High-Efficiency and High-Frequency Resonant Converter Based Single-Stage Soft-Switching Isolated Inverter Design and Optimization with Gallium-Nitride (GaN)

Isolated inverter can provide galvanic isolation which is necessary for some applications with safety regulations. Traditionally, a two-stage configuration is widely applied with isolated dc-dc stage and a sinusoidal pulse-width-modulated (SPWM) dc-ac stage. However, this two-stage configuration suffers from more components count, more complex control and tend to have lower efficiency and lower power density. Meanwhile, a large dc bus capacitor is needed to attenuate the double line frequency from SPWM for two-stage configuration. Therefore, the single-stage approach including an isolated dc-rectified sine stage and a line frequency unfolder is preferable. Since the unfolder circuit is at line frequency being almost lossless, the isolated dc-rectified sine stage becomes critical.

However, the relevant research for the single-stage isolated inverter is limited. People either utilize PWM based converter as dc-rectified sine stage with duty cycle adjustment or apply SRC or LLC resonant converter for better soft switching characteristics. For PWM based converter, hard switching restricts the overall inverter efficiency, while for SRC/LLC, enough wide voltage gain range and full range ZVS are the major issues.

This dissertation aims to provide solutions for a high-efficiency, high-frequency resonant converter based single-stage soft-switching isolated inverter design. The LLC and LCLCL resonant converters are applied as the isolated dc-rectified sine stage with variable frequency modulation (VFM). Therefore, the rectified sine wave generation consists of many dc-dc conversion with different switching frequencies and an efficient dc-rectified sine stage design needs each dc-dc conversion to be with high efficiency.

This dissertation will first propose the optimization methods for LLC converter dc-dc conversion. ZVS models are derived to ensure fully ZVS performance for primary side GaN devices. As a large part in loss breakdown, the optimization for transformer is essential. The LLC converter can achieve above 99% efficiency with proposed optimization approach. Moreover, the channel turn-off energy model is presented for a more accurate loss analysis.

With all the design and optimization considerations, a MHz LLC converter based isolated inverter is designed and a hybrid modulation method is proposed, which includes full bridge (FB) VFM for output high line region and half bridge (HB) VFM for output low line region. By changing from FB to HB, the output voltage gain is reduced to half to have a wider voltage gain range. However, the total harmonic distortion (THD) of output voltage at light load will be impacted since the voltage gain will be higher with lighter load at the maximum switching frequency.

A MHz LCLCL converter based isolated inverter is proposed for a better output voltage THD at light load conditions. The paralleled LC inside the LCLCL resonant tank can naturally create a zero voltage gain point at their resonant frequency, which shows superior performance for rectified sine wave generation. Besides the better THD performance, the LCLCL converter based isolated inverter also features for easier control, better ZVS performance and narrower switching frequency range.

Meanwhile, the LCLCL based inverter topology has bi-directional power flow capability as well. With variable frequency modulation for ac-dc, this topology is still a single-stage solution compared to the traditional two-stage solution including PFC + LLC configuration.