LIGHT EMITTING DIODE DRIVER

[0001] This application claims priority to U.S. Provisional Application No. 62/016,899 filed Jun. 25, 2014, which is hereby incorporated by reference in its entirety.

[0002] The disclosure relates to the field of LED illumination products and more particularly to high efficiency LED power converters or drivers.

[0003] As more light-emitting diode (LED) illumination systems penetrate the general lighting market, demands on performance, including efficiency, increase. LED-based illumination systems are not only expected to provide higher quality light over a longer operational life, but these LED-based illumination systems are also expected to do so efficiently across all applications. While much research and development in this area has been directed toward new LED materials, manufacturing equipment and processes, the converters or drivers that power the LED-based illumination systems significantly influence the overall efficiency of the systems.

[0004] LEDs used for illumination applications often require a regulated current at a voltage above a minimum level to deliver consistent (i.e., without periodic modulation or flicker) light output. The LED must also continue to operate without flicker even when disruptions or dropouts in the input power occur. To accommodate these requirements, conventional converter topologies deploy a two-stage arrangement having a boost converter followed by a buck converter. The boost converter is used since it can be designed to achieve a near-unity power factor (PF). To maintain this high PF, however, the boost converter output voltage, or intermediate voltage, must be at least twice the root mean square (RMS) of the input voltage, requiring the second step-down buck converter stage. The buck converter reduces the intermediate voltage to that required by the LED and also delivers a highly regulated, low ripple current into the LED to minimize flicker.

[0005] In this arrangement, the higher the intermediate voltage, the smaller the storage capacitor across the output of the boost converter required to hold the LED voltage through any dropout periods. However, as this voltage is increased, the converter becomes less efficient. In very small LED lamps such as the MR16, this leads to a very challenging tradeoff between efficiency, cost, and lamp size. Typical efficiencies for boost and buck converters with 3:1 transformation ratios are around 90%. Thus, the net efficiency of this combination is the product of the efficiency of the two stages, or approximately 81% (90%×90%).

[0006] Furthermore, the buck converter requires that the intermediate voltage (the voltage output of the boost stage), be significantly higher than the minimum operational LED voltage. This results in a significant amount of energy stored in the boost capacitor that cannot be extracted by the buck converter to hold up the LED. This again leads to having to size the energy storage components of the converters larger than desired.

[0007] Applicant therefore identifies a need to power LEDs without flicker or dropout, and yet provide high efficiency. The present invention fulfills this need among others.

[0008] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the invention. It is not intended to identify key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the more detailed description that is presented later.

[0009] Embodiments of the present invention relate to an LED power converter having two boost converter stages, arranged and controlled to provide improved power efficiency as well as a high power factor (PF), dropout tolerance, and optimal sizing and use of energy storage components. The high efficiency is generally achieved by having only one boost stage operational during a given period. The first boost stage is on during periods when input power is present, whereas the second boost stage is on during periods when input power is low or off (i.e., “dropout”). The first boost stage delivers a high PF to power the LED during powered periods, whereas the second boost stage uses energy from the energy storage components to power the LED during dropout periods. These attributes make certain embodiments of the present invention ideal for small, hot LED lamps, such as the MR16 LED replacement lamp.

[0010] In one embodiment, the present invention relates to a driver for generating an output voltage V_out to power at least one light emitting diode (LED) having a minimum operating voltage V_{LED min}, the driver comprising: (a) at least one first voltage converting stage comprising an input terminal for receiving an input voltage V_IN and an output terminal, and being configured to increase the V_IN to a first output voltage V_1st at the output terminal; (b) at least one charge storage device electrically connected to the output terminal and having a charge output voltage V_C; (c) at least one second voltage converting stage having an input electrically connected to the charge storage device, the second voltage converting stage being configured to increase the V_C to at least V_{LED min}; and (d) at least one mode controller to switch between at least a first mode and a second mode, in the first mode, the first voltage converting stage charges the charge storage device to power the LED without substantial contribution from the second voltage converting stage, and, in the second mode, the second voltage converting stage powers the LED.

[0011] In another embodiment, the present invention relates to a method of powering at least one light emitting diode (LED) having a minimum operating voltage V_{LED min} using a driver comprising a first voltage converting stage comprising an input terminal for receiving an input voltage V_IN and an output terminal, and being configured to increase the V_IN to a first output voltage V_1st at the output terminal; a charge storage device electrically connected to the output terminal and having an charge output voltage V_C; a second voltage converting stage having an input electrically connected to the charge storage device, the second voltage converting stage being configured to increase the V_C to at least V_{LED min}, the method comprising: (a) operating the driver in a first mode in which the first voltage converting stage charges the charge storage device to power the LED without substantial contribution from the second voltage converting stage; and (b) operating the driver, in a second mode in which the second voltage converting stage powers the LED.

[0020] Referring to FIG. 1, a schematic of one embodiment of the LED driver 104 of the present invention is shown. 1. Specifically, the driver 104 generates an output voltage V_out to power at least one light emitting diode (LED) 103 having a minimum operating voltage V_{LED min}. The driver comprises a first voltage converting stage (or first boost stage) 112 comprising an input terminal 112a for receiving an input voltage V_IN and an output terminal 112b, and being configured to increase the V_IN to a first or intermediate voltage V_1st at the output terminal. The output terminal is electrically connected to a charge storage device 116, which has a charge output voltage V_C. The driver also comprises a second voltage converting stage (or second boost stage) 118 having an input 118a electrically connected to the charge storage device. The second voltage converting stage is configured to increase V_C to at least V_{LED min}. The first and second voltage converting stages are regulated by a mode controller 122, which switches between at least a first mode and a second mode. In the first mode, the first voltage converting stage charges the charge storage device to power the LED without substantial contribution from the second voltage converting stage, and, in the second mode, the second voltage converting stage powers the LED. These features and select alternative embodiments are described in greater detail below. The disclosed embodiments are not intended to be limiting of the claims.

[0021] Referring back to FIG. 1, an LED system 100 is depicted which incorporates the driver 104 described above. The system 100 includes a power conditioning front end 102, the driver connected to the power conditioner 102, and an LED load 103 connected to the driver 104.

[0022] The purpose of the power conditioning front end 102 in system 100 is to provide input power with a direct current (DC) and voltage V_IN to driver 104. The power conditioning front end 102 comprises a transformer 108 that accepts power from an alternating current (AC) source 106. The AC source 106 may be sinusoidal power, or “chopped” power as may be provided by a dimmer switch (e.g., see dimmer system chop, as shown). As is known in the art, a sinusoidal power cycle can be chopped by a dimming system where the sinusoidal wave is chopped (e.g., chopped down to zero) a controlled amount, responsive to operation of the dimming system controls. The extent of the chopped portion is denoted as a “phase angle” ranging from 0 degrees (no chop down) to 180 degrees (complete cutout of the power). Such dimming systems may chop out a portion of the leading-edge of the waveform (e.g., triac dimmers) or may chop out a portion of the trailing edge of the waveform (or some combination of the two). Transformer 108 can be of an electronic or magnetic type, and can have various transformation ratios depending on the target implementation of system 100.

[0023] A rectifier 110 receives the AC signal at the output of transformer 108 and rectifies it to a DC signal having Vin at the output of rectifier 110. For example, in one embodiment, Vin is 17 Volts peak DC rectified from a 12 VAC transformer output at a frequency of 60 Hz.

[0024] The LED load 103 may comprise, for example, a single LED or an array of LEDs arranged in a series, in parallel, or in a combination thereof. Some LED loads (e.g., for illumination applications) require a driver 104 to provide a well regulated drive current within an operational voltage range at a target power, P_OUT. The operational voltage range is characterized by a minimum voltage V_{LED min} determined by the LED device type and arrangement comprising LED load 103. V_{LED min} values are well known, readily available characteristics of an LED. Typical values for V_{LED min} are 20 Volts-30 Volts.

[0025] The driver 104 receives DC input power V_IN at an input terminal 112a. The driver 104 functions to increase the voltage of V_IN (e.g., 12 v) to an output voltage V_OUT. Typical V_OUT values are, for example, 20, 25, and 30 VDC. In one embodiment, the driver comprises at least two voltage converting stages 112, 118, wherein only one stage operates at given period. The first boost stage is on during periods when input power is present, whereas the second boost stage is on during periods when input power is low or off (i.e., “dropout” or “cutoff”). The first boost stage delivers a high PF to power the LED during powered periods, whereas the second boost stage uses an increased amount of energy from the energy storage components to help power the LED during dropout periods.

[0026] The first voltage converting stage 112 may be any known electronics to increase or boost voltage, suitable electronics include, for example, boost, buck-boost, flyback, Cuk, sepic or other converter topologies.

[0027] In one embodiment, the first voltage converting stage 112 is controlled by a first converter controller 114, which regulates the “duty cycle” of the stage, or, in other words, turns the main switch of the first voltage converting stage 112 on and off to control V_1st. Specifically, the first converter controller 114 is connected to first voltage converting stage 112 to monitor signals, provide signals, and provide feedback (e.g., pulse-width modulated (PWM) feedback) to enable first voltage converting stage 112 to deliver a regulated current to a first charge storage device 116. A representative signal connecting first converter controller to first voltage converting stage 112 is shown as signal B1_C. Signal B1_C represents a feedback signal (e.g., the PWM signal controlling first voltage converting stage).

[0028] The first charge storage device 116 serves to store the output from the first voltage converting stage, and, in one embodiment, serves to provide constant, stable power at Vc to (1) the output terminal in the first mode, and (2) the second voltage converting stage in the second mode. The first charge storage device may be implemented using any known electrical storage device including, for example, a capacitor or a battery. In one embodiment, the first storage device is a capacitor.

[0029] In one embodiment, the first voltage converting stage and the first charge storage device are configured to match substantially Vc (in the first mode) with the operating voltage of the LED to improve the efficiency of the driver. (It is generally known that efficiency of a boost circuit decreases as the ratio of the output voltage to input voltage increases) Specifically, Vc is essentially at the voltage needed to operate the LED (e.g., V_LED(min)). To match Vc with the operating voltage of the LED, in one embodiment, the boost ratio of first voltage converting stage is between about 1.2 to about 10, and, in a more particular embodiment, the boost ratio is about 2 to about 20.

[0030] The first storage device should be sized to provide adequate power to the second voltage converting stage during the second mode. In one embodiment, the system operates in the second mode when Vin drops below a certain level for a certain period (discussed in detail below). Accordingly, the power storage capacity of the device depends on the expected duration of a low Vin condition. For example, in one embodiment, the size of a capacitor (C_Size) representing first charge storage device 116 can be calculated by Equation (1):

$\begin{array}{cc}{C}_{\mathrm{Size}}=\frac{2\times P_{\mathrm{OUT}}\times T_{\mathrm{DROP}}\left(\max \right)}{\eta \times \left({V_C\left(\mathrm{nom}\right)}^2-{V_{\mathrm{BOOST}}\left(\min \right)}^2\right)}& \left(1\right)\end{array}$

Where, P_OUT is the output power of the second voltage converting stage, and η is the efficiency of second voltage converting stage 118 which will be providing P_OUT, T_{DROP MAX} is the maximum duration of V_IN being below V_{RMS min}, V_C(nom) is nominal voltage on said capacitor, and V_BOOST(min) is the lowest permissible Vc.

[0031] Thus, as T_DROP(max) increases so should the size of the capacitor. An example of sizing the capacitor or other charge storage device is provided below in connection with FIG. 4B. The driver 104 further comprises a second voltage converting stage 118, a second converter controller (e.g., duty cycle controller 120), a mode controller 122, and a second charge storage device 124.

[0032] The second voltage converting stage 118 receives input power from the output of the first charge storage device. The second voltage converter stage functions to increase the voltage from Vc to the operating voltage of the LED. Like the first voltage converter stage, the second voltage converting stage may be any known electronics to increase or boost voltage, suitable electronics include, for example, boost, buck-boost, flyback, Cuk, sepic or other converter topologies. It should be noted with respect to the second voltage converting stage, that the boost ratio will change as Vc drops during the second mode. That is, during the second mode, while the second voltage converting stage is drawing power from the first charge storage device, Vc will drop (discussed in detail below with respect to FIG. 4B), requiring the boost ratio to increase to provide sufficient Vout for the LED.

[0033] In one embodiment, a second converter controller 120 is used to control the second voltage converting stage by controlling, for example, the duty cycle of the second stage. Specifically, in one embodiment, the controller 120 is connected to a second voltage converting stage 118 to monitor signals, provide signals, and provide feedback (e.g., PWM feedback) to enable the second voltage converting stage 118 to deliver a regulated current to the LED 103 or, optionally, to a second charge storage device 124. A representative signal connecting second converter controller 120 to second voltage converting stage 118 is shown as signal B2_C. Signal B2_C represents a feedback signal (e.g., the PWM signal controlling second voltage converting stage 118).

[0034] Mode controller 122 is connected to second voltage converting stage 118 to monitor voltages and provide signals to enable second voltage converting stage 118 to operate in various modes. Signal B2_M is shown connecting mode controller 122 to second voltage converting stage 118. Signal B2_M can serve as the mode indicator signal to control the mode of second voltage converting stage 118. In some embodiments, the mode controller includes connections to multiple nodes within the driver 104. In some embodiments, second voltage converting stage 118 operates in two modes: a powered mode (or passive mode, see FIG. 2A) and in a dropout mode (or active mode, see FIG. 2B). In one embodiment, the first voltage converting stage is on during the second mode, and, in another embodiment, is on continuously, although in these embodiments, it may not be actually operating due to a voltage dropout condition.

[0035] In one embodiment, the first and second voltage converting stages are operatively connected to a driver output terminal having V_out, and V_out remains essentially constant during the first and second modes.

[0036] In one embodiment, a second charge storage device 124 is connected to the output of the second voltage converting stage. Like the first charge storage device 116, can be implemented using a capacitor. Such a second charge storage device 124 supports the voltage V_OUT produced by second voltage converting stage 118 (e.g., to drive LED load 103).

[0037] In a dimmer system (e.g., triac) and similar embodiments, the system 100 may also comprise a phase cut angle detector 121 to sense power carrying signals from the rectifier 110, to determine characteristics of the power carrying signals as modulated (e.g., chopped) by the dimming system, and to send a signal to the second controller. The second controller in turn determines the periods of drop-out and controls the second voltage converting stage and/or mode controller so as to operate the active mode of the second voltage converting stage 118 only during the dropout periods.

[0038] The operation of the drive 104 and system 100 is considered with respect to FIGS. 2A and B, FIG. 3 and FIGS. 4A-C.

[0039] FIG. 2A depicts a diagram 2A00 of a driver 104 operating in the first mode or a powered mode 202. In powered mode 202, second voltage converting stage 118 and a second charge storage device 124 can be configured by mode controller 122 to effectively deliver the regulated current and voltage V_C available at first charge storage device 116 directly to converter output 126. In powered mode 202, driver 104 therefore functions as a single-stage converter, delivering the high efficiencies that characterize that configuration. In some embodiments, driver 104 accepts a 12V_rms input at V_IN and steps it up to 36V_rms with first voltage converting stage 112 serving to directly drive the required LED voltage and current at converter output 126. At this 3:1 step-up ratio, first voltage converting stage 112 can be designed to provide a very high PF and can achieve about 90% efficiency.

[0040] FIG. 2B depicts a diagram 2B00 of driver 104 operating in the second mode or a dropout mode 204. In some embodiments, dropout mode 204 is enabled when the input voltage at V_IN is measured to be in a low voltage range (e.g., in a dropout condition). Under these conditions, first voltage converting stage 112 has insufficient input power to continue to holdup the voltage V_C at the first charge storage device 116. Second voltage converting stage 118 and second charge storage device 124 are therefore configured by mode controller 122 to draw the remaining energy from first charge storage device 116 and drive the required LED voltage and current at converter output 126. In dropout mode, driver 104 therefore also serves to function as a single-stage converter, delivering the high efficiencies of that configuration. In some embodiments, the transformation ratio of second voltage converting stage 118 is near unity since the voltage V_C across first charge storage device 116 is designed to be within the operational voltage range of the LED. At this low step-up ratio, second voltage converting stage 118 can be designed to achieve about 95% efficiency.

[0041] FIG. 3 presents annotated waveforms 300 showing operation of a driver 104 with continuous input power, according to some embodiments. All waveforms shown in FIG. 3 have the same horizontal axis showing the same period of time and are shown in the same scale. As shown in FIG. 3, the V_IN voltage 302 is a voltage signal representing a fully-rectified, continuous sinusoidal power input having a steady state RMS voltage of V_rms. As shown, the V_IN voltage 302 provides power to the driver 104, and the B2_M control signal 308 stays low to configure the driver 104 to powered mode 202. The B1_C PWM signal 304 can operate with up to a 100% duty cycle so as to attempt to draw power from the line at all times. Alternatively the B1_C PWM signal 304 can operate the duty cycle to allow first voltage converter 112 to deliver V_C 310 and the V_OUT 312 that is within the LED operational voltage range. During the time duration that second voltage converting stage 118 is in powered mode 202, the B2_C signal 306 state can be undefined.

[0042] FIG. 4A presents annotated waveforms 4A00 showing operation of a driver 104 with input power dropout, according to some embodiments. All waveforms shown in FIG. 4 have the same horizontal axis showing the same period of time and are shown in the same scale. As shown in FIG. 4A, the V_IN voltage 402 depicts an entire AC cycle throughout which cycle no power is available to the driver 104. For a 60 Hz input power frequency, the T_DROP dropout period 403 is approximately 16.7 ms. When mode controller 122 senses this drop in V_IN voltage 402, it drives the B2_M control signal 408 high to configure driver 104 to dropout mode 204. The B1_C PWM signal 404 duty cycle will decrease significantly during T_DROP dropout period 403 to attempt to keep the V_C voltage 410 and the V_OUT voltage 412 within the LED operational voltage range. However, first voltage converting stage 112 is ineffective, even at 0% duty cycle when no input power is present, so the B2_C signal 406 therefore begins to operate with a duty cycle to allow second voltage converting stage 118 to step up the V_C voltage 410 to a V_OUT voltage 412 that is within the LED operational voltage range. Even though V_C voltage 410 falls below V_LED(min), second voltage converting stage 118, in combination with a sufficiently-sized charge storage device, is able to hold V_OUT voltage 412 within the LED operational range. When the input power returns, the B2_M control signal 408 goes low to configure the driver 104 back to powered mode 202.

[0043] In some embodiments, the driver 104 has a smaller (e.g., less expensive, smaller physical size) first charge storage device 116 than the charge storage devices in conventional converter topologies. In some embodiments, first charge storage device 116 can be a capacitor and is commonly called the “holdup capacitor” or “intermediate capacitor”. A larger voltage drop occurs at V_C voltage 410 during a given dropout period, thus a smaller first charge storage device 116 can be used by the driver 104 since a second voltage converting stage 118 can continue to drive an LED even when the voltage across the first charge storage device 116 drops below V_LED(min). More specifically, the function of the second voltage converting stage 118 allows the voltage drop at Vc voltage 410 to sag down well below V_LED(min) while still maintaining drive current to the LEDs. This in turn allows first charge storage device 116 to be substantially reduced in terms of capacitance and physical size. In contrast, conventional converter topologies using such smaller charge storage devices are not able to continue to drive the LED when this intermediate voltage is below V_LED(min)—conventional converter topologies need a relatively larger holdup charge storage capacity to avoid any disruptions in LED operation. Embodiments of driver 104 further enable other energy storage components and devices (e.g., inductors) to be smaller-sized, and in some cases, less expensive.

[0044] FIG. 4B presents annotated waveforms 4B00 showing operation of driver 104 with an example of worst case input power dropout. In one embodiment of driver 104, the size of the holdup capacitor representing first charge storage device 116 can be determined from the conditions depicted in the waveforms in FIG. 4B. These conditions are intended to represent a worst case dropout condition of a particular embodiment of driver 104. As shown in FIG. 4B, the V_IN voltage 414 exhibits a T_DROP(max) dropout period 415 during which no AC power is available to driver 104. During T_DROP(max) dropout period 415, the V_C voltage 422 across first charge storage device 116 continues to drop from its nominal level V_C(nom) until input power returns.

[0045] Given the conditions described and illustrated in FIG. 4B for this embodiment, the size of a holdup capacitor (C_HOLDUP) representing first charge storage device 116 can be calculated by Equation (1) set forth above. Specifically, if P_OUT is 10 W, T_DROP(max) is 16.7 ms or one 60 Hz AC power cycle, η is 95% for a low transformation ratio boost converter, V_C(nom) is 32V, and V_BOOST(min) is 16V to reflect an assumed maximum 2:1 transformation ratio design for second voltage converting stage 118, then C_HOLDUP will be 458 μF.

[0046] FIG. 4C presents annotated waveforms 4C00 showing operation of a driver with an example of chopped input power, according to some embodiments. As shown, V_IN voltage 414 is chopped by the dimming system beginning at time t_C. This extends the duration of t_DROP. The phase cut angle detector 121 senses the chopped nature of voltage 414 and determines characteristics of the power carrying signals as modulated (e.g., chopped) by the dimming system. For example, a shift in the phase (e.g., via a zero crossing) is detected, or the voltage levels are directly sensed and timed. The phase cut angle detector 121 sends a signal to duty-cycle controller 120 to cause the duty-cycle controller to assert B2_M to indicate dropout mode at time t_C. Additional signaling from the phase cut angle detector 121 controls the second voltage converting stage 118 so as to lower the drive current to the LEDs to a level commensurate with the user's setting of the dimming control.

[0047] The driver configuration of the present invention is highly efficient. For example, during an extended period (T_TOTAL) of continuous operation of the system 100, it is expected (although not necessary) that the driver 104 be operated in the first mode for a period (T_P) that comprises the majority of T_TOTAL, while operating in the second mode (e.g., during voltage dropout) for a shorter period (T_D) only under certain conditions (e.g., in a dropout condition) of the aforementioned input voltages. With the overall efficiency of high efficiency driver 104 characterized by the first voltage converting stage 112 efficiency (η_B1) in the first or powered mode 202 (described above in connection with FIG. 2A), and characterized by the second voltage converting stage 118 efficiency (η_B2) in second mode or dropout mode 204 (described above in connection with FIG. 2B), the driver 104 average efficiency (η_AVG) can be calculated by Equation (2):

$\begin{array}{cc}{H}_{\mathrm{AVG}}=\frac{\left(T_P\times {\eta }_{B1}\right)+\left(T_D\times {\eta }_{B2}\right)}{T_{\mathrm{TOTAL}}}& \left(2\right)\end{array}$

[0048] If T_P is 99% of T_TOTAL, T_D is 1% of T_TOTAL, η_B1 is 90%, and η_B2 is 95%, then the driver 104 is therefore expected to exhibit an average efficiency η_AVG of 90.05% during continuous operation.

[0049] Finally, it should be noted that there are alternative ways of implementing the embodiments disclosed herein. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the claims are not to be limited to the details given herein, but may be modified within the scope and equivalents thereof.