Delivering ground-breaking USB-C reference designs and finished modules

Pulsiv Limited is to release a series of reference designs and assembled modules for USB-C applications that will provide an average efficiency of more than 95%. This ground-breaking achievement, which minimises energy waste under all operating conditions, has been created in collaboration with Innoscience and Frenetic. Designs will be released throughout 2024 to support a new class of sustainable USB-C chargers, adapters, and in-wall sockets. The first 65W solution is expected to be announced towards the end of March 2024.

The front-end of the design utilises Pulsiv OSMIUM technology to efficiently manage the AC to DC conversion process with zero inrush current and no input voltage derating. Employing an intelligent active valley fill approach, this patented method also allows the use of smaller system components compared to conventional designs. The DC-DC converter in the 65W variant is based on an industry-standard QR flyback. However, when combining a OSMIUM front-end design with optimised magnetics from Frenetic, it is now feasible to use an EQ20 core, which provides a 20% reduction in the flyback transformer size.

Frenetic CEO, Chema Molina comments: “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.”

The use of GaN components from Innoscience has assisted in further minimising losses by lowering the RDS(on) and decreasing parasitic capacitance while also optimising the overall BoM cost.

General manager for Innoscience EMEA, Denis Marcon adds: “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.”

Pulsiv chief product officer, Dr Tim Moore has been managing the roadmap of USB-C solutions and comments: “We are very excited to be bringing this game-changing technology to the market and deliver our mantra of ‘doing more while using less’. 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.”

To accelerate and simplify the design process, three options will be offered:

Complete reference designs will be available on the company website where engineers can download a document package that includes a datasheet, schematic, BoM, and EMC test data.

Fully assembled, ultra-compact, and EMC-compliant finished modules will be produced by the company to demonstrate a size-optimised design and facilitate rapid prototyping of each reference design. They can also be easily integrated into end products without incurring any further design, development, or manufacturing costs.

Evaluation boards will be developed for customers who wish to test and/or adapt the design for their own needs and will be stocked by a number of distribution partners. A datasheet with schematic, BoM, EMC test data, Gerbers, and PCB layout files will also be available.