The Coreless Ignition Revolution: How GaN Modules Achieve 220mJ Energy Density

1. Why Magnetic Cores Limit Ignition Performance

Traditional ignition transformers hit a wall at 150mJ per pulse. Why?

Core losses: Ferrite cores suffer 60% higher eddy losses above 100kHz, wasting energy as heat

Saturation risk: Silicon steel cores lose 40% inductance under DC bias, causing unstable arcs

Size penalty: Magnetic cores occupy >50% volume in 30kV igniters

The solution? Eliminate the core entirely.

2. GaN + Coreless Synergy: The 220mJ Breakthrough

Structural Innovation

Key tech: SP-P magnetic resonance enables direct capacitor-coil energy transfer

GaN Integration Advantages

2MHz switching: Arc formation time <50ns (vs. 200ns for silicon)

Zero Qrr loss: Eliminates reverse recovery distortion (pulse distortion <2%)

Monolithic design: Driver + GaN HEMT + protection in one package (70% size reduction)

3. Power Density Blueprint: From 150mJ to 220mJ

Multi-stage Energy Compression

Critical components:

Ceramic stacked capacitors: ESR <1mΩ

dV/dt >150V/ns switching (e.g., TI LMG3522)

Thermal-Electric Co-Design

Dual-side cooling: Top copper pillars + bottom AlSiC substrate (thermal resistance <0.5°C/W)

Pulse thermal model:
ΔT=Epulse⋅frepCthΔT=Cth​Epulse​⋅frep​​
At 220mJ/100Hz: ΔT <15°C with BN-epoxy encapsulation

4. Real-World Impact: Hydrogen Engines & Industrial Burners

Industrial case: Natural gas burner using coreless modules:

CO emissions ↓15% (leaner combustion)

Maintenance costs ↓40% (no core aging)

5. Overcoming Production Challenges