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Technical Lecture

High-Frequency Magnetics

T05.5 - PCB-Winding Integrated Transformer for 800-V Dual Active Bridge Converter using 1.2-kV GaN Devices

Tuesday, March 18, 2025
9:50 AM – 10:10 AM ET
Location: Level Three, A301
This paper introduces a novel PCB-winding integrated inductor-transformer for an 800-V Dual Active Bridge (DAB) converter. It demonstrates one of the first 1200-V GaN DABs, omitting the use of multi-level topologies. The newly developed split-PCB integrated inductor-transformer eliminates the series inductor and addresses key design challenges in high-voltage, high-frequency converters, such as parasitic capacitance mitigation. An optimal transformer is achieved through a combination of analytical and finite element calculations. Limitations due to parasitic capacitances, inadvertently high in PCB transformers, are detailed and mitigated in 3 optimised transformer prototypes. A novel design approach achieves the target leakage inductance by tuning the turns and degree of interleaving in the PCB windings. Furthermore, experiments and simulations provide a comprehensive comparative analysis. Finally, these are implemented in two distinct proof-of-concept DAB converters at 250 kHZ and 500 kHZ with 1200-V GaN transistors. The results underline the potential of PCB-winding integrated magnetics and 1200-V GaN devices towards high-performance yet cost-effective automotive converters.