Overview
This document provides an overview of onsemi's System Solution Guide for USB-C Battery Chargers. It covers market trends, system implementation, and detailed descriptions of power management and conversion technologies used in modern USB-C chargers.
The guide highlights onsemi's components and reference designs that enable high-efficiency, compact, and feature-rich USB-C charging solutions.
Market Information & Trend
The USB-C Battery Charger market is characterized by increasing demand for higher power, faster charging, and advanced features like extended power range (EPR) and programmable power supply (PPS). Key trends include the adoption of GaN (Gallium Nitride) technology for improved efficiency and smaller form factors, as well as enhanced data transfer capabilities and protocol compatibility.
Key Trends:
- Market Outlook: Growing demand for USB-C chargers across various devices (smartphones, laptops, tablets).
- Extended Power Range & Types: Support for higher power levels and multiple output configurations.
- Faster Data Transfer Capabilities: Integration of data transfer alongside power delivery.
- Protocol Compatibility: Adherence to USB PD 3.0, PD 3.1, and PPS standards.
- GaN Technology: Utilization of GaN HEMTs for higher switching frequencies, reduced losses, and smaller component sizes.
System Implementation
USB-C battery charger systems are typically implemented in stages, involving primary and secondary power conversion stages. Architectures are designed to optimize efficiency, thermal performance, and compliance with power delivery standards.
Architectures and Main Stages:
- Primary Stage: Often includes Power Factor Correction (PFC) and the main power conversion (e.g., Flyback, LLC).
- Secondary Stage: Handles output rectification, regulation, and USB PD protocol communication.
System Description
The system description focuses on the core functionalities and specifications of USB-C battery chargers.
USB Type-C Pinout Configuration & USB-C PD Specification
The USB Type-C connector offers a reversible plug orientation and supports various data and power roles. USB Power Delivery (PD) specifications, including PD 3.0, PD 3.1 Extended Power Range (EPR), and Programmable Power Supply (PPS), define how power is negotiated and delivered between devices, enabling higher power transfer and greater flexibility.
AC-DC Power Conversion & PD Control
AC-DC power conversion stages are responsible for converting mains voltage to the required DC voltage. This involves components like transformers, rectifiers, and switching elements. Power Delivery (PD) control is managed by dedicated controllers that handle communication with the connected device to negotiate voltage and current profiles, ensuring safe and efficient charging.
Solution Overview
Block Diagram - USB-C Battery Charger
The block diagrams illustrate the power management and power conversion technologies used in USB-C battery chargers. They feature components such as PFC controllers, high-frequency quasi-resonant (QR) flyback/LLC controllers, gate drivers, synchronous rectification, iGaN, and MOSFET devices. These elements are categorized into primary and secondary stages to enhance system efficiency.
USB-C Battery Charger - AC Input Block Diagram Description:
The AC input path typically starts with an AC Input, followed by a Bridge Rectifier (optional if TPFC is used). A TP PFC Controller manages power factor correction. The primary switching stage uses a High-Frequency Quasi-Resonant (HF QR) Flyback or LLC topology, often employing a high-voltage GaN HEMT with integrated driver (iGaN) as the primary switch. A transformer couples the primary and secondary stages. The secondary stage includes a secondary switch (e.g., LV-MV MOSFET), Synchronous Rectification (SR) rectifier, and an output stage comprising a Buck Controller (optional), Load Switch, and ESD Protection. Control signals are managed by a Primary Control system, Secondary Control system, Flyback/LLC Controller, SR Controller, and a Protocol Controller. A Gate Driver and Optocoupler facilitate signal transfer between stages. A USB-C Interface with Port Controller and CC1/CC2 pins connects to the DC Output Type-C Connector.
USB-C Battery Charger - DC Input (Auto) Block Diagram Description:
For DC input scenarios, the path begins with a DC Input. A DC-DC Conversion stage, which may include Buck/Boost converters, LDOs, and Diodes, processes the input voltage. A Low-Voltage to Medium-Voltage (LV-MV) MOSFET acts as a switch, followed by a Load Switch and ESD Protection. The output is delivered via a USB-C Interface connected to a Port Controller and then to the DC Output Type-C Connector. Control is managed by a Protocol Controller.
onsemi offers an interactive block diagram tool to explore these solutions further. [Link to onsemi IBD Tool]
USB-C PD Charger Reference Designs
Leveraging its technical expertise, onsemi offers a suite of highly efficient system reference designs and evaluation boards for USB-C PD chargers.
Table 2: onsemi's series of USB-C PD system reference boards
| Power Rating | Topologies | Support | Output Voltage | Efficiency (Max.) | Typical Application |
|---|---|---|---|---|---|
| 65 W | HF QR Flyback + SR | PD3.0 & PPS protocol | 3 V - 21 V (PPS) | > 93% | Smart phone, PAD, NB adapter |
| 100 W | CrM Boost PFC+HF QR Flyback + SR | PD3.0 & PPS protocol | 3 V - 21 V (PPS) | > 92% | Smart phone, PAD, NB adapter |
| 240 W | TP CrM PFC + 2 Switch Flyback | PD3.1 EPR | up to 48 V | > 95% | Adapter for computer and smartphone, Industrial and lighting power supply |
| 240 W | TP CrM PFC + LLC UHD | PD3.1 EPR | up to 48 V | > 96% | Adapter for computer and smartphone, Industrial and lighting power supply |
240W TP CrM PFC + 2 Switch Flyback Reference Design
This reference design utilizes the Totempole CrM PFC + 2SW Flyback Topology and supports high-frequency operation with iGaN. It is designed for high-efficiency charging, supporting PD3.1 multi-output with voltages ranging from 5V to 48V at 5A. Key features include:
- AC input from 90V to 264V.
- High Frequency operation with iGaN.
- Totempole CrM PFC + 2SW Flyback Topology.
- Simulated circuit to support PD3.1 multi-output.
- Output voltage: 5V, 9V, 12V, 15V, 20V, 28V, 36V & 48V / 5A.
- Ripple & Noise: <150 mV.
- Efficiency: Average 94.75% / 95.43% and Full load 95.12% / 96.17% @115VAC / 230VAC and 48V / 5A.
- Precise output protection: OVP (Over Voltage Protection), OCP (Over Current Protection), SCP (Short Circuit Protection), Open loop protection.
- PCBA size: 89mm x 51mm x 21.5mm, 40W/in³.
A description of the evaluation board (EVB) for this design is provided, showing a printed circuit board layout optimized for performance.
Key Components
The guide details several onsemi components crucial for USB-C battery chargers:
- 650V GaN HEMT with Integrated Driver (iGaN): Enables higher efficiency and smaller form factors.
- T10 LV-MV MOSFETs: Low-voltage to medium-voltage MOSFETs for secondary side switching.
- Super-junction (SJ) MOSFETs: High-performance MOSFETs for primary side switching.
- PFC Controller NCP1680: For power factor correction.
- QR Flyback Controller NCP1345: For high-frequency quasi-resonant flyback converters.
- USB PD Controller FUSB15101: A programmable USB Type-C and Power Delivery 3.1 Source Controller with PPS Support.
USB PD Controller FUSB15101
The FUSB15101 is a programmable USB Type-C and Power Delivery 3.1 Source Controller with PPS Support. It offers a flexible and robust solution for implementing USB PD functionality.
Key Features:
- Fully Programmable and Upgradable Open-source Firmware providing API for Customer Specific Device Policy Manager Development.
- Robust Collection of Peripherals including DACs, ADC, NTCs and NMOS Gate Driver.
- Programmable Constant Voltage & Current Control with Cable Drop Compensation.
- USB PD 3.1 with PPS Support and integrated VCONN support for E-Marked Cables.
- Idle and Sleep Modes to Meet CoC and DoE Requirement.
- Full Fault Protection - OVP, OUP, OCP and OTP.
- Integrated UART Transceiver.
Typical Applications: AC-DC USB PD Compliant Adapters, Wall Chargers for Mobile Phones and Tablets, Computing Devices, Power Banks.
The document references an evaluation board (EVB) and a Software Development Kit (SDK) for the FUSB15101, facilitating easier development and implementation.
A textual description of the AC/DC Application Schematic shows the integration of the FUSB15101 with other power components, and an image of the FUSB15101 chip package (20-pin QFN 4 x 4mm) and its socket are mentioned.
Further Information
To unlock more System Solution Guides and gain additional benefits, users are encouraged to register on the onsemi website. Benefits include joining the community forum, utilizing developer tools like the Elite Power Simulator, and watching exclusive webinars and seminars.
A link to "Open full System Solution Guide" is available.
Legal Disclaimer: The information provided is for informational purposes only. onsemi disclaims all warranties and liabilities related to the use of its products. Users are responsible for validating product suitability for their specific applications and ensuring compliance with all applicable laws and regulations. onsemi products are not intended for use in life support systems or critical medical devices.
USB-C Battery Charger | onsemi
