Challenge

Supplying 65W of charging in a small USB-C charger

The USB-C chargers are built with switch mode power supplies (SMPS), which include several magnetics to work. The problem when semiconductor companies are trying to minimize volume and losses is in the main transformer. This component is the bulky one and general efficiency depends on it.

The whole package shape depends on the transformer. The limitation of reducing the size is in the accuracy of the design and simulation tools. It could take 1 year months to simulate all the options using current tools in the market.

Solution

Through Frenetic, iteration was fast using Core Optimizer and Leakage Inductance Models

Frenetic technology allowed Pulsiv to find the optimal combination of core and winding in a matter of hours and iterate the adjustments of their chip and power board in a matter of months.

The key models that allowed them to achieve that goal were:

1. Core Optimizer, to find the best core and number of turns combination, analyzing thousands of options
2. Core loss and 2D winding losses model to ensure we keep the temperature under control
3. Leakage inductance model, allowing to have an accurate value before building any sample.

Results

A 65 W USB-C charger with more than 97% of peak efficiency

The result was a 65 W USB-C charger with more than 97% of peak efficiency and 96% of average and creating a tremendous impact on the sales of Pulsiv semiconductor.

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IDEAL APPLICATIONS: USB-C Chargers, Adapters, & In-Wall/Desk Sockets