Patent ID: 11923778
Assignee: INNOSCIENCE (SUZHOU) TECHNOLOGY CO., LTD.
Field: Electrical machinery, apparatus, energy (Electrical engineering)
Classification: CPC H  Y | IPC H

Claim 11:
12. A method for manufacturing a GaN-based power converter, the method comprising:
preparing a printed circuit board (PCB) comprising a plurality of planar conductive coils respectively formed on a plurality of PCB layers for constructing a transformer and a coupler, and a plurality of conducting traces and vias for integrating a plurality of electrical components of the power converter; wherein the transformer has a transformer primary winding and a transformer secondary winding; and the coupler has a coupler primary winding and a coupler secondary winding;
forming a middle opening at a central region of the plurality of planar conductive coils and two side openings at two opposite adjacent regions of the plurality of planar conductive coils;
assembling the plurality of electrical components of the power converter to the PCB; wherein the plurality of electrical components includes at least a primary switch electrically connected to the transformer primary winding; a secondary switch electrically connected to the transformer secondary winding; a primary controller electrically connected to the primary switch and the coupler primary winding; and a secondary controller electrically connected to the secondary switch and the coupler secondary winding;
fixing a pair of ferrite cores to a top surface and a bottom surface of the PCB respectively such that the ferrite cores are bonded with each other with their middle protrusions and side protrusions aligned with their counterparts and passing through the respective middle and side openings;
encapsulating the plurality of electrical components and the PCB with a thermal conductive compound;
wherein the primary controller comprises:
a primary driver configured to generate a primary control signal for controlling the primary switch;
an oscillator configured to continually generate a carrier wave; and
a modulator configured to:
receive the carrier wave from the oscillator and the primary control signal from the primary driver; and
modulate the carrier wave based on the primary control signal to generate a synchronization signal.