13 Sep 2017

InnoSwitch3 94% Efficient Offline Flyback Switcher IC Family

Power conversions company, Power Integrations has launched its InnoSwitch™3 family of offline CV/CC flyback switcher ICs. The new devices achieve up to 94% efficiency across line and load conditions, reducing power supply losses by a further 25% and enabling the development of compact power supplies up to 65 W without heatsinks. InnoSwitch3 devices are ideal for power supplies with tight energy consumption, footprint or thermal constraints, particularly those targeting mandatory Total Energy Consumption (TEC) specifications.

Power efficiency is particularly important factor in any power converter because it enables costs to be reduced along with achieving a smaller volume as much less power has to be dissipated. This reduces the requirement for heatsinking and larger high dissipation components. Small increases in efficiency make a massive change in dissipation.

To give a view of the extent of the improvement, legacy adaptors possibly had an efficiency of around 87% and the Power Integrations initial Innoswich devices were able to improve the efficiency so that the volume to be reduced to less than half the legacy adaptors. Now with Innoswitch 3 has increased the efficiency to to 94% and this enables the size to be reduced still further.

The InnoSwitch3 IC family is optimized into three application-specific series:

  • CE: Current External. Includes accurate CC/CV regulation with external output current sense for optimum design flexibility. Targets compact single-voltage chargers, adapters, IoT and building automation.

  • CP: Constant Power. Ideal for USB Power Delivery (PD), rapid charging and other applications where a dynamic output voltage is required.

  • EP: Embedded Power. Features the family’s highest-rated MOSFET (725 V) and provides full line and load protection with excellent multi-output cross-regulation for demanding industrial applications and appliances.

These newest flyback switcher ICs employ Power Integrations’ innovative isolated digital communications technology, FluxLink™, plus synchronous rectification, quasi-resonant switching and a precise secondary-side feedback sensing and control circuit. This results in highly efficient, accurate, reliable power supply circuits without the need for optocouplers. InnoSwitch3 devices are CCC, UL and VDE safety-certified to bridge the isolation barrier, and the InSOP™-24 package provides a low-profile, thermally efficient solution with extended 11.5 mm creepage and clearance between primary and secondary sides for high reliability, surge and ESD robustness.

Power supply protection

Supply protection is taken for granted but also it is particularly important because many devices are left powered on almost permanently and have to ensure that through a variety of conditions including input surges, etc they remain reliably supplying power. If failures occur in either the circuits being supplied or the supply itself, they must provide the required protection.

To meet this demand, the new devices incorporate a host of protection features, including lossless line over-voltage and under-voltage, output over-voltage, over-power, over-current and over-temperature protection, as well as output rectifier short-circuit protection.

Device sub-families are provided with either latching or auto-recovery capability, according to the typical demands of each target application space. All InnoSwitch3 ICs feature on-board high-voltage MOSFETs (rated at 650 V for the CP and CE series and 725 V for the EP series).

The efficiency of the Innoswitch3 easily meets the 94% efficiency level. Even at low input voltages it meets the 94% level, and under better conditions increases to nearly 95%. This reduces heat dissipation by a 25% and this enables the overall supply volume to be reduced to 0.3 of the value of a supply giving 87% efficiency.

The efficiency levels bring other advantages. Not only does the new Innoswitch3 considerably exceed many standards for efficiency on power converters. IT also can help reduced the overall power consumption keeping supplies below the level where power correction is needed.

Comments Mike Matthews, VP of product development at Power Integrations: “InnoSwitch3 ICs represent a new state of the art in flyback power supply design. These new devices surpass the previously unrivaled efficiency of our InnoSwitch products, reducing losses by a further 25% and delivering the highest available efficiency across all line and load conditions. With unmatched system simplicity and low component count, InnoSwitch3 ICs enable exceptionally compact, reliable power supplies for a vast range of applications.”

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