The Co-packaged GaN ICs (Elevation HL955X) Make Ultra-thin Fast Charger Even Smaller

Introduction

In recent years, fast charging for mobile devices has been very popular, which also boosts the development of the whole fast charging accessories industry. On the one hand, fast charging speeds are constantly increasing. On the other hand, the shape of the charger has also changed from a conventional “big black brick” to a square mini charger or an ultra-thin fast charger. Many well-known brands, like OPPO, Realme, Huawei, Nubia, and Belkin, have released related products.
The co-packaged GaN IC can integrate most components and control circuits into one chip, reducing external components and saving PCB space. So, there’s no need for multiple small PCBs, and a single main PCB can accommodate all components. With the planar transformer, the design of an ultra-thin “cookie” charger can be easily realized.
Elevation, which has deep technical accumulation in co-packaged GaN ICs, provides a variety of ultra-thin GaN fast charging solutions based on its co-packaged GaN ICs, which can meet different output power applications. And today, ChargerLAB will introduce two of them to you.

Demo of 45W Ultra-thin GaN Fast Charger

The planar transformer is placed in the hollow of this 45W demo. And two high-voltage electrolytic capacitors are parallel to the PCB. This solution dramatically increases space utilization and qualifies for UL62368, FCC, GB4943, GB17625.1, CE, ERP 6, and other standards.

This 45W demo has dual USB-C connectors for output and enough space for foldable prongs. Its weight is about 35.4g (1.25 oz) and the size is about 77.64 x 40.99 x 7.38mm (3.06 x 1.61 x 0.04 inches). Pretty compact. So, the power density reaches 1.92W/cm³.

When the output is fully loaded at 100-240V AC, 50/60Hz, the power will not drop like similar products on the market. A single USB-C port supports five fixed PDOs of 5V/3A, 9V/3A, 12V/3A, 15V/3A, 20V/2.25A, and a set of PPS of 3.3V-21V 3A. And it’ll be divided into 27W+18W or 35W+10W or 22.5W+22.5W when charging two devices simultaneously.

There’s a co-packaged GaN IC of Elevation HL9552 in the primary circuit, which integrates 260mΩ GaN power FET and a multi-mode PWM controller. The standby power consumption is less than 20mW. And it can support cycle-by-cycle current limit, AOCP, OTP, LPS, and other functions. It also supports QR, DCM, CCM, and multi-frequency hybrid operating modes.

It adopts QFN5 x 6 package and provides multiple operating frequencies of 300kHz/225kHz/129kHz/82kHz, which give engineers more flexibility to design and optimize transformer size and EMI performance. It can achieve a wide VDD range without an additional clamper circuit, which can save BOM cost and reduce PCB size.

Demo of 65W Ultra-thin GaN Fast Charger

The 65W demo adopts a double-layer PCB structure. The planar transformer is embedded in the upper layer of the PCB. Four electrolytic capacitors are embedded into the lower PCB to make full use of space. It’s also qualified for UL62368, FCC, GB4943, GB17625.1, CE, ERP 6, and other standards.

The 65W demo is also equipped with dual USB-C ports. And the input end has enough space for foldable prongs. Its weight is about 45g (1.59 oz) and the size is about 91.05 x 40.24 x 8.5mm (3.58 x 1.58 x 0.33 inches). So, the power density reaches 2.09W/cm³ with high integration.

Like the 45W demo, at 100-240V AC, 50/60Hz, when the output is fully loaded, the power will not drop like similar products on the market. A single USB-C port supports five fixed PDOs of 5V/3A, 9V/3A, 12V/3A, 15V/3A, 20V/3.25A, and a set of PPS of 3.3V-21V 3A. And it’ll be divided into 45W+18W or 18W+45W when charging two devices simultaneously.

This 65W demo adopts the high frequency and high power density DC-DC power module from Cyntec. Model is MPN24AD03-UP. It integrates PWM controller and MOSFET, which can automatically switch to a PWM/power saving mode according to the load.

The power module can support up to 3A output current, with an input voltage of 4.75V-26.5V and an output voltage of 3V- 21V. The single-stage buck conversion allows these devices to directly step down high-voltage input for up to 98% conversion efficiency. It’s with programmable output voltage by FB pins and supports USB PD requirements.

There’s a co-packaged GaN IC of Elevation HL9550 in the primary circuit. It integrates 170mΩ GaN power FET and a multi-mode PWM controller. 
It supports QR, DCM, CCM, and multi-frequency hybrid operating modes, which can achieve better EMI performance with a smart driver and by frequency hopping.
This chip can meet the LPS requirements through the built-in circuit and achieve a wide range of voltage output without an additional VDD clamper circuit.

It also adopts QFN5 x 6 package and has different optional switching frequencies and modes, which give engineers more flexibility to design and optimize transformer size and EMI performance. The uniquely designed pad not only separates the power trace and the controlling trace, but makes it easier to design the layout of a fast charger. Meanwhile, the larger GND copper can enhance heat dissipation performance. 

If you’re interested in two Demos of Elevation 45W/65W ultra-thin fast charger, feel free to contact: Shenzhen Jingweida Electronics Technology Co., Ltd.
General Manager: Peng Ping
Tel: +86 15986627889
E-mail: jingweida001@163.com
Address: Room 602, Block A, Duocai Science and Technology Innovation Park, No.5 Guanle Road, Luhu Community, Guanhu Street, Longhua District, Shenzhen

Summary of ChargerLAB

Because of the excellent portability, ultra-thin biscuit-sized fast chargers have been very popular in recent years. The GaN technology and the planar transformer can greatly reduce the thickness of the chargers. The foldable prongs allow it to fit in a pocket without obstacles.
Those ultra-thin GaN fast charging solutions launched by Elevation take full advantage of the high integration and high performance of its co-packaged GaN ICs. The unique PCBA design can achieve extremely high power and bring a very competitive option to the market.