Integrated flyback converter IC reduces component count in USB PD EPR power supplies

February 20, 2025

New InnoSwitch™5-Pro ac-dc converters from Power Integrations use a zero-voltage switching flyback topology and advanced synchronous rectification FET control to produce 95% efficiency, shrink the power supply and reduce component count.

Power Integrations has announced the release of the InnoSwitch5-Pro family of programmable flyback switcher ICs, which offer more than 95% efficiency in streamlined ac-dc converter designs. The new converters feature a novel secondary-side control scheme which can perform zero-voltage switching without a dedicated and costly additional high-voltage switch.  

 

The new product features a 750 V or 900 V PowiGaN™ gallium nitride (GaN) primary switch, a primary-side controller, FluxLink™ isolated feedback, and a secondary controller with an I2C interface. It enables OEMs to realize designs for single- or multi-port USB Power Delivery (PD) adapters that are more compact and efficient. It supports the new USB PD extended power range (EPR) protocol.  

 

The low conduction losses of the integrated GaN power switch enable power-system designers to implement very dense adapter layouts with far fewer components than asymmetric half-bridge (AHB) circuits or active clamp designs. A Power Integrations demonstration design for a 140 W/28 V USB PD adapter uses only 106 components in a system measuring just 4.2 in3 

 

The excellent efficiency of the InnoSwitch5-Pro allows designers to eliminate heat-sinks, heat spreaders and potting materials for thermal management, further reducing the size, weight, component cost and manufacturing complexity of their products. In addition, the flyback topology used by the InnoSwitch5-Pro ICs is easier to implement than AHB, and can operate from a universal mains supply with or without a PFC stage.

Features

  • Better than 2% output-voltage accuracy 
    • Supports compliance with UFCS protocol 
  • Up to 140 kHz switching frequency 
  • Synchronous rectification driver and secondary-side sensing 
  • Drives low-cost N-channel FET series load switch 
  • Integrated 3.6 V supply for external microcontroller 
  • Digitally controlled via I2C interface 
  • Less than 30 mW no-load power consumption

Applications

  • High density power adapters 
  • Multi-protocol power adapters  
  • Direct-charge mobile device chargers 
  • Battery chargers 
  • Notebook computers 
  • High-end smartphones  
  • Portable consumer products 
  • Adjustable LED ballasts 
Power Integrations — InnoSwitch5 Pro Flyback Converter IC

Evaluation Board

Part Number: RDK-1002

The RDK-1002 from Power Integrations is a reference design kit which facilitates development with the InnoSwitch™5-Pro family of flyback switcher ICs. It implements a USB Power Delivery 3.1 extended power range (EPR) power supply supporting loads up to 140 W. It operates from an input-voltage range of 90 V to 265 V ac, and achieves conversion efficiency of up to 95%. It supports variable output voltages in a range from 5 V to 28 V.

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