GaN Power Converter PCB Transformer for Reliable Isolated Sync
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Solution Overview
Problem
Existing GaN-based power converters face challenges in achieving reliable and stable communication between primary-side and secondary-side controllers, especially at higher frequencies, and struggle with miniaturization due to the complexity of transformer manufacturing and the limitations of opto-couplers in terms of power consumption, lifespan, and reliability.
Innovation Solution
A GaN-based power converter design featuring a multi-layered printed circuit board (PCB) with planar electromagnetic components, including a transformer and magnetic coupler, where synchronization signals with a carrier frequency different from the switching frequency are used to ensure proper switching of primary and secondary switches, and ferrite cores are shared to minimize size and maximize reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional transformers with wound coils are used, then power transfer function is achieved, but device size and manufacturing complexity increase
Solution Approach 1:
The patent replaces the traditional mechanical winding process with planar PCB trace patterns that form the transformer coils. The transformer is constructed using standard PCB fabrication techniques (copper traces on circuit board layers) instead of manual or automated wire winding, eliminating the complex bobbin structure and winding machinery while achieving the same electromagnetic coupling function.
Solution Approach 2:
The patent transitions from three-dimensional wound coils to two-dimensional planar traces on PCB layers. The transformer coils are formed by copper traces on different layers of the PCB, creating magnetic coupling through vertical alignment of planar structures rather than through three-dimensional winding, thereby reducing overall device volume and simplifying manufacturing.
2Reliability
If opto-couplers are used for communication between controllers, then isolation is achieved, but power consumption increases and reliability decreases
Solution Approach 1:
The patent replaces opto-coupler-based optical communication with direct magnetic field coupling through the PCB structure. The synchronization signal is transmitted through magnetic coupling between trace patterns on different PCB layers, eliminating the need for optical components, LEDs, and photodetectors, thereby reducing power consumption and improving reliability through a solid-state magnetic coupling mechanism.
3Productivity
If operating frequency is increased, then power conversion efficiency is improved, but cross-talk between transformer and coupler increases
Solution Approach 1:
The patent implements frequency-specific trace routing and spatial arrangement where the transformer and magnetic coupler traces are positioned and oriented to minimize mutual interference at the operating frequency. The PCB layout uses different layer configurations and trace orientations for power transfer versus synchronization signal transmission, creating localized electromagnetic field patterns that reduce cross-talk while maintaining high-frequency operation efficiency.
4Volume of moving object
If transformer and coupler are separately manufactured, then individual optimization is achieved, but overall device size increases
Solution Approach 1:
The patent merges the transformer and magnetic coupler into a single integrated PCB structure where both functions are implemented using the same planar trace patterns and ferrite core material on the same circuit board. The PCB serves simultaneously as the structural support, electrical connection medium, and magnetic coupling element for both power transfer and synchronization signal transmission, eliminating the need for separate transformer and coupler assemblies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances communication reliability and compactness, allowing for higher frequency operations without cross-talk between the transformer and coupler, thereby improving the stability and efficiency of the power converter while facilitating integration into smaller mobile devices.
Implementation Method 1
The transformer is configured to transfer power by switching on and off the primary switch and the secondary switch at a switching frequency
Implementation Method 2
The coupler is configured to transfer a synchronization signal from the primary controller to the secondary controller
Data Source
AI summary
The present invention provides a high efficiency, high density GaN-based power converter comprising: a transformer; a magnetic coupler; a primary switch; a secondary switch; a primary controller; a secondary controller; a multi-layered print circuit board (PCB) comprising: one or more planar coils respectively formed on one or more PCB layers and aligned with each other for constructing the transformer and the coupler; and a plurality of conducting traces and vias for providing electrical connection among the transformer, the coupler, a primary switch, a secondary switch, a primary controller and a secondary controller. The power converter further comprises a pair of ferrite cores being fixed to a top surface and a bottom surface of the PCB respectively and commonly shared by the transformer and the coupler.