Power Integrations extends flyback topology to enable 440 W
Power Integrations has introduced a breakthrough in flyback topology extending the power range of flyback converters to 440 W—well beyond the limits that traditionally required more complex resonant and LLC topologies. Their new TOPSwitchGaN flyback IC family unites the company’s PowiGaN technology with its TOPSwitch IC architecture, reducing complexity, eliminating heat sinks in many cases, shortening design time and lowering total system cost.
TOPSwitchGaN ICs provide 92 percent efficiency across the load range—from 10 percent to 100 percent load—and beat European Energy-related Products (ErP) regulations at less than 50 mW power consumption for standby and off modes. The device does this without the need for synchronous rectification.
PowiGaN switches deliver much lower RDS(ON) than silicon. This results in reduced conduction losses which dramatically increase the power capability of flyback converters. These new devices incorporate 800 V PowiGaN switches, which provide surge withstand capabilities and low switching losses, meaning that they can operate at switching frequencies of up to 150 kHz to minimise transformer size.
No-load consumption is well below 50 mW at 230 VAC including line sense, and up to 210 mW of output power is available for 300 mW input at 230 VAC to run housekeeping functions when units are in standby mode.
The new ICs are available in two styles. For ultra-slim designs, low-profile eSOP-12 surface-mount packaging enables 135 W (85–265 VAC) to be delivered without a heat sink for applications such as appliances. The vertical orientation of the eSIP-7 package minimises PCB footprint and has a thermal impedance equivalent to a TO-220-packaged part. By mounting a metal heat sink using a simple clip, the extended power range is achieved for applications including power tools, e-bikes, and garage openers. Because TOPSwitchGaN ICs are pin-to-pin compatible with TinySwitch-5 off-line switcher ICs, designers can use the same methodology for applications spanning 10 W up to 440 W.
