Presentation Description: For decades isolated signal chain, measurements, and gate drive applications have relied on bulky discrete magnetics to design an isolated bias supply. Constrained by ferrite material and/or laminate dielectric strength, existing integrated transformer technologies have reached their ceiling of power density, efficiency and EMI. Recently, several isolated DC-DC modules with integrated air-core transformer for reducing the solution size. However, the EMI compliance running with tens-MHz switching and air-core transformer windings is always a nightmare. This session introduces the industry-pioneering 64MHz low-EMI transformer integration technology and advanced low-RθJA flip-chip packaging to resolve these technical barriers, achieving 30x higher power density. Critical design considerations, value proposition, and performance comparison are discussed to show how to simply automotive and industrial isolated bias supply designs. Experimental results with an ultra-small 4×5×1-mm3 VSON-12 leadless package delivering up to 2-W nominal power with outstanding efficiency, power capability, regulation will be discussed. The isolation barrier robustness enabling >200V/ns CMTI and advanced control schemes enabling minimum EMI filter components to meet CISPR-32 and CISPR-25 requirements will be shown as well. Finally, the powerful scalability enabling compact DC/DC modules meeting both basic and reinforce isolation requirement will be introduced. The small wide-body SOIC packages solves critical 5kVrms isolation and thermal challenges. Several hardware design examples will reveal substantial system benefits, including compact battery management units of emerging 1.5kV energy storage systems, SiC-based 3.6kW HV-to-LV DC-DC for EV/PHEV with 800V battery, 7.5kW GaN-based 48V battery backup unit for AI/cloud-computing servers, and 500W GaN-based micro solar inverters. Overall, the presentation is tailored to provide audience the following four takeaways. Firstly, the audience will acquire the latest summary on the development trend, system architecture, and design challenges of isolated bias supply; Secondly, the audience will learn different approaches to design high-density low-EMI isolated DC-DC converters with an integrated air-core transformer, where apple-to-apple performance comparison and critical design challenges are covered in detail. Thirdly, the audience will understand the operating principles, performance overview, and system-level design examples. Fourthly, the content will help audience to learn critical application techniques to maximize thermal-derating power and improve EMI.
