232 and a voltage sensing circuit 240 comprising the
`feedback circuit 230. To provide the carrier for modulation,
`a further secondary carrier coil 242 is coupled to one of the
`outer legs of the core 20. One of the legs of this transformer
`coil 242 is coupled to an isolation feedback transformer T2.
`The current sensing circuit takes the output of the center
`tap of the secondary coil 212 and provides a voltage drop
`across resistor R9 that is provided to current sensing ampli-
`fier circuit 232. The output of the current sensing amplifier
`circuit 232 is added to a voltage dropped across R13 and is
`
`Prong, Inc. Exh. 1007 p. 43
`
`Prong, Inc. Exh. 1007 p. 43
`
`

`

`5,838,554
`
`7
`provided to an amplifier 244 in the voltage sensing circuit
`240. The other input in the voltage sensing circuit is a
`reference voltage developed by the zener reference diode
`246 and also provided as a biasing level to the current
`sensing amplifier circuit 232. The output of the amplifier 244
`is provided to the base of bipolar transistor Q3, which may
`be a MMBT2907T, configured in a common base
`configuration, to amplitude modulate the current through the
`secondary side coil 246.
`The primary side coil 156 of feedback transformer T2 is
`magnetically coupled to the secondary side coil of 246 and
`generates an amplitude modulated signal that is envelope
`detected and integrated to provide a feedback voltage at
`input 22 of the controller 150.
`As a result, as the amplitude of the envelope of the
`modulated signal increases, the voltage at input 22 of the
`controller 150 increases. When the controller 150 deter-
`
`mines that the voltage has exceeded a predetermined limit,
`indicating that either the current or voltage at the output has
`increased beyond the predetermined maximum, the relative
`phase difference of driver signals 152 and 154 is increased.
`If the amplitude at input 22 decreases below a predetermined
`threshold indicating that the voltage or the current is below
`the desired levels, the relative phase of signals 152 and 154
`is decreased toward