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Abstract
DClDC
i,j=l
1 Introduction
Switching DC/DC power supplies with insulation voltages
in the order of tens ofkV and output powers in the order of
some Ws are required for both low and high power
applications such as: driving the gates of high power
IGBTs; supplying insulated transducers; high power
conversion and research.
In these applications, the reliability of the insulation
between input and output is determined by the power
supply transformer and a considerable amount of
transformer volume is dedicated to insulation. When a low
profile is aIso required, an interesting solution is using
planar coreless Printed Circuit Board (PCB) transformers
[ 11, where the high electrical rigidity provided by the FR4
(30 kV/mm) can offer very good insulation performance,
as well as significantly reduce manufacturing costs.
Unfortunately, designing a coreless PCB transformer is not
straightforward because on the one hand analytical models
are available only for circular windings [Z] and they are
quite complex. On the other, despite being quite effective,
finite element modeling [2] is usually not available to the
circuit designer. Furthermore, high switching frequencies
up to IO MHz are required [I], making industrial
implementation dificuIt. For these reasons a DC/DC
power supply with a coreless transformer was analyzed,
with the aim of providing a complete design procedure and
converter characterization. In Sections I1 and 111 a
nunerica1 method to calculate auto and mutual inductances
for coreless PCB transformers is presented together with
its implementation as a Matlab' function. In Section 1V the
converter is analyzed and the output characteristic together
with the maximum output power is calculated.
Experimental results presented in Section V confirm
theoretical predictions.
0-7803-8662-0104/$20.00
02004 IEEE
i,j=l
--
596
.. . --
#3
#2
I
1.55
10
1
10
10
6
0.5
10
10
Transf. No
Rint [mml
Rext [mm]
#1
d I"[
N1
N2
10
1:
#4
3.2
15
#5
1.5
0.8
7
11
3
16
10
10
f u n c c i o n [L12]=mutual(Rint.Rext,NL,NZ,d,N)
IN
IO0
Comp.time[s]i
L12calc. [nH] 302.5
L12meas. [nH]
R=linspace(Rint,Rext,N);
Ql=linspace (0,2*pi*Nl,N) ;
Q2-linspace(0,2*piiN2,N);
R1=[ (R.*cos (Ql) 1 I , (R.*sin(Ql)1 ' I ;
R2=[(R.*cos(Q2))',LR.*sin(QZ)I'];
dRl=diff (Rl); dRZ=diff ( R 2 ) ; L12=0;
for m=l:N-1,
200
306.2
average slice
length [mm]
2.2
400
4
308.0
800
16
1600
65
308.5
308.6
2.6
2.8
2.8
0.55
0.27
0.14
1
I
300
AL17%
f o r n=l:N-1,
L12=LlZtle-7*dRl ( n , : ) *dR2 (m, : ' /
sqrt (norm(R1(n, : -R2 (m,: ) , 2 ) * 2 t d A 2 ) ;
end
1.1
end
#I
LI2meas.rnHl 300
LlzcaIc.[nH] 307.4
2.5
A%
#4
#5
370
#3
430
I100
1056
383.8
473.8
1248
1108
3.73
10.2
13.4
4.5
#2
597
Jb
112
114
118
19
78
321
1302
I 21.0 I
600
11.6
-7
L
meas. [ ~ H J
ALII%
34.2
~~1
5.1
-0.3
TransfNO
Winding
L;; mes
nH
1,2or3
4
1or2
1,2
600
1450
1850
L;i cal
[nH]
569.4
1568
1923
VI = L,,
A%
3.9
dt
L,,
di
v2 =L,++L,,L
dt
5.1
8.1
di,
-+
di,
-
dt
di
dt
4 1
(7)
Converter analysis
I---
598
'in
2vFLll
L I2
where:
Experimental results
LAYER 3
LAYER 4
Given maximum primary losses d p I u 4 x , which are dated Fig. 3. Laboratory prototypc dcvelopcd. Layer 1: primary stage, layer 2:
to PCB overtemperature, the minimum switching
primary winding, layer 3: secondary winding, laycr 4: output rectificr.
599
Tek Esegui I
U
b
(Trigger
t.. . . . I . .
..
: . . . : . . . . . . . . . . . . . : . . . . : . . . . : , . . .1
. .
qChll 1 O . O V
5.OOV
IPl200nsj
Chl Z
m~~0.000s
00
-II
6.604
IO
[wl
IO0
10
where
.,.
10.
.,,
.,
1OB
10
93
;
-*
e
86
measured
-calculated
.-.-e
--t, m -
-a-
600
60
50
R
E40
>.
.-
30
E 20
10
pcut Iwl
References
6 Conclusions
A low-profile high insulation voltage D O C converter
with coreiess PCB transformers has been presented. The
inductances of the transformer were calculated with a
simple yet quite accurate numerical procedure, which was
verified on various transformer prototypes. The converter
was then analyzed and expressions for the output voItage
and maximum output power derived.
601