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PCB) Power Transformer with Ferrite Polymer Composite S IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 16, NO. 4, JULY 2001 493 A Low-Profile Power Converter Using Printed-Circuit Board (PCB) Power Transformer with Ferrite Polymer Composite S. C. Tang, Member, IEEE, S. Y. Ron Hui, Senior Member, IEEE, and Henry Shu-Hung Chung, Member, IEEE Abstract—A new design of low-cost and low-profile power transformer is presented in this paper. The manufacturing cost of a power transformer can be reduced using the proposed printed-cir- cuit board (PCB) transformer. The transformer windings are etched on the opposite sides of a double-sided PCB. Self-adhesive ferrite polymer composite (FPC) sheets are stuck on the two PCB surfaces to shield the magnetic flux induced from the transformer windings. The PCB transformer does not require manual winding and bobbin. A power converter prototype employing the PCB transformer has been implemented. The technique of choosing the optimum switching frequency of the power converter using PCB transformer is addressed in this paper. The maximum power delivered from the prototype is 94 W. The maximum efficiency of the power converter is 83.5%. Fig. 1. Dimensions of the transformer. Index Terms—Coreless printed-circuit-board transformers, low- profile converter. II. STRUCTURE OF THE PRINTED-CIRCUIT BOARD (PCB) TRANSFORMER WITH FERRITE POLYMER COMPOSITE (FPC) I. INTRODUCTION SHEETS HE continuous improvement of power electronics has T made it possible to increase the switching speeds of power The printed-circuit board (PCB) transformer in the low-pro- devices. Switching frequency of several hundreds of kilo-Hertz file power converter is used to provide isolation and transfer is commonly adopted in switching power supplies. High-fre- power. The primary and secondary windings, shown in Fig. 1, quency operation can lead to a reduction of magnetic size and are respectively printed on the opposite sides of a printed-cir- an increase of power density. As the frequency increases, the cuit board. When the PCB transformer is operated in low- core loss becomes a limiting factor that cannot be ignored. power-level applications, such as isolated gate drive circuit Recently, coreless printed-circuit-board (PCB) transformers for power MOSFETs and IGBTs, magnetic core can be elim- have been investigated for signal and power transfer [1]–[9]. inated [1]–[9]. Previous research shows that the magnetic flux It has been found that coreless PCB transformers can be generated from coreless PCB transformer employed in gate used for high-frequency operation from about 200 kHz and drive circuit for power MOSFET is negligible compared with upwards. The elimination of magnetic cores and the use of the magnetic flux generated from the high current-carrying printed windings open a new way to manufacture low-profile copper tracks connected to the drain terminal of the power transformers with high power density. MOSFET [7]. When the PCB Width transformer is utilized for In this paper, the study of a low-profile power converter using power transfer applications, the magnetic flux generated from coreless PCB transformer is reported. The special feature of the the transformer has to be confined. Two self-adhesive ferrite proposed converter is the use of a coreless PCB transformer as polymer compose (FPC) sheets [10] are stuck on both sides of the isolation transformer for power transfer [13]. The recently the PCB transformer to shield the magnetic flux. Fig. 2 shows developed ferrite polymer composite is used to enclose the mag- the cross-section of the PCB transformer. The geometric param- netic field of the transformer. eters are listed in Table I. The primary and secondary windings lay on the oppose sides of FR-4 epoxy resin glass fiber lam- inate. In the manufacturing process of PCB, a layer of high electrical breakdown solder mask is sprayed on the surfaces of Manuscript received March 27, 2000; revised April 6, 2001. This work was supported by the Research Grant Council of Hong Kong under CERG Project the PCB. Solder mask is used to prevent the PCB tracks from 9040446. Recommended by Associate Editor K. Ngo. mis-soldering. In the case of the PCB transformer, the solder The authors are with the Department of Electronic Engineering, City Univer- sity of Hong Kong, Kowloon, Hong Kong (e-mail: [email protected]). mask can also provide isolation between the copper windings Publisher Item Identifier S 0885-8993(01)05959-2. and the FPC sheets. 0885–8993/01$10.00 ©2001 IEEE 494 IEEE TRANSACTIONS ON POWER ELECTRONICS, VOL. 16, NO. 4, JULY 2001 Fig. 3. Equivalent circuit of PCB transformer with FPC sheet (includes g , and resistive load, ). and , are equal to 0.206 H. The mutual inductance Fig. 2. Cross section of the PCB power transformer with FPC sheets. is 2.173 H. From [9], the voltage gain, , and input impedance, , of the transformer can be boosted by an TABLE I GEOMETRIC PARAMETERS OF PCB POWER TRANSFORMER external resonant capacitor. The resonant frequency can be chosen flexibly with appropriate value of . The voltage gain and the input impedance of the transformer can be expressed by as follows: Voltage Gain (2) (3) where III. CHARACTERISTICS OF THE PCB TRANSFORMER In this section, the characteristics of the PCB transformer in high frequency range, 100 kHz to 10 MHz, are described. The equivalent circuit model (includes the resonate capacitor, , and resistive load, ) of the PCB transformer with FPC sheet is shown in Fig. 3. The circuit model is similar to the accurate high frequency circuit model for coreless PCB transformer [5]. The loss in the FPC sheets can, in principle, be represented by a resistor, , connected across the mutual inductance, . and However, it has been pointed out that [11] the loss in the ferrite substrates is negligible compared with the proximity effects in the conductor windings in planar sandwich inductors. Thus, the resistor, , can be ignored in the circuit model in order to Input power to the transformer simplify the analysis. The distributive parameters of the PCB transformer are measured by an impedance analyzer HP4194A. (4) Because the geometry of the primary and secondary windings is identical, the winding resistances are the same and follow the Output power delivered from the transformer empirical equations: (5) (1) Efficiency of the transformer From (1), the winding resistances increase with operating fre- quency. This phenomenon is mainly due to skin effects and proximity effects. The capacitive and inductive parameters are measured at 10 MHz. The interwinding capacitance, , is 86 pF. The (6) leakage inductances of the primary and secondary windings, TANG et al.: LOW-PROFILE POWER CONVERTER 495 Fig. 4. Voltage gain of the PCB transformer using FPC sheet with g a QWH pF and various resistive load, . Fig. 6. Circuit schematic of the half-bridge converter. IV. POWER CONVERTER PROTOTYPE AND EXPERIMENTAL RESULTS The PCB transformer is driven by a half-bridge converter as shown in Fig. 6. Both the upper and lower side switches are IRF630 power MOSFET ( V and ). The power MOSFET is in TO-220 package. In the con- verter prototype, the back metal plate of the TO-220 package (connected to the drain of the MOSFET) is soldered directly on the copper pad of the printed-circuit board. This technique facil- itates heat dissipation from the MOSFETs’ dies and reduces the lead inductances of the power MOSFETs. Moreover, the con- Fig. 5. Efficiency of the PCB transformer using FPC sheet with g a QWH pF verter can be very thin. The thickness of the TO-220 package and various resistive load, . power MOSFET is 4.69 mm. The thickness of the PCB trans- former is 1.0 mm. When surface mount components are em- In the paper, the PCB transformer is used to drive a resistive ployed in the converter prototype, the thickness of the power load, , through a full-wave bridge rectifier as shown in Fig. 6. converter is determined by the thickness of the power MOSFET From [12], the equivalent resistance, , in the (2)–(6) can package. be approximately related to as The supply voltage of the half-bridge is 120 V dc. The res- onant capacitor, , is 390 pF so that the maximum efficiency (7) of the power converter is between 2 MHz and 4 MHz as de- scribed in Section III. In the half-bridge converter, a 40 ns dead From (2), the voltage gain of the PCB transformer using FPC time is introduced between the two MOSFETs’ gating signals. sheet with 390 pF resonant capacitor is plotted in Fig. 4. The This dead time prevents shoot-through current from flowing into efficiency plot of the PCB transformer, shown in Fig. 5, can be the two MOSFETs at the transition time. The power converter obtained from (6). Since the PCB transformer acts as a power is tested with various switching frequencies (from 1 MHz to transformer, high power efficiency is desirable. The maximum- 4 MHz) and load resistance (from 30 to 200 ). Under an efficiency-frequency (MEF) is about 4 MHz. At this frequency, open-loop condition, the output voltage, , of the power con- the transformer efficiency is about 94% when . verter is plotted in Fig. 7. Operating the transformer at this MEF is the most favorable. Fig. 8 shows the measurement setup of the PCB transformer However, when the transformer is driven by power MOSFET in the half-bridge power converter. Because neither of the trans- switches, the switching losses of the power MOSFETs must be former terminals is common to the converter’s ground, differen- considered. Because the switching losses of the power MOS- tial voltage probes P5205 from Tektronix are used to measure FETs are directly proportional to the switching frequency, the the primary and secondary voltages of the PCB transformer.
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