PCB Planar GaN Power Converter With Magnetic Signal Coupling
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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 ensure proper switching of primary and secondary switches, and ferrite cores are used to minimize size and enhance 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 PCB-based planar coil structures. The transformer coils are formed by etching conductive patterns directly onto PCB layers, eliminating the need for manual or automated wire winding around bobbins. This substitution dramatically simplifies manufacturing while reducing the overall device volume through integrated circuit board construction.
Solution Approach 2:
The patent transitions from three-dimensional wound coil structures to two-dimensional planar coil patterns on PCB layers. By laying out the transformer windings as flat conductive traces on circuit boards and stacking multiple PCB layers, the design achieves the necessary inductance and coupling in a compact, miniaturized form factor suitable for modern electronic devices.
2Reliability
If opto-couplers are used for communication between controllers, then electrical 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 flux coupling between windings on the same core, eliminating the need for light-emitting and light-detecting components. This magnetic coupling approach reduces power consumption while improving reliability through simpler, more robust magnetic field-based isolation.
Solution Approach 2:
The ferrite cores serve dual functions: they provide magnetic coupling for synchronization signal transmission between controllers and simultaneously enable power transfer through the transformer windings. This multi-functionality eliminates the need for separate opto-coupler components, reducing both power consumption and component count while improving overall system reliability.
3Productivity
If operating frequency is increased, then power conversion efficiency is improved, but communication stability between controllers deteriorates
Solution Approach 1:
The patent introduces ferrite cores as magnetic intermediaries that couple the primary and secondary sides through magnetic flux. These cores provide a stable magnetic path that maintains coupling integrity even at high switching frequencies, enabling reliable synchronization signal transmission while supporting efficient high-frequency power conversion. The ferrite material properties are specifically selected to maintain low losses and stable permeability at the operating frequency range.
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 enables reliable communication and stable operation at higher frequencies, reduces the size of the power converter, and avoids cross-talk between the transformer and coupler, leading to improved reliability and efficiency.
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.