PCB Planar GaN Power Converter With Magnetic Signal Isolation
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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 planar coils are integrated on PCB layers, and a pair of ferrite cores are used to ensure efficient power transfer and synchronization between primary and secondary switches, avoiding cross-talk by using a carrier frequency different from the switching frequency.
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 coil structures fabricated using PCB manufacturing techniques. The transformer coils are formed as planar patterns on circuit board layers, eliminating the need for manual or automated wire winding around cores, thus reducing both device size and manufacturing complexity while maintaining the power transfer function.
Solution Approach 2:
The patent transitions from three-dimensional wound coil structures to two-dimensional planar coil patterns. By laying out the coils as flat patterns on PCB layers rather than winding them in space, the design achieves significant size reduction and simplifies manufacturing while preserving the electromagnetic coupling functionality.
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 isolation with magnetic coupling through shared ferrite cores. The synchronization signals are transmitted via magnetic fields through the common core structure, eliminating the need for opto-couplers and their associated high power consumption and reliability issues while maintaining galvanic isolation.
Solution Approach 2:
The ferrite core structure serves dual functions: it provides magnetic coupling for power transfer through the transformer and simultaneously enables synchronization signal transmission through the magnetic coupler. This multi-functionality eliminates the need for separate opto-coupler components for communication.
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 employs frequency differentiation where the transformer operates at a primary switching frequency for power conversion while the magnetic coupler operates at a different synchronization frequency. This local frequency assignment within the shared ferrite core structure allows high-frequency operation for improved efficiency while minimizing cross-talk through spectral separation.
Solution Approach 2:
The patent uses periodic switching at differentiated frequencies for the transformer and magnetic coupler. By operating the primary switch and secondary switch at different periodic frequencies, the system achieves high-frequency power conversion efficiency while the frequency separation prevents harmful cross-talk between the two magnetic components.
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 stability at high frequencies, enables a more compact size for integration into mobile devices, and reduces energy losses by minimizing cross-talk between transformer and coupler components.
Implementation Method 1
a transformer configured to transfer power by switching on and off the primary switch and the secondary switch at a switching frequency
Implementation Method 2
a magnetic coupler configured to transfer a synchronization signal from the primary controller to the secondary controller
Implementation Method 3
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
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.