Design and Analysis of a High Current GaN Based PCB for Dual Active Bridge Converter for Electric Aircraft Applications

This article centers on the design and performance assessment of a GaN-based low voltage side power stage tailored for a 5 kW, 28 V, 1:29 dual active bridge (DAB) converter. While existing literature showcases GaN-based DAB converters’ potential with various power ratings and step ratios, this study focuses on the challenges encountered when striving for higher power ratings and a higher step ratio due to increased current demands. The article emphasizes key considerations when constructing a high current power stage, including optimal device selection, effective device paralleling, managing power loop inductance, and ensuring thermal stability, all of which significantly influence the converter’s overall performance. Ultimately, the research seeks to advance GaN-based power conversion technology for electric aircraft applications, capitalizing on its higher power density and higher switching frequency capabilities for 28 V aircraft operations.