Planar PCB Transformer and Coupler for GaN Converter 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 synchronization signals with a different carrier frequency are used to ensure proper switching of primary and secondary switches, avoiding cross-talk and enabling compact integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional transformers with wound coils and bobbins are used, then power transfer function is achieved, but device size and manufacturing complexity increase
Solution Approach 1:
The patent replaces traditional mechanical winding processes 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 of mechanical manufacturing with a printed circuit approach significantly reduces device volume and manufacturing complexity while maintaining the electromagnetic coupling function.
Solution Approach 2:
The patent transitions from three-dimensional wound coil structures to two-dimensional planar coil patterns on PCB layers. By unfolding the traditional toroidal or cylindrical coil geometry into flat spiral or meander patterns on the PCB surface, the transformer achieves the same magnetic coupling effect with reduced volume and simplified manufacturing processes.
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 communication with magnetic field-based communication using planar magnetic couplers integrated on the PCB. This substitution eliminates the need for LED excitation and photodetector circuits, significantly reducing power consumption while improving communication reliability through direct magnetic coupling between primary and secondary side controllers.
Solution Approach 2:
The patent changes the communication mechanism from optical parameter domain to magnetic field parameter domain. By using magnetic flux coupling instead of light transmission, the system achieves better reliability through immunity to ambient light interference and reduces power consumption by eliminating the high-current LED driving requirements of opto-couplers.
3Productivity
If operating frequency is increased for faster switching, then power conversion efficiency improves, but cross-talk between transformer and coupler increases
Solution Approach 1:
The patent segments the electromagnetic fields by assigning different frequency ranges to the power transfer function and the communication function. The transformer operates at a lower switching frequency for power conversion, while the magnetic coupler operates at a higher frequency for controller communication. This frequency segmentation prevents cross-talk and allows both functions to coexist without interference.
Solution Approach 2:
The patent applies different quality characteristics to different parts of the PCB layout. The transformer coils are designed with specific trace widths, spacing, and patterns optimized for high-current power transfer at lower frequencies, while the magnetic coupler traces are designed with different geometries optimized for low-current signal communication at higher frequencies. This local optimization minimizes cross-talk while maintaining both functions' performance.
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 provides reliable and stable communication between controllers, supports high-frequency operations, and achieves a more compact size, enhancing the integration of functions in mobile devices while minimizing energy losses and improving reliability.
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
Data Source
AI summary
The present invention provides a multi-functional printed circuit board (PCB) for assembling a plurality of components of a power converter in to a single package. The PCB comprises: 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 plurality of components of the power converter.