Design Example Report
Title
Specification
Application
Author
Document
Number
Date
Revision
3.0 W Charger using LNK363P
Input: 85 – 265 VAC
Output: 5.0V / 600 mA
Cell Phone Charger
Power Integrations Applications Department
DER-62
August 24, 2005
1.0
Summary and Features
•
•
•
Low cost CV/CC cell phone charger
No Load consumption less than 300 mW
Meets CEC efficiency and no-load specification
The products and applications illustrated herein (including circuits external to the products and transformer
construction) may be covered by one or more U.S. and foreign patents or potentially by pending U.S. and foreign
patent applications assigned to Power Integrations. A complete list of Power Integrations’ patents may be found
at
www.powerint.com.
Power Integrations
5245 Hellyer Avenue, San Jose, CA 95138 USA.
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-62
3W Charger using LNK363P
August 24, 2005
Table Of Contents
Introduction ................................................................................................................ 4
Power Supply Specification........................................................................................ 4
Schematic .................................................................................................................. 5
3.1
With RCD clamp ................................................................................................. 5
3.2
With Zener clamp and bias winding .................................................................... 5
4 PCB............................................................................................................................ 6
5 Bill Of Materials—RCD clamp .................................................................................... 6
6 Transformer Specification .......................................................................................... 7
6.1
Electrical Diagram............................................................................................... 7
6.2
Electrical Specifications ...................................................................................... 7
6.3
Materials ............................................................................................................. 7
6.4
Transformer Build Diagram ................................................................................. 8
6.5
Transformer Construction ................................................................................... 8
7 Transformer Spreadsheets ........................................................................................ 9
8 Performance Data .................................................................................................... 11
8.1
Efficiency vs CEC ............................................................................................. 11
8.1.1
With RCD Clamp, no bias winding ............................................................. 11
8.1.2
With Zener Clamp and Bias winding .......................................................... 12
8.2
Efficiency vs Input Voltage ................................................................................ 12
8.2.1
With RCD clamp, no bias winding.............................................................. 12
With zener clamp and bias winding ........................................................... 13
8.2.2
8.3
No-Load Input Power ........................................................................................ 13
8.3.1
RCD clamp, no bias winding...................................................................... 13
8.3.2
Zener clamp clamp and bias winding......................................................... 14
8.4
Output Regulation ............................................................................................. 14
8.5
Thermal Performance ....................................................................................... 15
8.5.1
Thermal testing set up ............................................................................... 15
8.5.2
Test results of RCD clamp ......................................................................... 15
Thermal performance of Zener clamp and bias winding. ........................... 15
8.5.3
9 Waveforms............................................................................................................... 16
9.1
Drain Voltage, Normal Operation ...................................................................... 16
9.2
Drain Voltage During Startup ............................................................................ 17
9.3
Output Voltage Start-up Profile ......................................................................... 17
10
Output Ripple Measurements ............................................................................... 18
10.1.1 Ripple Measurement Technique ................................................................ 18
10.1.2 Measurement Results ................................................................................ 20
Conducted EMI..................................................................................................... 21
11
12
Transformer construction with bias winding.......................................................... 22
12.1 Electrical Diagram............................................................................................. 22
12.2 Transformer Build Diagram ............................................................................... 22
13
Revision History.................................................................................................... 23
1
2
3
Page 2 of 24
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-62
3W Charger using LNK363P
August 24, 2005
Important Note:
Although this board is designed to satisfy safety isolation requirements, the engineering
prototype has not been agency approved. Therefore, all testing should be performed
using an isolation transformer to provide the AC input to the prototype board.
Design Reports contain a power supply design specification, schematic, bill of materials,
and transformer documentation. Performance data and typical operation characteristics
are included. Typically only a single prototype has been built.
Page 3 of 24
Power Integrations
Tel: +1 408 414 9200 Fax: +1 408 414 9201
www.powerint.com
DER-62
3W Charger using LNK363P
August 24, 2005
1 Introduction
This document is an engineering prototype report describing a 3.0 W power supply
utilizing a LNK363P. This power supply is intended as a cell phone charger evaluation
platform. Power Integrations E-shield technology of transformer construction allows this
design to meet EMI requirement without using a common mode choke.
The document contains the power supply specification, schematic, bill of materials,
transformer documentation.
Figure 1 –
Populated circuit board – Top view
2 Power Supply Specification
Description
Input
Voltage
Frequency
No-load Input Power (230 VAC)
Output
Output Voltage 1
Output Ripple Voltage 1
Output Current 1
Total Output Power
Continuous Output Power
Efficiency
Environmental
Conducted EMI
Safety
Ambient Temperature
T
AMB
Meets CISPR22B / EN55022B
Designed to meet IEC950, UL1950
Class II
Symbol
V
IN
f
LINE
Min
85
47
Typ
Max
265
64
0.5
5.75
666
Units
VAC
Hz
W
V
mV
mA
W
%
Comment
2 Wire – no P.E.
50/60
V
OUT1
V
RIPPLE1
I
OUT1
P
OUT
η
4.75
534
5.0
60
600
3.0
20 MHz Bandwidth
59
typical at full load, 25
o
C
0
50
o
C
Free convection, sea level
Page 4 of 24
Power Integrations
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