Wireless Low-Power Transfer for Galvanically Isolated High-Voltage Applications

Abstract

For various applications, such as gate drivers for transistors, wireless chargers for mobile devices and cars, and isolated measurement equipment, an isolated DC power supply for electronic components is required. In this work, a new concept for an isolated power supply with insulation strength of 50 kV and power transmission of up to 60 W to supply measurement equipment with 12 or 24 V is presented. Furthermore, high overall efficiency of 82.5% at 55 W is achieved. Feasibility is demonstrated in a real application powering data acquisition electronics at high reference potential. Our new concept uses a coreless printed circuit board (PCB) transformer (15 cm × 10 cm × 4 cm and a weight of 480 g) designed for maximum efficiency via a coil layout and close proximity of adjacent coils on one PCB while reaching high isolation strength via the PCB material and potted coils. To increase efficiency, we investigated different coil geometries at different frequencies. A low-cost design consisting of two Qi charging coils mounted on one PCB is compared with our integrated PCB transformers manufactured from a four-layer PCB with ferrites applied on the outside. With this new design, high isolation voltages are possible while reaching high transformer efficiency of up to 90%.