This thesis is mainly composed of two parts. The first part is to introduce the planar transformer-based circuits and their applications. The mixed-mode S parameters and the grounding effects for planar transformers are discussed. A physical model has been developed for modeling the planar transformers. In the second part, a new coil winding technique for planar transformers has been presented to realize a high-efficiency planar transformer with arbitrary turn ratio for power-split/combine and phase-shift applications. Especially, the power-split/combine architecture based on a planar transformer of cellular shape is first presented in this thesis, enabling various kinds of passive components to be widely realized using the integrated passive device processes. As an example, this thesis proposes a design procedure for high-efficiency balun component. Firstly, design a high Q transformer that considers the load impedance effects. Secondly, design the ground reference for un-balanced signal on the virtual ground symmetry axis for balanced signals. Thirdly, design impedance matching networks for minimizing un-balanced and balanced port return losses. Then, a high performance planar transformer-based balun design can be done.

The increased power consumption and power density demands of modern technologies have increased the technical requirements of DC/DC and AC/DC power supplies. In this regard, the primary objective of the power supply researcher/engineer is to build energy efficient, high power density converters by reducing the losses and increasing the switching frequency of converters respectively. Operating the converter circuits at higher switching frequencies reduces the size of the passive components such as transformers, inductors, and capacitors, which results in a compact size, weight, and increased power density of the converter. Therefore, the thesis work is focussed on the design, analysis and evaluation of isolated converters operating in the 1 - 5MHz frequency region with the assistance of the latest semi conductor devices, both coreless and core based planar power transformers designed in Mid Sweden University and which are suitable for consumer applications of varying power levels ranging from 1 – 60W. In high frequency converter circuits, since the MOSFET gate driver plays a prominent role, different commercially available MOSFET gate drivers were evaluated in the frequency range of 1 - 5MHz in terms of gate drive power consumption, rise/fall times and electromagnetic interference (EMI) and a suitable driver was proposed. Initially, the research was focused on the design and evaluation of a quasi resonant flyback converter using a multilayered coreless PCB step down transformer in the frequency range of 2.7 – 4MHz up to the power level of 10W. The energy efficiency of this converter is found to be 72 - 84% under zero voltage switching conditions (ZVS). In order to further improve the energy efficiency of the converter in the MHz frequency region, the new material device GaN HEMT was considered. The comparisons were made on a quasi resonant flyback DC-DC converter using both the Si and GaN technology and it was found that an energy efficiency improvement of 8 – 10% was obtained with the GaN device in the frequency range of 3.2 – 5MHz. In order to minimize the gate drive power consumption, switching losses and to increase the frequency of the converter in some applications such as laptop adapters, set top box (STB) etc., a cascode flyback converter using a low voltage GaN HEMT and a high voltage Si MOSFET was designed and evaluated using a multi-layered coreless PCB transformer in the MHz frequency region. Both the simulation and experimental results have shown that, with the assistance of the cascode flyback converter, the switching speeds of the converter can be increased with the benefit of obtaining a significant improvement in the energy efficiency as compared to that for the single switch flyback converter. In order to further maximize the utilization of the transformer, to reduce the voltage stress on MOSFETs and to obtain the maximum power density from the converter circuit, double ended topologies were considered. Due to the lack of high voltage high side gate drivers in the MHz frequency region, a gate drive circuitry utilizing the multi-layered coreless PCB signal transformer was designed and evaluated in both a half-bridge and series resonant converter (SRC). It was found that the gate drive power consumption using this transformer was around 0.66W for the frequency range of 1.5 - v 3.75 MHz. In addition, by using this gate drive circuitry, the maximum energy efficiency of the SRC using multilayered coreless PCB power transformer was found to be 86.5% with an output power of 36.5W in the switching frequency range of 2 – 3MHz. In order to further enhance the energy efficiency of the converter to more than 90%, investigations were carried out by using the multiresonant converter topology (LCC and LLC), novel hybrid core high frequency planar power transformer and the GaN HEMTs. The simulated and experimental results of the designed LCC resonant converter show that it is feasible to obtain higher energy efficiency isolated DC/DC converters in the MHz frequency region. The peak energy efficiency of the LCC converter at 3.5MHz is reported to be 92% using synchronous rectification. Different modulation techniques were implemented to regulate the converter for both line and load variations using a digital controller. In order to realize an AC/DC converter suitable for a laptop adapter application, consideration was given to the low line of the universal input voltage range due to the GaN switch limitation. The energy efficiency of the regulated converter operating in the frequency range of 2.8 – 3.5MHz is reported to be more than 90% with a load power of 45W and an output voltage of 22V dc. In order to determine an efficient power processing method on the secondary side of the converter, a comparison was made between diode rectification and synchronous rectification and optimal rectification was proposed for the converters operating in the MHz frequency range for a given power transfer application. In order to maintain high energy efficiency for a wide load range and to maintain the narrow switching frequency range for the given input voltage specifications, the LLC resonant converter has been designed and evaluated for the adapter application. From the observed results, the energy efficiency of the LLC resonant converter is maintained at a high level for a wide load range as compared to that for the LCC resonant converter. Investigations were also carried out on isolated class E resonant DC-DC converter with the assistance of GaN HEMT and a high performance planar power transformer at the switching frequency of 5MHz. The simulated energy efficiency of the converter for the output power level of 16W is obtained as 88.5% which makes it feasible to utilize the designed isolated converter for various applications that require light weight and low profile converters. In conclusion, the research in this dissertation has addressed various issues related to high frequency isolated converters and has proposed solution by designing highly energy efficient converters to meet the current industrial trends by using coreless and core based planar transformer technologies along with the assistance of GaN HEMTs. With the provided solution, in the near future, it is feasible to realize low profile, high power density DC/DC and AC/DC converters operating in MHz frequency region suitable for various applications. / High Frequency Switch Mode Power Supplies

This dissertation aims to design and implement wireless passive components using domestic integrated passive device (IPD) technology. The research focuses on exploiting novel 3-D structures for various kinds of IPD-based wireless passive components including high-quality and high-efficiency planar transformers, baluns, filters, and combiners to achieve miniature size and high performance. A physical model has been developed for modeling the planar transformers. In this dissertation, a scalable transformer model in integrated passive device technology is further used to correlate with the coupled-line sections of a conventional Marchand balun. This improves the efficiency of the design of planar transformers with equivalent coupled-line parameters such as the coupling factor, and even- and odd-mode characteristic impedances and quality factors. Additionally, the proposed model-based design approach provides effective optimization techniques that incorporate geometrical and material parameters. In addition, a compact transformer-based coupled balun bandpass filter design is proposed based on integrated circuit technology and the equivalent circuit is established. Using a planar transformer with high-density fully symmetrical wiring not only greatly reduces the component size but also provides a superior stopband rejection and selectivity. Finally, by using the spiral-shaped resonators, the dual-band third-order bandpass filter has been implemented on organic substrates. The proposed BPF design is verified to overcome the elements¡¦ parasitic effects, and thus can be miniaturized and optimized with high degree of freedom. The simulation and measurement results have good agreement for the proposed design in this dissertation.

This dissertation studies and implements highly miniaturized bandpass filter designs for wireless System-in-Package (SiP) applications. Based on the coupling matrix synthesis method, the external quality factors and coupling coefficients can be extracted by selecting the proper tapped-line feeding position and coupling spacing in geometrical configuration. Despite their high performance, most conventional microstrip bandpass filter designs require a bulky area for achieving, making them difficult to implement SiP applications. This dissertation first develops a stacked LC resonator and a stacked spiral resonator (SSR) in an embedded passive substrate (EPS) for realizing miniature single- and multi-band bandpass filters. Moreover, multiple transmission zeros created on both sides of each passband provide high stopband roll-off rates. The designed performance and size are comparable to those of low-temperature co-fired ceramic (LTCC) bandpass filters. As another conventional means of implementing RF passive components, the integrated passive device (IPD) process can produce large-value inductors and high-density capacitors, simultaneously. This dissertation fully utilizes the advantages of IPD technology to implement very compact bandpass filter designs with multiple transmission-zero frequencies at stopband by using a high-density wiring planar transformer configuration. Furthermore, due to the fully symmetric geometry, the transformer-coupled bandpass filter can be easily converted into a balun bandpass filter, capable of providing a superior balance performance with a significantly higher common mode rejection ratio (CMRR) level. The electromagnetic (EM) simulation results, as obtained by using Ansys-Ansoft HFSS, agree with the measurement results for all of the proposed designs in this dissertation.

This master's thesis describes the development of switching power supply with planar transformer. Deals with selection of a suitable integrated circuit together with the topology, a purchase of prototype for the reference measurements and debugging its own power supply. Further design and implementation of planar transformer and in the final implementation, debugging, and measurment's its own prototype. Power supply was fully functional and reached the expected parameters.

This work presents the design and analysis of two Litz wire transformers for a 500 kHz, 18 kW input­parallel output­series partial power processing converter (IPOS PPP). Because the two power paths in the IPOS PPP operate as “dc transformers” (DCX), both transformers are designed with the goal of leakage inductance minimization in order to reduce gain variation around the resonant frequency. The selected winding topology with the lowest leakage inductance results in an impedance mismatch among parallel secondaries used in the majority power path transformer, resulting in poor current sharing. In order to balance the goals of leakage inductance minimization and even current sharing, a new winding technique called “intra­leaving” is presented which reduces current sharing error from 50%, to 5%. A design rule for “intra­leaving” is also established which extends the winding method to different winding configurations and higher numbers of parallel winding. A novel cooling duct designed with computational fluid dynamics is used for transformer thermal management. The cooling duct uses two 30 mm 7.7 CFM fans to cool the transformer winding and achieves a small height of 43 mm and only 6.8 W power consumption. Using the cooling duct, 106 °C peak winding temperature and 76 °C peak core temperature is achieved at 15 kW load, an ∼ 8% reduction compared to using a conventional 120 mm fan 41 CFM fan. The two transformers with the cooling system achieve 635 W/in3 power density, 1U height compliance, and 99.4% peak efficiency. / M.S. / As society moves towards the electric grid of the future, there have been increased calls for the research and development of resonant power converters due to their high efficiency, high power density, and low electromagnetic interference. The high frequency transformer is one of the main components of the resonant converter system as it contributes substantially to the converters volume, power loss, and thermal management risks. This work seeks to address the trade­offs between leakage inductance minimization and transformer current sharing and proposes a winding method called “intra­leaving” which achieves both. Using “intra­leaving” current sharing error was reduced from 50%, to 5%. Operating transformers at high frequency reduces their volume in accordance with Faraday’s law but also increases thermal risks due to decreased core surface area, higher winding fill factor, and higher loss per unit volume. A novel cooling duct designed using computational fluid dynamics is presented using two 30 mm 7.7 CFM fans and achieves a small height of 43 mm and only 6.8 W power consumption. Using the cooling duct, 106 °C peak winding temperature and 76 °C peak core temperature is achieved at 15 kW load, an ∼ 8% reduction compared to using a conventional 120 mm fan 41 CFM fan. The transformers with the cooling system designed in this work achieve 635 W/in³ power density, 1U height compliance, and 99.4% peak efficiency.

This thesis focuses on the design issues of the multiple-output boost full-bridge converter, which is constructed by cascading the boost regulator with the inductor-less full-bridge converter. The design of the boost regulator has been proposed briefly with component selection and compensator design. After that, the inductor-less full-bridge converter is analyzed extensively. In the first place, the operation principle of the inductor-less full-bridge converter is introduced. Later, the effect of parasitic resistance and inductance is analyzed in an L-R series circuit model as step-response, which relates the drop of output voltage to the load current. Then, the effects of the dc blocking capacitor for the unbalanced load condition and unbalanced duty cycle are tackled. The theoretical results are compared with the experimental results and the simulation results to verify the relationship between the output voltage drop and load current. The overall efficiency of the converter is tested under various conditions. The design of the planar transformer is critical to limit the profile of the converter and the leakage phenomenon. A planar transformer fit for the inductor-less full-bridge converter is designed and analyzed in 3D FEA software. An N-port transformer model is proposed to implement the inductance matrix into the leakage inductance matrix for circuit analysis. Based on this N-port model several measurements to extract the parameters in this model are proposed, where only the impedance analyzer is needed. Finally, the effects of trace layout and encapsulation on breakdown voltage in PCB are summarized from experimental results. / Master of Science

This report presents a project that has been made to present the design of a planar transformer as a part of a series loaded resonant DC/DC converter in a power unit. The design is based on an existing transformer that is not planar and so the characteristics of the transformer is translated into a planar version. A multilayer printed circuit board (PCB) design was made to fit a chosen magnetic ferrite core that was chosen based on the magnetic characteristics of the old core. Calculations were made for the loss of both core and windings and the final results show that it is possible to design a planar transformer from a traditional transformer.

Dans l’aéronautique et plus précisément dans les avions tout électrique, l’objectif visé est de réduire les masses et volumes des composants. Pour cela, les actionneurs électriques remplacent progressivement les actionneurs hydrauliques et mécaniques. Ces actionneurs électriques ont besoin d’être commandés ; le projet THOR (projet européen dans lequel s’inscrit cette thèse) vise entre autres à développer un étage de commande permettant de piloter des interrupteurs de puissance. Les interrupteurs étant situés à proximité directe de l’étage driver et les tensions de sorties pouvant atteindre 3 kV, une isolation galvanique est obligatoire. Anciennement, les optocoupleurs étaient utilisés pour assurer l’isolation galvanique dans les étages de commande. Cependant, afin de pouvoir utiliser ces composants dans un environnement thermique contraignant et assurer une meilleure intégration, les opto-coupleurs ne sont plus adaptés et sont remplacés par des transformateurs. Dans ce contexte, s’inscrivent les travaux de cette thèse où l’objectif principal est de développer, réaliser et caractériser des transformateurs planaires intégrables répondant au cahier des charges THOR. Dans un premier temps, un état de l’art sur les différentes technologies de fabrication de transformateurs planaires est établi avant de choisir la technologie et les matériaux utilisés dans ces composants. Dans un deuxième temps, on s’intéresse au choix et au dimensionnement du transformateur. Deux structures répondant au cahier des charges THOR ont été retenues et dimensionnées à l’aide d’un logiciel de simulation (HFSS) : une structure entrelacée et une structure ‘face to face’. Ces deux structures ont été réalisées et caractérisées à l’aide d’un LCRmètre en basse fréquence et d’un Analyseur Vectoriel de Réseaux (VNA) en haute fréquence. Pour les deux structures, la caractérisation a permis de vérifier les valeurs des inductances magnétisantes supérieures à 1 μH souhaitées par le projet THOR et des facteurs de couplages supérieurs à 0,9 déterminées par simulation. D’autres paramètres importants du cahier des charges ont été également extraits à savoir la capacité interbobinage où des capacités inférieures à quelques pF ont été obtenues et des résistances d’enroulement inférieures à 10 Ω ont été relevées / In aeronautics and more specifically in an all-electric aircraft, the main objective is to reduce the mass and volume of the components. For this, the electric actuators gradually replace hydraulic and mechanical actuators. These electric actuators need to be commanded; THOR project (European project supporting this thesis) aims to develop a control stage to command the power switches. The switches are located in the direct vicinity of the driver stage with an output voltage that can reach up to 3 kV hence the need for a galvanic isolation. Formerly, the opto-couplers were used to provide galvanic isolation in the control stages. However, in order to use these components in thermal constraining environment and ensure better integration, opto-couplers are no longer appropriate and are replaced by transformers. In this context, the main objective of this thesis is to develop, realize and characterize integrated planar transformers that meet the THOR specifications. At first a state of art on the different manufacturing technologies of planar transformers is established before choosing the technology and the materials used in the fabrication of our planar transformers. In a second step, we are interested in the choice and size of the transformer structure. Two structures that met the THOR specifications were selected and resized using a simulation software (HFSS). Finally, these two structures were realized and characterized using an RLC-meter at low frequency and a Vector Network Analyzer (VNA) at high frequency. For both structures, the characterization allowed to verified the magnetizing inductance greater than 1 μH desired by the THOR project and a coupling factor greater than 0,9 obtained par simulations. Other important parameters were also extracted namely the inter-winding capacity where less than few pF wasobtained and the windings resistance has been identified less than 10 Ω

Ce travail concerne la conception, la réalisation et la caractérisation d’un transformateur de commande pour interrupteurs de puissance à grille isolée, le transformateur assurant l’isolation galvanique entre étage de commande et circuit de puissance. L’objectif du travail n’était pas de répondre à un cahier des charges précis mais de développer une nouvelle voie technologique pour la réalisation de transformateur planaire intégrable. Les principales caractéristiques d’un tel transformateur sont : - une inductance élevée (rapport inductance/surface occupée le plus grand possible) ; - des résistances séries faibles ; - un couplage capacitif entre primaire et secondaire le plus faible possible. Ces contraintes nous ont conduits à étudier un transformateur planaire à couches magnétiques dont les enroulements primaire et secondaire sont enterrés dans le matériau magnétique afin de réduire l’entrefer. La structure Face to Face a été retenue avec un décalage de 45° entre enroulements primaire et secondaire. Après une étude en simulation, chaque enroulement enterré dans un matériau ferrite a été réalisé séparément puis assemblé pour donner naissance au transformateur. De très nombreuses étapes technologiques : micro usinage laser femtoseconde, dépôts de cuivre par pulvérisation cathodique, photolithographie, planarisation, gravure chimique … ont été mises en oeuvre. Le transformateur ainsi réalisé est constitué d’un empilement de couches magnétiques, conductrices et isolantes. Il a été caractérisé des très basses fréquences jusqu’à plusieurs dizaines de MHz. Les résultats de mesure obtenus sont proches des résultats de simulation, la bande passante du transformateur s’étendant de 20kHz à 7MHz / This work concerns the design, realization and characterization of a control transformer for insulated gate power switches, the transformer providing galvanic isolation between driving stage and power circuits. The aim of the work was not to respond to a precise specification but to develop a new technological path for the realization of an integrable planar transformer. The main characteristics of such transformer are: - high inductance (ratio of inductance / area occupied as large as possible); - low series resistances; - a capacitive coupling between primary and secondary as small as possible. These constraints guided us to study a planar transformer with magnetic layers whose primary and secondary windings are buried in the magnetic material in order to reduce the air gap. The Face to Face structure was chosen with a 45 ° offset between primary and secondary windings. After a numerical study, windings buried in a ferrite material were fabricated separately and then assembled to give rise to the transformer. Many technological steps: femtosecond laser micromachining, copper deposits by sputtering, photolithography, planarization, chemical etching ... have been implemented. Thus, the transformer produced consists of a stack of magnetic, conductive and insulating layers. It has been characterized from very low frequencies up to several tens of MHz. The measurement results obtained are close to simulation results, the bandwidth of the transformer extending from 20 kHz to 7 MHz