Multi-Functional PCB With Planar Coils 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 coils for transformers and magnetic couplers, utilizing a pair of ferrite cores and a synchronization signal with a different carrier frequency to ensure proper switching of primary and secondary switches, thereby 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 bobbin structures are used, then power transfer function is achieved, but device size and manufacturing complexity increase
Solution Approach 1:
The patent replaces traditional mechanical wound coil structures with planar spiral coils fabricated on PCB layers. This substitution eliminates the need for bobbins, winding machines, and complex assembly processes, while achieving the same magnetic coupling function through planar geometry. The planar coils are created using standard PCB manufacturing techniques, dramatically simplifying production.
Solution Approach 2:
The invention transitions from three-dimensional wound coil structures to two-dimensional planar spiral patterns on PCB layers. This dimensional reduction enables compact integration, allows multiple transformers to be placed in parallel on the same PCB area, and facilitates automated manufacturing through standard PCB fabrication processes.
2Reliability
If opto-couplers are used for communication between primary and secondary controllers, then isolation is achieved, but power consumption increases and reliability decreases
Solution Approach 1:
The patent introduces a magnetic coupler as an intermediary for communication between primary and secondary controllers. This magnetic field-based intermediary provides galvanic isolation while consuming minimal power, replacing the opto-coupler's light-based mediation which requires continuous power for LED emission and photodetector operation.
Solution Approach 2:
The invention replaces the opto-coupler's optical system with a magnetic field-based communication system. This substitution eliminates the need for LEDs, lenses, and photodetectors, reducing power consumption and improving reliability by using passive magnetic coupling that is not susceptible to optical alignment issues or LED degradation.
3Speed
If operating frequency is increased for faster charging, then charging speed improves, but cross-talk between transformer and coupler increases
Solution Approach 1:
The patent segments the magnetic field usage by assigning different frequency ranges to the transformer (power transfer) and magnetic coupler (communication). This frequency segmentation allows both components to operate simultaneously without significant cross-talk, enabling high-frequency operation for fast charging while maintaining reliable communication.
Solution Approach 2:
The invention changes the operating parameters by using differential frequency ranges for power transfer and communication functions. The transformer operates at high frequency for efficient power transfer, while the magnetic coupler uses a different frequency range for communication, eliminating interference and enabling simultaneous high-speed operation.
4Volume of moving object
If planar coils are used to reduce profile, then device compactness improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent makes the PCB serve multiple functions: it provides mechanical support, electrical connections through traces and vias, and the magnetic coupling structure through planar coils. This multi-functionality eliminates the need for separate coil forms and bobbins, reducing overall device profile while using standard PCB manufacturing processes that inherently provide sufficient precision.
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 compact size, facilitating the integration of multiple 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
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 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.