GaN-Based High Power High Frequency Wide Range LLC Resonant Converter

The next generation of aircraft technology will leverage advanced electronics to achieve high SWaP-C solutions. State-of-the-art communications, controls, and power electronics have achieved higher packing densities to drastically miniaturize and consolidate on-board electronics. Even with improvements in device(s) efficiency, such densely packed electronics are still responsible for generating significant heat. This miniaturization and integration, as is the case with wide-bandgap devices such as GaN and SiC, have outpaced conventional thermal management solutions for heat sinking, heat spreading, and heat transport. SET group has developed a beyond state-of-the-art high-power-density power converter. This technology has been under development since the NASA 2017 SBIR Phase I titled “GaN-based High Power High Frequency Wide Range LLC Resonant Converter.” The development leverages three main technologies: Space-grade Gallium Nitride HEMTs, high-power density planar magnetics, and an innovative thermal management system (TMS) device architecture that in turn, leverages three key technologies: discrete & integrated sub-millimeter micro-fluidic wicking structures, integrated conformal (landscaped) heat-sinking geometries, and bi-metal heat exchangers; all physically consolidated through a single-step assembly/production process (additive manufacturing). During the Phase II effort, SET group has consolidated all the electronics (power stage and controls) within a DOSA half-brick footprint. The unit has a rectangular power density of 30W/cm3 and a system specific power of 15 kW/kg has been reached, with a target of 20kW/kg by the end of the Phase II effort. This Phase II-E proposal, titled GaN-based High Power High Frequency Wide Range LLC Resonant Converter will focus on in-depth analysis and environmental testing. The testing of the unit will be performed both at SET group’s facilities and at NASA’s Glenn Research Center. The target TRL level for the unit is 8.

SET group’s power conversion technology will have the most significant impact on NASA’s electric aircraft development efforts and the Artemis program. NASA’s electric aircraft development includes the Single-aisle Turboelectric Aircraft with an Aft Boundary-Layer (STARC-ABL), future electric X-plane, and other Advanced Air Vehicles. Artemis’ Lunar Gateway would also be the ideal platform for validating WBG power devices in space.

SETgroup’s technology will have the most significant impact on commercial eVTOL/Urban Air Taxi efforts. General aviation platforms (power range of 15-300 kW), stands to reap the most benefit in the short-term.Given the application’s requirement for a minimum of 8kW/kg power-to-weight ratio, SET group’s 20kW/kg seeks to enable the speed of development for near-future commercial electric aircraft

This is a mature technology (TRL 8) — the realistic path in is usually NASA's Technology Transfer Program: licensing an existing NASA patent, or a Space Act Agreement to use NASA facilities/expertise directly. NASA also runs a startup licensing program with no upfront fee for companies formed to commercialize a specific NASA technology.

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