PD90W Adapter Proposal

20230131

Internal use – confidential

 Outline

 Mechanical Design
 Electrical Specification
 Electrical Block Diagram
 Electrical Design
 Electrical PCB Layout
 Exploded View
 Thermal Simulation
 Flow Chart

2 Internal use – confidential

 90W Charger │Mechanical Design

23mm 100mm

54mm

外壳:
材质：PC
颜色：黑色

Type-C Cable:
材质：PVC
颜色：黑色

3 Internal use – confidential

 90W Charger │ Electrical Specification

Item Specification Conditions

Input Voltage Range 90-264VAC
Input Frequency Range 47Hz ~ 63Hz
5V/3A ; 9V/3A ; 12V/3A ; 15V/3A;20V4.5A
Output Voltage & Current (PPS can be modified to add 3.3V~21V/5A max 85W)
Output Ripple/Noise 5V/200mV,9V/200mV,12V/200mv,15V/200mv, 20V/300mv
Protection OVP , OTP , OCP, SCP

Energy Efficiency Average Efficiency meet DOV VI & CoC V5

Operating Ambient
-10oC~40oC
Temperature
CASE Temperature 75℃ max at 25℃ AMB
Life Time >13140H
SAFETY Standard IEC62368 (Can be applied IEC60335 for Dyson)
Altitude Limit 5000M

4 Internal use – confidential

 90W Charger │ Electrical Block Diagram

n
Q’
Type C
AC input VP VS CF
Cable
Fuse EMI filter Bridge Load
Switch
Q
Boost

Power Flow
Flyback
PFC
Signal Flow Controller

Flyback Photo
Protection PD Controller
Controller Coupler

 Universal AC input voltage

 Complete protection

5 Internal use – confidential

 90W Charger │ Electrical Design

Part
Item Vendor Function
Number

1 NCP1622 BOOST PWM controller

BOOST MOSFET
2 NV6134

3 NCP1342 flyback PWM controller

4 NV6134 flyback MOSFET

5 BSC0805LS SR MOSFET

6 MP6908A Transformer

7 WT6633P PD controller

6 Internal use – confidential

 90W Charger │ Electrical Design

PWM IC

On semiconductor On semiconductor Weltrend

NCP1622 NCP1342 WT6633P

Features: Features: Features:

[1]Xcap discharge [1]9-28V Vcc working voltage [1]PD& PPS & QC Controller
[2]9~30V Vcc working voltage [2]Adjust OPP function [2]3-24V Vcc working voltage
[3]Follow boost controller [3] Widely used in notebook
adapter design

7 Internal use – confidential

 90W Charger │ Electrical Design

Transformer Design
Structure Parameter
Schematic
sandwiched

Core=PC95(ATQ25) AE=100mm2
Lp=400uH
原边绕组圈数=36Ts
副边绕组圈数=5Ts
Vcc绕组圈数=16Ts

Maximun flux density Maximun primary Mosfet Maximun secondary Mosfet

calculate voltage calculate voltage calculate
Bmax=Lp*Ipeak/(AE*Np) Vds=Vin + N *( Vo+Vf)+Vspike Vds=Vin/N + Vo+ Vspike

Bmax=0.278 Vds≈575Vmax Vds≈85Vmax

8 Internal use – confidential

 90W Charger │ PCB Layout
optocoupler Transformer
Common Chock Common Chock Vcc Cap Y-Cap

Fuse

Varistor
SR Mosfet

PD IC
X-Cap

Bridge Output cap

Bulk cap

CBB cap DM chock PFC Switch GAN

PFC PWM Controller Flyback Switch GAN
Controller

9 Internal use – confidential

*Just for reference ,will adjusted according to actual situation
 90W Charger │Exploded View

Top_Shielding

PCBA

Cover
C6 Socket 线卡

Type-C Cable
Housing

Bottom_Shielding

10 Internal use – confidential

 90W Charger │ Thermal Simulation

Loss Distributions

PCB 0.1W
0.08W

0.42W
0.24W

1.1W
1.65W

0.15W
0.02W

0.11W
0.15W
0.89W

0.17W 1. 05W
0.9W
0.05W

Input: 90Vac/60Hz
Output: 20V/4.5A
Total Loss= 7.08W
Efficiency= 92.7%

11 Internal use – confidential

 90W Charger │ Thermal Simulation
AMB=25℃ Max=74.3℃ Meet IEC62368
Case Thermal

AMB=25℃ Max=69.03℃ Meet IEC62368

12 Internal use – confidential

 90W Charger │ Thermal Simulation

Case Thermal

AMB=40℃ Max=106.75℃ Meet Component’s SPEC

13 Internal use – confidential

 90W Charger │ Flow Chart
1.IQC 2.SMT 3.AI 4.前置处理

1.传统零件装插 2.波峰焊 3.自动量脚长 4.AOI 5.FT1测试 6.分板

7.自动点胶 8.超音 9.GAP/STEP检 10.老化测试 11.耐压测试 12.共模测试

查

13.FT2测试 14.听异音 15.自动镭雕 16.清洁，外检 17.热缩 18.装箱，堆栈

14 Internal use – confidential

 Ian

15 Internal use – confidential