Infineon launches hybrid power controller for smaller chargers
Infineon Technologies has combined the simplicity of a flyback converter with the efficiency of a resonant converter in its latest XDP digital controller
The E-series of the XDP hybrid flyback digital controller uses an asymmetrical half-bridge (AHB) topology for various AC-DC applications, including aftermarket and OEM chargers, adapters, power tools, e-bike chargers, industrial switching power supplies, TV power supplies, and LED drivers.
The E-series integrates gate drivers for gallium nitride (GaN) and silicon : both XDPS2201E and XDPS2221E supports GaN and Si switches, providing flexibility in choosing power components based on performance and cost objectives. The adaptive power factor correction (PFC) and hybrid-flyback control adapts the PFC bus voltage according to operating conditions, which is vital for optimizing efficiency during average and light-load operations.
A high-voltage 600V start-up cell for fast VCC charging is essential for quick power-up sequences and maintaining efficiency under variable load conditions.
Burst-mode control provides the low no-load standby power, a critical factor in enhancing energy efficiency across operational conditions.
The XDPS22xx family addresses the main problems related to high-density adapters operating at moderate switching frequencies. The hybrid topology can ensure zero-voltage switching (ZVS) and zero-current switching (ZCS) over line and load and lays the foundation for the highest conversion efficiency by using the magnetization current to achieve ZVS on the primary-side half-bridge and ZCS on the synchronous rectification switch. The parasitic leakage inductance is an integral part of the converter.
Unlike other topologies, hybrid flyback transformers do not need to store all the energy, thus reducing the charger’s size. Hybrid flyback can achieve full ZVS operation on the primary side, and full ZCS operation on the secondary side, and the leakage energy is recycled, increasing the efficiency. The duty-cycle directly influences the output voltage, offering a solution to the limitations of the LLC topology in applications requiring a wide range of output voltage output.
A reference design for a 170W charger using the XPDS2201E HFB controller supports wide input designs from 18V to 42V for eBike and Power Tool chargers.
The converter has high peak efficiency of 95% and two control inputs that define the setpoints for the constant current (CC) and constant voltage (CV) regulation loops. This is suitable for battery charging applications in combination with a safety switch and charging controller. A voltage doubler ensures configurable wide input range to cover different residential voltages across the world.
Details of the E-series XDP hybrid flyback controller ICs from Infineon are here.
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