High-density 380 V–12 V $LLC$ resonant converters typically employ planar transformers with integrated leakage inductance. To achieve Zero-Voltage Switching (ZVS), an air gap is introduced to adjust the magnetizing inductance ($L_m$). However, this gap alters the internal magnetic field (H) distribution. In Center-Tapped (CT) structures, this alteration leads to asymmetric leakage inductances between the positive and negative half-cycles, causing resonant frequency mismatch and performance degradation, particularly under light-load conditions. In this work, the asymmetrical leakage inductance effect in a CT transformer for a 380 V–12 V $LLC$ resonant converter is systematically investigated. A mathematical model is derived to quantify the leakage inductance distribution, revealing that the relative position between the air gap and the windings significantly affects the symmetry. Based on this modeling analysis, the centralized assembly method is identified as the optimal solution to ensure impedance symmetry. The accuracy of the proposed model and the effectiveness of this structure are validated through Finite Element Analysis (FEA) simulations and a hardware prototype of a 250-W, 600-kHz $LLC$ converter. Results demonstrate that this method eliminates the approximately 11% leakage inductance discrepancy (1.8 μH vs. 1.6 μH), ensuring stable operation across the full load range.

Electric propulsion (EP) has become a pivotal technology in modern space exploration, enabling prolonged mission durations, increased payload capacity, and precise deep-space navigation through its superior thrust efficiency and low propellant consumption. However, the performance of EP systems is fundamentally limited by the power processing unit (PPU), with the DC-DC power converter serving as the core of the PPU. Existing research on DC-DC converters often focuses on generic topologies, failing to address the divergent power demands of distinct EP types and the harsh space-specific constraints. This review aims to fill this gap by systematically analyzing DC-DC power converters tailored for EP systems. First, the core requirements of converters across major EP categories are classified. Then, converter topologies are compared by evaluating the suitability for EP operational and space constraints. Moreover, high step-up conversion techniques are explored that bridge the gap between low-voltage spacecraft buses and thruster power needs. Furthermore, this review highlights emerging technologies driving EP converter advancement, such as wide-bandgap semiconductors for improved power density and efficiency, planar magnetics for miniaturization, and direct-drive architecture for simplified Hall-effect thruster integration. It also identifies unresolved challenges, including balancing power density with thermal robustness, mitigating radiation-induced degradation, and suppressing electromagnetic interference (EMI). Finally, it outlines future research directions, such as optimizing WBG-compatible converter topologies, developing advanced thermal management solutions, and standardizing EP-specific design guidelines. This work provides a practical reference for PPU engineers, linking converter design to EP unique demands and space constraints while guiding innovations to advance EP technology for next-generation space missions, from low-Earth orbit satellites to interplanetary exploration.

Aerospace power systems, including satellites in low earth orbit (LEO) and geostationary earth orbit (GEO), face stringent thermal constraints to minimize size, weight, and power (SWaP). Gallium nitride (GaN) devices offer superior radiation hardness—critical for the harsh space environment—and MHz-level switching capabilities. This high-frequency operation minimizes passive components, particularly magnetics, thereby reducing the overall volume. However, above 10 MHz, magnetic cores become impractical due to material limitations. To address these issues, this article proposes a design methodology for a GaN-based quasi-square-wave (QSW) buck converter integrated with a PCB air-core inductor. First, the impact of the switching frequency and dead time on the zero-voltage switching (ZVS) condition is elaborated. Then, a power loss model accounting for various loss mechanisms is presented. To overcome high GaN body diode reverse conduction loss, an auxiliary diode is employed. Based on the model, a design procedure is developed to optimize the inductor for 10 MHz operation while maximizing efficiency. To validate the design, a 28 V/12 V, 18 W prototype was built and tested. Experimental results demonstrate a peak efficiency of 86.5% at 10 MHz. The auxiliary diode improves efficiency by 4%, verifying reverse conduction loss mitigation. Thermal analysis confirms a full-load case temperature of 62.2 °C, providing a 47.8 °C safety margin compliant with aerospace derating standards. These findings validate the solution for high-frequency, space-constrained aerospace applications.