(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2013/0188397 A1
`Wu et al.
`(43) Pub. Date:
`Jul. 25, 2013
`
`US 2013 0188397A1
`
`(54) SWITCH WEAR LEVELING
`(71) Applicant: Utah State University, North Logan, UT
`(US)
`72) Inventors: Hunter Wu, Logan, UT (US); Kylee
`(72)
`Sealy, Logan, 9. (US); S. y
`Gilchrist, Logan, UT (US)
`(73) Assignee: UTAH STATE UNIVERSITY, North
`Logan, UT (US)
`
`(21) Appl. No.: 13/748,074
`
`(22) Filed:
`
`Jan. 23, 2013
`
`Related U.S. Application Data
`(60) Provisional application No. 61/589,599, filed on Jan.
`23, 2012.
`s
`
`Publication Classification
`
`(51) Int. Cl.
`HO2M3/335
`
`(2006.01)
`
`(52) U.S. Cl.
`CPC ................................. H02M3/33576 (2013.01)
`USPC ............................................................ 363A17
`
`(57)
`
`ABSTRACT
`
`An apparatus for Switch wear leveling includes a Switching
`module that controls Switching for two or more pairs of
`Switches in a Switching power converter. The Switching mod
`ule controls Switches based on a duty cycle control technique
`and closes and opens each Switch in a Switching sequence.
`The pairs of Switches connect to a positive and negative
`terminal of a DC voltage source. For a first switching
`sequence a first Switch of a pair of Switches has a higher
`Switching power loss than a second Switch of the pair of
`Switches. The apparatus includes a Switch rotation module
`that changes the Switching sequence of the two or more pairs
`of Switches from the first Switching sequence to a second
`Switching sequence. The second Switch of a pair of Switches
`has a higher switching power loss than the first switch of the
`pair of Switches during the second Switching sequence.
`
`
`
`X:
`
`XI.
`
`Controller block diagram for optimal efficiency
`
`Ex.1015 / IPR2022-00529 / Page 1 of 65
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`

`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 1 of 40
`
`US 2013/0188397 A1
`
`
`
`
`
`V
`68 O
`
`Converter
`104
`
`Switch Wear
`Leveling
`Apparatus
`102
`
`FIG. 1
`
`
`
`
`
`Switch Wear Leveling
`ApparatuS
`102
`
`Switching Module
`202
`
`Switch Rotation
`Module
`204
`
`FIG. 2
`
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 2 of 40
`
`US 2013/0188397 A1
`
`
`
`Switch Wear Leveling Apparatus
`102
`
`Switching Module
`202
`
`Switch Rotation
`Module
`204
`
`Switch Wear
`Module
`302
`
`FIG. 3
`
`Ex.1015 / IPR2022-00529 / Page 3 of 65
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`

`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 3 of 40
`
`US 2013/0188397 A1
`
`400n
`
`
`
`Converter
`104
`
`401 Ya
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Switch Wear
`Leveling
`ApparatuS
`102
`
`FIG 4A
`
`Converter
`104
`
`SWitch Wear
`Leveling
`Apparatus
`102
`
`FIG. 4B
`
`Ex.1015 / IPR2022-00529 / Page 4 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 4 of 40
`
`US 2013/0188397 A1
`
`402n
`
`VocC
`
`Converter
`
`
`
`Converter
`Components
`412
`
`
`
`
`
`
`
`
`
`Switch Wear
`Leveling
`Apparatus
`102
`
`FIG. 4C
`
`Ex.1015 / IPR2022-00529 / Page 5 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 5 of 40
`
`US 2013/0188397 A1
`
`
`
`
`
`
`
`Converter
`104
`Converter Components
`412
`
`
`
`
`
`Switch Wear
`Leveling
`ApparatuS
`102
`
`FIG. 5
`
`Ex.1015 / IPR2022-00529 / Page 6 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 6 of 40
`
`US 2013/0188397 A1
`
`
`
`- - - - - - - - - - - -|--------[
`
`>
`
`FIG. 6
`
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 7 of 40
`
`US 2013/0188397 A1
`
`
`
`702
`
`Control Switching for Pairs of Switches
`in a Converter
`
`704
`
`Change the Switching Sequence of the
`Pairs of Switches
`
`FIG. 7
`
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 8 of 40
`
`US 2013/0188397 A1
`
`800n
`
`
`
`802
`
`Control Switching for Pairs of Switches in a
`Converter
`
`804
`
`Track Switching Sequence
`
`806
`
`Change the Switching Sequence of the Pairs
`of Switches to Balance Switching Based on
`Tracking of Switching Sequence
`
`FIG. 8
`
`Ex.1015 / IPR2022-00529 / Page 9 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 9 of 40
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`US 2013/0188397 A1
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Power
`Factor
`V C) Correction Vic
`36
`
`Rectification
`902
`
`
`
`Secondary
`Receiver Pad
`916
`
`Converter
`104
`
`Circuit
`918
`
`Feedback
`Signals
`
`Control
`Signals
`
`N 2 Secondary
`Primary Decoupling
`Receiver Controller
`Pad
`920
`94
`
`Sensor?
`Position
`Detection
`924
`
`
`
`LCL Load
`Resonant
`Converter
`906
`
`WireleSS
`Communications
`922
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`Feedback
`Signals
`
`Control
`Signals
`
`
`
`Primary
`Controller
`908
`
`
`
`
`
`
`
`Switch Wear
`Leveling
`Apparatus
`102
`
`Sensord
`Position
`Detection
`910
`
`Wifeless
`Communications
`912
`
`FIG. 9
`
`Ex.1015 / IPR2022-00529 / Page 10 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 10 of 40
`
`US 2013/0188397 A1
`
`
`
`esa
`
`D
`
`9
`is
`2
`s
`
`5
`
`o C Ver. Range G
`
`190
`
`185 o
`S.
`
`O
`
`i
`CO
`
`180
`
`Hor. Range
`
`O
`
`50
`1OO
`150
`2OO
`Vertical/Horizontal Misalignment(mm)
`
`175
`
`250
`
`Misalignment conditions for vertical and horizontal misalignment.
`h=0 trend represents the profile of vertical misalignment under zero
`horizontal offset. W=200 trend represents the profile of horizontal
`misalignment under 200mm of height separation.
`
`FIG. 10
`
`Ex.1015 / IPR2022-00529 / Page 11 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 11 of 40
`
`US 2013/0188397 A1
`
`
`
`600
`
`500
`
`400
`
`300
`
`200
`
`C
`100
`
`FG4ON120AND
`... KW4ON12OH3
`--RG7PH42UPEF
`
`12
`
`16
`15
`1.4
`13
`17
`Normalised Coupling kn (kiko)
`FIG. 12
`
`18 1.9
`
`2
`
`Ex.1015 / IPR2022-00529 / Page 12 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 12 of 40
`
`US 2013/0188397 A1
`
`140
`
`Temperature Comparison of GBT
`
`-x-T-25C
`
`
`
`8 O
`
`6 O
`
`4 O
`
`7
`
`1
`
`11
`
`12
`
`13 14 15 1.6
`17 18 1.9
`Normalised Coupling k (kiko)
`The losses in the H-bridge for different temperatures for RG7PH42UPBF
`FIG. 13
`
`2
`
`Ex.1015 / IPR2022-00529 / Page 13 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 13 of 40
`
`US 2013/0188397 A1
`
`·
`
`
`
`
`
`
`
`Switch Heatsink Thermal Design
`FIG. 14
`
`Simplified IGBT Gate Drive Circuit
`FIG. 15
`
`••••••****************************** * 3
`***************************
`
`Ex.1015 / IPR2022-00529 / Page 14 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 14 of 40
`
`US 2013/0188397 A1
`
`:
`
`Vide
`
`
`
`LCL Converter with Split inductor Design
`FIG. 16
`
`1702
`
`1706
`
`
`
`12Lb. C s
`
`^^^^
`
`:
`
`Li 3
`
`*
`
`C
`in L.
`
`1704
`
`Adjustable inductor
`
`FIG. 17
`
`Ex.1015 / IPR2022-00529 / Page 15 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 15 of 40
`
`US 2013/0188397 A1
`
`
`
`O,06 O.08
`
`0.1
`
`O. 12 O. 4 0.16 018 0.2
`Magnetic Flux Density (T)
`Flux density of AC inductor design for LCL converter using E55 core.
`FIG. 18
`
`0.22 O.24 0.26
`
`Ex.1015 / IPR2022-00529 / Page 16 of 65
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 16 of 40
`
`US 2013/0188397 A1
`
`
`
`Circular pad structure and dimension (Top View)
`FIG. 19
`
`Ex.1015 / IPR2022-00529 / Page 17 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 17 of 40
`
`US 2013/0188397 A1
`
`O.4
`
`
`
`O.35
`
`O.3
`
`O.25
`
`O.2
`
`120
`
`140
`
`200
`180
`160
`Distance between pads (mm)
`Coupling coefficient vs. vertical height for PT pad
`
`220
`
`240
`
`260
`
`FIG. 20
`
`Ex.1015 / IPR2022-00529 / Page 18 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 18 of 40
`
`US 2013/0188397 A1
`
`
`
`6000
`
`5000
`
`4000
`
`3 O O O
`
`2000
`
`1O O O
`
`120
`
`140
`
`200
`18O
`160
`Distance between pads (mm)
`
`220
`
`240
`
`260
`
`Uncompensated power of PT pads for different vertical heights
`
`FIG 21
`
`Ex.1015 / IPR2022-00529 / Page 19 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 19 of 40
`
`US 2013/0188397 A1
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`
`
`Dimensions and Configuration of Ferrite Arm Support Structure
`
`FIG. 22
`
`Ex.1015 / IPR2022-00529 / Page 20 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 20 of 40
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`US 2013/0188397 A1
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`
`
`Dovetail Groove Dimensions
`FIG. 23
`
`Ex.1015 / IPR2022-00529 / Page 21 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 21 of 40
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`US 2013/0188397 A1
`
`
`
`O
`O
`
`20
`
`40
`
`:
`120
`100
`80
`60
`Conduction Angle (degs)
`Primary track current vs. conduction angle
`FIG. 24
`
`140
`
`160
`
`-
`18O
`
`Ex.1015 / IPR2022-00529 / Page 22 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 22 of 40
`
`US 2013/0188397 A1
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`io- ... x&
`
`Rect. Turns
`Ratio
`
`Equivalent efficiency model circuit diagram of secondary decoupling
`pickup (see also Figure 29)
`FIG. 25
`
`
`
`Equivalent efficiency model circuit diagram of primary LCL converter
`(see also Figure 11)
`FIG. 26
`
`Ex.1015 / IPR2022-00529 / Page 23 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 23 of 40
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`US 2013/0188397 A1
`
`
`
`...
`
`Calc, n
`
`M is
`
`(+ Qia) iX, L
`(1-D)V sin(o/2)
`
`Controller block diagram for optimal efficiency
`FIG. 27
`
`Ex.1015 / IPR2022-00529 / Page 24 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 24 of 40
`
`US 2013/0188397 A1
`
`
`
`Duty Cycle
`
`Coupling coefficient estimation using: upper traces for k=2kmin (M=60H)
`and lower traces for k=1.14kmin (M=34.2H)
`FIG. 28
`
`Ex.1015 / IPR2022-00529 / Page 25 of 65
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`
`Jul. 25, 2013 Sheet 25 of 40
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`
`
`Secondary decoupling pickup (Secondary circuit)
`
`FIG. 29
`
`Ex.1015 / IPR2022-00529 / Page 26 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 26 of 40
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`US 2013/0188397 A1
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`
`
`0.75
`
`O.7
`
`0.65
`
`0.6
`
`O
`
`0.1
`
`0.2
`
`O3
`
`O6
`0.5
`0.4
`DC inductance (H)
`DC power output vs. Ldc
`
`O.7
`
`0.8
`
`0.9
`
`1
`-3
`
`FIG. 30
`
`Ex.1015 / IPR2022-00529 / Page 27 of 65
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`Jul. 25, 2013 Sheet 27 of 40
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`US 2013/0188397 A1
`
`300
`
`
`
`250
`
`200
`
`150
`
`1OO
`
`50
`
`O
`
`O.
`
`O.2
`
`0.5
`0.4
`0.3
`DC inductance (H)
`
`0.6
`
`0.7
`
`0.8
`
`0.9
`
`1
`-3
`
`AC current peak to peak amplitude normalized against DC average value vs. Ldc
`
`FIG. 31
`
`Ex.1015 / IPR2022-00529 / Page 28 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 28 of 40
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`US 2013/0188397 A1
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`
`
`2
`
`2.5
`
`4.
`
`3.5
`3
`Switching Frequency (10 Hz)
`Secondary decoupling pickup efficiency vs. Switching frequency of an exemplary
`decoupling circuit
`
`4.5
`
`5
`
`FIG. 32
`
`Ex.1015 / IPR2022-00529 / Page 29 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 29 of 40
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`1oot Locus Editor for Open Loop 1 (OL1)
`
`O
`
`
`
`
`
`2COO 1000
`
`1 OOO 2000 3OOO 4000
`Real Axis
`Bode Editor for Open loop
`
`1 (OL1
`
`180G.M. 80 dB
`-140-Freq 0 radisec
`
`O
`
`102
`
`10
`10
`Frequency (rad/sec)
`Root locus and bode plot of decoupling circuit
`FIG. 33
`
`105
`
`6
`
`Ex.1015 / IPR2022-00529 / Page 30 of 65
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`-
`
`- - - 0.4Q2
`-O- 0.2O2
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`O.75
`
`O.7
`
`O
`
`0.2
`
`0.6
`0.4
`Duty Cycle
`
`0.8
`
`1
`
`Efficiency of System G2k=114kin (v-246mm, h=0mm). Line represents
`analytically calculated results and markers represented experimental measured
`results. The data is taken for different loading conditions, when matched to a
`percentage of the maximum Q2v loading condition.
`FIG. 34
`
`Ex.1015 / IPR2022-00529 / Page 31 of 65
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`
`Jul. 25, 2013 Sheet 31 of 40
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`US 2013/0188397 A1
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`
`
`O
`
`O.2
`
`O6
`0.4
`Duty Cycle
`
`O.8
`
`1
`
`Efficiency of System C2k=2.0kmin (v=172mm, h=0), Line represents analytically
`calculated results and markers represented experimental measured results. The
`data is taken for different loading conditions, when matched to a percentage of
`the maximum Q2v loading condition,
`FIG. 35
`
`Ex.1015 / IPR2022-00529 / Page 32 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 32 of 40
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`
`
`WE64"
`
`V-9.0"
`
`We 10.3"
`
`vs5.9" has 8"
`
`w8.1" sces"
`
`O
`
`OOO
`
`2000
`3000
`Output Power (W)
`
`4000
`
`5000
`
`6000
`
`Practical overal system efficiency measurements when output voltage is allowed
`to vary, 5kW transfer occurs when the DC output is 300 W.
`
`FIG. 36
`
`Ex.1015 / IPR2022-00529 / Page 33 of 65
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`Patent Application Publication
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`Jul. 25, 2013 Sheet 33 of 40
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`US 2013/0188397 A1
`
`:
`(-):
`150
`asurement
`
`&
`
`Side view of field reasurement setup
`
`
`
`
`
`s
`
`3.
`
`Distance from centre of pad (an
`Magnetic field measurement results for 5 kW system operating under worst
`conditions. The highest field strength was found at vertical height of 200 mm and
`horizontal misalignment of 150 mm.
`
`FIG. 37
`
`Ex.1015 / IPR2022-00529 / Page 34 of 65
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`Jul. 25, 2013 Sheet 34 of 40
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`
`
`Body average measurement from 4 measurement points on a 1500 mm tal
`female human body. The highest field strength was found at a vertical height of
`255 mm and zero horizontal misalignment.
`
`FIG 38
`
`Ex.1015 / IPR2022-00529 / Page 35 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 35 of 40
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`US 2013/0188397 A1
`
`
`
`O
`
`0.2
`
`O.8
`
`1
`
`0.6
`0.4
`Duty Cycle
`Efficiency of System Gk=114kin (v=246mm, h=0mm). Line represents
`analytically calculated results and markers represented experimental measured
`results. The data is taken for different loading conditions, when matched to a
`percentage of the maximum Q2v loading condition.
`FIG. 39
`
`Ex.1015 / IPR2022-00529 / Page 36 of 65
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`

`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 36 of 40
`
`US 2013/0188397 A1
`
`
`
`O
`
`O.2
`
`O4
`Duty Cycle
`
`O6
`
`O.8
`
`1
`
`Efficiency of System G2k-2. Okin (vir 172mm, h-0). Line represents analytically
`calculated results and markers represented experimental measured results. The
`data is taken for different loading conditions, when matched to a percentage of
`the maximum Q2v loading condition.
`FIG. 40
`
`Ex.1015 / IPR2022-00529 / Page 37 of 65
`APPLE INC. v. SCRAMOGE TECHNOLOGY LTD.
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`

`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 37 of 40
`
`US 2013/0188397 A1
`
`
`
`O
`
`0.2
`
`0.4
`Duty Cycle
`
`O.6
`
`O.8
`
`Current values for waveforms i, ii, and i2 for Q2-0.2O2 and kr2kmin
`FIG. 41
`
`Ex.1015 / IPR2022-00529 / Page 38 of 65
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`Patent Application Publication
`
`Jul. 25, 2013 Sheet 38 of 40
`
`US 2013/0188397 A1
`
`
`
`O.94
`
`0.92
`
`0.9
`
`0.88
`
`0.86
`
`O.84
`
`O.82
`
`0.8
`
`D
`s
`
`WE172
`
`V-200
`
`V=246
`
`w=172 he 75
`
`W2200 hr 140
`
`AOOO
`
`5000
`
`1 OOO
`
`2000
`
`3OOO
`Pout (W)
`Efficiency measurement under a wide range of operating conditions. W=172 is
`for a vertical height of 172 mm with zero misalignment. W-200 is for a vertical
`height of 200 mm and horizontal misalignment of 140 mm.
`FIG. 42
`
`Ex.1015 / IPR2022-00529 / Page 39 of 65
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`

`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 39 of 40
`
`US 2013/0188397 A1
`
`
`
`YOKOGAWA
`2011 11921:47:01
`Stopped
`1
`
`Main 62.5 k
`
`Nora
`625 Sis
`
`Edge C-27.0A
`e
`O
`Auto
`
`1.7789. A
`RSC1
`SEE 159290 A
`169.734 W
`C-3
`C-4
`m
`DC Fu: DC Fu
`DCFB DC F
`50.OAdiv 500A 50.OW'div 800 Wid
`100A1W 100A1 W 50:1
`1000:1
`
`19.79351 kHz
`Freq(C1)
`Rns(C3) 21.8977 W
`
`YOKOGAWA 201
`1 1 01921.4444
`Stoppeg
`
`Nona
`S25 Sis
`
`Edge Ch2 13.0A
`
`29.0277 A
`Rns(c1)
`22.37.17 A
`Rns(C2)
`301,192 W
`Mean(CA
`CH3
`Ca
`C1 CH2
`DC Fu DC Fu
`DC FuB
`DC. Fu
`50.0Adiv 500Ady 50.OWidy 500 Widiv
`
`FreqC1) 19.93175khz
`Rns(C3) 35.5033 W.
`
`Push O: OW
`Of
`C ise
`
`(b)
`(a) P=2kW, (b) P=5kW (G) wa-246mm ha-Omm. Top to bottom trace, is (Figure 11),
`i1 (Figure 11), i2 (Figure 29), and Vs (Figure 29) (inverse of duty cycle).
`FIG. 43
`
`Ex.1015 / IPR2022-00529 / Page 40 of 65
`APPLE INC. v. SCRAMOGE TECHNOLOGY LTD.
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`

`Patent Application Publication
`
`Jul. 25, 2013 Sheet 40 of 40
`
`US 2013/0188397 A1
`
`
`
`YOKOGAWA 2011/10/1921:47:01
`Stopped
`1
`
`Main: 62.5 k .
`
`Norna
`625WS's
`
`Edge CH27.0A
`
`enrico
`SSE 42,
`ms(C2)
`15.92
`169,734 W
`C-2
`C-3
`C-4
`C-1
`DC Fu DC F
`DC Fu: DC Fut:
`60.0Adiv 5OOAdiv 50.OW? div 5OO Wiciw
`100A1 W 1GAW 50:1
`1OOO1
`
`sonm
`FreqC1) 19.79351 kHz
`Rns(C3) 21.8977 W
`O
`
`YOKOGAWA 20111101
`9 21:38.44
`Stopped
`1768
`7
`
`Main 62.5k
`
`Normat
`625WS's
`
`Edge Ch2413,0A
`Auto
`1Ousldiv
`
`20.0751k-2
`Fred (C1)
`Rns(C3) 35.3317 W
`
`16.6250 A
`Rns(c1)
`SE 35.4488 A
`Mean(CA)
`298,570 W
`CH2
`CH3
`CH4
`-1
`DC FuB DC. Fu DC Fu: DC Fu
`SEYEY ESVidy
`Yidy
`OOA1W 100A1W 50:1
`1000:1
`(b)
`(a) P-2kW, (b) P-5kW G v-246mm h-0mm. Top to bottom trace, it (Figure 11),
`i (Figure 11), 2 (Figure 29), and W. (Figure 29) (inverse of duty cycle).
`FIG. 44
`
`Push O: OW
`s
`
`Ex.1015 / IPR2022-00529 / Page 41 of 65
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`

`US 2013/0188397 A1
`
`Jul. 25, 2013
`
`SWITCH WEARLEVELING
`
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`0001. This application claims the benefit of U.S. Provi
`sional Patent Application No. 61/589,599 entitled “WIRE
`LESS POWER TRANSFER SYSTEMAND METHODS
`and filed on Jan. 23, 2012 for Hunter Wu, et al., which is
`incorporated herein by reference for all purposes. U.S. patent
`application Ser. No.
`entitled WIRELESS POWER
`TRANSFERSYSTEM and filed on Jan. 23, 2013 for Hunter
`Wu, et al. is incorporated herein by reference for all purposes.
`
`FIELD OF THE INVENTION
`0002 This invention relates to switching power converters
`and more particularly relates to switch wear leveling for
`Switching power converters.
`
`SUMMARY
`0003. From the foregoing discussion, it should be apparent
`that a need exists for an apparatus, system, and method Switch
`wear leveling. Beneficially, Such an apparatus, system, and
`method would balance Switching power losses among
`switches to provide a more even switch wear for each of the
`Switches.
`0004 An apparatus for switch wear leveling is disclosed.
`A system and method also perform the functions of the
`method. The apparatus includes a switching module and a
`Switch rotation module. The Switching module controls
`Switching for two or more pairs of Switches in a Switching
`power converter. The switching module controls each of the
`two or more pairs of switches closed and open based on a duty
`cycle control technique. The Switching module closes and
`opens each Switch of the two or more pairs of Switches in a
`Switching sequence. The two or more pairs of Switches con
`nect to a positive terminal and a negative terminal of a direct
`current (DC) voltage source. For a first switching sequence
`a first Switch of a pair of Switches has a higher Switching
`power loss than a second switch of the pair of switches. The
`Switch rotation module changes the Switching sequence of the
`two or more pairs of switches from the first switching
`sequence to a second Switching sequence. The second Switch
`of a pair of Switches has a higher Switching power loss than
`the first switch of the pair of switches during the second
`Switching sequence.
`0005. In one embodiment, the apparatus includes a switch
`wear module that tracks Switching sequences and the Switch
`rotation module changes the Switching sequence based on
`tracking of the Switching sequences. In another embodiment,
`the Switch wear module tracks the Switching sequences by
`tracking an amount of time Switching using each Switching
`sequence. In another embodiment, the Switch wear module
`tracks the Switching sequences by tracking an amount of
`Switching cycles for each Switching sequence. In another
`embodiment, the Switch rotation module uses tracking of the
`Switching sequences to Switch between Switching sequences
`to balance an amount of Switching for each Switching
`Sequence.
`0006. In one embodiment, the switching module controls
`three pairs of switches and the switch rotation module
`changes the Switching sequence between the first Switching
`sequence, the second Switching sequence, and a third Switch
`ing sequence. In another embodiment, the Switch rotation
`
`module changes the Switching sequence during a startup con
`dition. In another embodiment, the switch rotation module
`changes the Switching sequence by changing which pair of
`Switches is first to be switched in a Switching sequence. In a
`further embodiment, the switch rotation module orders
`switching of the two or more pairs of switches so that a first
`pair of Switches is first in a first Switching sequence and a
`second pair of Switches is first in a second Switching
`Sequence.
`0007. In one embodiment, the switching power converter
`is a full-bridge derived topology. In another embodiment, the
`topology of the Switching power converter is a Voltage driven
`H-bridge, a current driven H-bridge, or a three-phase Voltage
`driven H-bridge. In another embodiment, the topology of the
`Switching power converter comprises an LCL converter. In
`another embodiment, the duty cycle control technique may
`include symmetric voltage cancellation (“SVC) control,
`asymmetric voltage cancellation (AVC) control, fixed con
`duction angle with variable Voltage control, and/or fixed con
`duction angle control. In another embodiment, the Switches
`of the two or more pairs of Switches are semiconductor
`Switches.
`0008. A system for switch wear leveling includes a switch
`ing power converter and a Switching module that controls
`Switching for two or more pairs of Switches in the Switching
`power converter. The Switching module controlling each of
`the two or more pairs of Switches closed and open based on a
`duty cycle control technique. The Switching module closes
`and opens each Switch of the two or more pairs of switches in
`a Switching sequence. The two or more pairs of Switches
`connect to a positive terminal and a negative terminal of a DC
`Voltage source. For a first Switching sequence, a first Switch of
`a pair of Switches has a higher Switching power loss than a
`second switch of the pair of switches. The system includes a
`Switch rotation module that changes the Switching sequence
`of the two or more pairs of Switches from the first switching
`sequence to a second Switching sequence and the second
`Switch of a pair of switches has a higher Switching power loss
`than the first switch of the pair of switches during the second
`Switching sequence. In one embodiment, the Switching power
`converter includes an LCL converter in an induction power
`transfer system.
`0009. A method for switch wear leveling includes control
`ling Switching for two or more pairs of Switches in a Switching
`power converter by controlling each of the two or more pairs
`of Switches closed and open based on a duty cycle control
`technique. Each switch of the two or more pairs of switches
`closes and opens in a Switching sequence. The two or more
`pairs of switches connect to a positive terminal and a negative
`terminal of a DC voltage source. For a first switching
`sequence, a first Switch of a pair of Switches has a higher
`Switching power loss than a second Switch of the pair of
`Switches. The method includes changing the Switching
`sequence of the two or more pairs of switches from the first
`Switching sequence to a second Switching sequence and the
`second Switch of a pair of Switches has a higher Switching
`power loss than the first switch of the pair of switches during
`the second Switching sequence.
`0010. In one embodiment, the method includes tracking
`the Switching sequence and changing the Switching sequence
`is based on tracking of the Switching sequence.
`0011. In another embodiment, tracking the switching
`sequence includes tracking an amount of time Switching
`using each Switching sequence and/or tracking an amount of
`
`Ex.1015 / IPR2022-00529 / Page 42 of 65
`APPLE INC. v. SCRAMOGE TECHNOLOGY LTD.
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`US 2013/0188397 A1
`
`Jul. 25, 2013
`
`Switching cycles for each Switching sequence. In another
`embodiment, the method includes balancing an amount of
`Switching for each Switching sequence based on tracking of
`the Switching sequences.
`0012 Reference throughout this specification to features,
`advantages, or similar language does not imply that all of the
`features and advantages that may be realized with the present
`invention should be or are in any single embodiment of the
`invention. Rather, language referring to the features and
`advantages is understood to mean that a specific feature,
`advantage, or characteristic described in connection with an
`embodiment is included in at least one embodiment of the
`present invention. Thus, discussion of the features and advan
`tages, and similar language, throughout this specification
`may, but do not necessarily, refer to the same embodiment.
`0013 Furthermore, the described features, advantages,
`and characteristics of the invention may be combined in any
`suitable manner in one or more embodiments. One skilled in
`the relevant art will recognize that the invention may be
`practiced without one or more of the specific features or
`advantages of a particular embodiment. In other instances,
`additional features and advantages may be recognized in
`certain embodiments that may not be present in all embodi
`ments of the invention.
`0014. These features and advantages of the present inven
`tion will become more fully apparent from the following
`description and appended claims, or may be learned by the
`practice of the invention as set forth hereinafter.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`0015. In order that the advantages of the invention will be
`readily understood, a more particular description of the inven
`tion briefly described above will be rendered by reference to
`specific embodiments that are illustrated in the appended
`drawings. Understanding that these drawings depict only
`typical embodiments of the invention and are not therefore to
`be considered to be limiting of its scope, the invention will be
`described and explained with additional specificity and detail
`through the use of the accompanying drawings, in which:
`0016 FIG. 1 is a schematic block diagram illustrating one
`embodiment of a system for switch wear leveling:
`0017 FIG. 2 is a schematic block diagram illustrating one
`embodiment of an apparatus for Switch wear leveling;
`0018 FIG. 3 is a schematic block diagram illustrating
`another embodiment of an apparatus for Switch wear leveling;
`0019 FIG. 4A is a schematic block diagram illustrating
`one embodiment of an apparatus for Switch wear leveling
`with a voltage driven H-bridge;
`0020 FIG. 4B is a schematic block diagram illustrating
`one embodiment of an apparatus for Switch wear leveling
`with a current driven H-bridge;
`0021
`FIG. 4C is a schematic block diagram illustrating
`one embodiment of an apparatus for Switch wear leveling
`with a three-phase voltage driven H-bridge;
`0022 FIG. 5 is a schematic block diagram illustrating one
`embodiment of an apparatus for Switch wear leveling with a
`voltage driven H-bridge LCL converter;
`0023 FIG. 6 is a timing diagram for an H-bridge con
`Verter.
`0024 FIG. 7 is a schematic flow chart diagram illustrating
`one embodiment of a method for switch wear leveling in
`accordance with the present invention;
`
`0025 FIG. 8 is a schematic flow chart diagram illustrating
`one embodiment of a method for switch wear leveling in
`accordance with the present invention;
`0026 FIG. 9 illustrates a block diagram of an exemplary
`inductive power transfer charging system;
`0027 FIG. 10 illustrates misalignment conditions for ver
`tical and horizontal misalignment. h=0 trend represents the
`profile of vertical misalignment under Zero horizontal offset.
`v=200 trend represents the profile of horizontal misalignment
`under 200 mm of height separation;
`0028 FIG. 11 illustrates an exemplary LCL load resonant
`converter;
`0029 FIG. 12 illustrates comparison of losses for a selec
`tion of switches for H-bridge;
`0030 FIG. 13 illustrates the losses in the H-bridge for
`different temperatures for IRG7PH42UPBF:
`0031
`FIG. 14 illustrates an exemplary switch Heatsink
`Thermal Design;
`0032 FIG. 15 illustrates an exemplary simplified IGBT
`Gate Drive Circuit;
`0033 FIG. 16 illustrates an exemplary LCL Converter
`with Split Inductor Design;
`0034 FIG. 17 illustrates an exemplary adjustable Induc
`tor;
`0035 FIG. 18 illustrates an exemplary flux density of AC
`inductor design for LCL converter using E55 core;
`0036 FIG. 19 illustrates an exemplary circular pad struc
`ture and dimension (Top View);
`0037 FIG. 20 illustrates coupling coefficient vs. vertical
`height for an exemplary IPT pad;
`0038 FIG. 21 illustrates uncompensated power of exem
`plary IPT pads for different vertical heights;
`0039 FIG.22 illustrates the dimensions and configuration
`of exemplary an ferrite arm Support structure;
`0040 FIG. 23 illustrates exemplary dove tail groove
`dimensions;
`0041 FIG.24 illustrates primary track current vs. conduc
`tion angle;
`0042 FIG. 25 illustrates equivalent efficiency model cir
`cuit diagram of an exemplary secondary decoupling pickup
`(secondary circuit) (see also FIG. 29);
`0043 FIG. 26 illustrates equivalent efficiency model cir
`cuit diagram of an exemplary primary LCL converter (see
`also FIG. 11):
`0044 FIG. 27 illustrates an exemplary controller block
`diagram for optimal efficiency;
`0045 FIG. 28 illustrates coupling coefficient estimation
`using (21). Blue trace is for k=2 k (M=60 uH) and Red
`trace is for k=1.14 kt (M=34.2 LH):
`0046 FIG. 29 illustrates an exemplary parallel pickup or
`secondary circuit with a secondary resonant circuit, a second
`ary rectification circuit, and a secondary decoupling circuit
`(in the form of a secondary decoupling converter);
`0047 FIG. 30 illustrates DC power output vs. Ldc;
`0048 FIG. 31 illustrates AC current peak to peak ampli
`tude normalized against DC average value vs. Ldc;
`0049 FIG. 32 illustrates secondary decoupling pickup
`efficiency VS. Switching frequency of an exemplary decou
`pling circuit;
`0050 FIG. 33 illustrates root locus and bode plot of an
`exemplary decoupling circuit;
`0051
`FIG. 34 illustrates efficiency of an exemplary sys
`tem (a k=1.14 kt (v–246 mm, h=0 mm). Line represents
`analytically calculated results and markers represented
`
`Ex.1015 / IPR2022-00529 / Page 43 of 65
`APPLE INC. v. SCRAMOGE TECHNOLOGY LTD.
`
`

`

`US 2013/0188397 A1
`
`Jul. 25, 2013
`
`experimental measured results. The data is taken for different
`loading conditions, when matched to a percentage of the
`maximum Q loading condition;
`0052 FIG. 35 illustrates efficiency of an exemplary sys
`tem (a k=2.0k (v=172 mm, h=0). Line represents analyti
`cally calculated results and markers represented experimental
`measured results. The data is taken for different loading con
`ditions, when matched to a percentage of the maximum Q.
`loading condition;
`0053 FIG. 36 illustrates practical overall system effi
`ciency measurements when output voltage is allowed to vary.
`5 kW transfer occurs when the DC output is 300 V:
`0054 FIG. 37 illustrates magnetic field measurement
`results for an exemplary 5 kW system operating under worst
`conditions. The highest field strength was found at vertical
`height of 200 mm and horizontal misalignment of 150 mm:
`0055 FIG.38 illustrates body average measurement from
`4 measurement points on a 1500 mm tall female human body.
`The highest field strength was found at vertical height of 255
`mm and Zero horizontal misalignment;
`0056 FIG. 39 illustra