240W in wall USB-C charger module hits 95% efficiency
UK startup Pulsiv has developed a series of reference designs and assembled modules for USB-C applications, including in-wall sockets up to 240W, that will deliver an average efficiency of more than 95%.
The technology combines the Pulsiv switching controller with GaN devices from Innoscience and magnetics from Frenetic for in wall charger designs. Designs will be released throughout 2024 to support a new class of sustainable USB-C chargers and adapters as well as the in-wall sockets. The first 65W design is expected to be announced towards the end of March 2024.
The front-end of the design uses the Pulsiv OSMIUM technology to efficiently manage the AC to DC conversion process with zero inrush current and no input voltage derating. Using an intelligent active valley fill approach, this method also enables the use of smaller system components compared to conventional designs. Reducing the size and increasing the efficiency to minimise heat loss is key to integrating the chargers into wall sockets to eliminate the need for separate charger units.
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The DC-DC converter in the 65W variant is based on an industry standard QR flyback. However, when combining a Pulsiv OSMIUM front-end design with optimised magnetics from Frenetic, it is now possible to use an EQ20 core, which provides a 20% reduction in the flyback transformer size.
Fully assembled, ultra-compact, and EMC-compliant finished modules will be produced by Pulsiv to demonstrate a size-optimised design and enable rapid prototyping of each reference design. They can also be easily integrated into end products without incurring any further design, development, or manufacturing costs.
The modules range from 65W to 240W, all suitable for embedded in sockets t
Evaluation boards will be developed for customers who wish to test and/or adapt the design for their own requirements and will be stocked by a number of distribution partners. A datasheet with schematic, bill of materials, EMC test data, Gerbers, and PCB layout files will also be available.
Pulsiv Chief Product Officer, Dr Tim Moore has been managing the roadmap of USB-C designs and modules. “By achieving more than 95% average efficiency, it enables us to provide efficient in-wall USB-C solutions that safely manage the critical thermal requirements. This enhances reliability, minimises overall size, and optimises cost to set a world-leading precedent in USB-C power supplies,” he said.
“By leveraging Pulsiv’s innovative OSMIUM technology, we’ve been able to highly optimise the magnetics to reduce size and drive the efficiency of the flyback transformer to a level we’ve not seen before. This significant development will enable customers to achieve new levels of performance, size, and cost, and we’re excited to be part of such an innovative solution,” said Frenetic CEO, Chema Molina.
The use of GaN components from Innoscience has helped to further minimise losses by lowering the RDS(on) and reducing parasitic capacitance, while also optimising the overall BoM cost.
“We’ve successfully demonstrated that GaN technology is perfectly suited to improving the performance of power electronics designs. Pulsiv OSMIUM technology adds further benefits by significantly improving the overall average efficiency and reducing energy waste. I’m delighted that Pulsiv has selected Innoscience GaN e-mode devices (InnoGaN) for their 65W reference design,” said Denis Marcon, General Manager for Innoscience in Europe.
Complete reference designs for the in wall charger designs will be made available on the Pulsiv website where engineers can download a document package that includes a datasheet, schematic, bill of materials, and EMC test data.
Specification
|
Ref number |
Input voltage |
Output voltage |
Output power |
Applications |
|
PSV-RDAD-65USB-1 |
100 – 264VAC |
5V – 20V DC |
65W |
Chargers, adapters, & in-wall sockets |
|
PSV-RDAD-65USB-2 |
85 – 115VAC |
5V – 20V DC |
65W |
Chargers, adapters, & in-wall sockets (US & Japan market) |
|
PSV-RDAD-70USB |
100 – 240VAC |
5V – 20.6V DC |
70W |
Chargers, adapters, & in-wall sockets (supports Apple MacBooks) |
|
PSV-RDAD-140USB |
TBC |
5V – 28V DC |
140W |
Chargers, adapters, & in-wall sockets |
|
PSV-RDAD-240USB |
TBC |
5V – 48V DC |
240W |
Chargers, adapters, in-wall sockets, & high-end laptop power supplies |
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