Power Integrations Extends The Power Range Of Flyback Topologies To 440W, Creating A Simpler Power Solution Than Resonant Designs

San Anton, TX ( BUSINESS WIRE ) - Power Integrations (Nasdaq: POWI ) , a leading company in high-efficiency power conversion using high-voltage integrated circuits , today announced a breakthrough technology for flyback topologies, extending the power range of flyback converters to 440W—far exceeding the limits of traditionally more complex LLC resonant topologies. The new TOPSwitchGaN ™ flyback IC family combines the company’s groundbreaking PowiGaN ™ technology with its signature TOPSwitch ™ IC architecture, simplifying system design, eliminating the need for heatsinks in many cases, shortening design cycles, improving manufacturability, and reducing total system cost.

“This is more than just a product upgrade—it’s a fundamental shift in how engineers design power supplies,” said Silvestro Fimiani, Director of Product Marketing at Power Integrations. “For decades, as power levels have increased, designers have had to turn to resonant topologies such as LLC. With TOPSwitchGaN, we’ve pushed flyback topologies to previously unattainable power ranges, enabling engineers to achieve high efficiency and high performance with a much simpler architecture.”

The integrated solution using TOPSwitchGaN achieves 92% efficiency across a load range of 10% to 100%, with power consumption below 50mW in standby and shutdown modes, easily meeting European Energy Related Products (ErP) regulations. This performance is achieved without the need for synchronous rectification, making it ideal for high-end home appliances, e-bike chargers, and industrial applications.

The R _DS(ON) of PowiGaN switches is significantly lower than that of silicon switches, resulting in reduced conduction losses and a substantial improvement in the power handling capability of flyback converters. These new devices utilize 800V-rated PowiGaN switches, offering excellent surge protection and low switching losses, and can operate at switching frequencies up to 150kHz, minimizing transformer size.

With a 230V AC input voltage (under the condition of input voltage detection), the no-load power consumption is far less than 50mW; when the device is in standby mode, with a 230V AC input voltage, it can still provide up to 210mW of output power when the input power is 300mW, as an auxiliary power supply for the device in standby mode.

Fimiani continued, “TOPSwitch was the first device to integrate an offline power switch into a small package, and billions have been sold since 1994. The name represents innovation in power conversion. Engineers trust TOPSwitch’s efficiency and ease of use, and now these advantages will benefit a wider range of designs. TOPSwitchGaN increases the power range of flyback architecture to an unprecedented 440W, expanding the application of flyback circuits to areas that previously required more complex topologies.”

The new IC is available in two package options. For ultra-thin designs, the flat eSOP™-12 surface-mount package delivers 135W (85–265VAC) output power without a heatsink, suitable for applications such as home appliances. The eSIP™-7 package's vertical architecture minimizes PCB footprint while offering thermal resistance comparable to TO-220 packages. A wider power range is achieved through the use of a simple clip-on metal heatsink, suitable for applications such as power tools, e-bikes, and garage door access control. Since the TOPSwitchGaN IC is pin-compatible with the TinySwitch™-5 offline switching power supply IC, designers can use the same solution for applications ranging from 10W to 440W.

Supply situation and resources
TOPSwitchGaN starts at $1.00 (for orders of 10,000 units or more). The following reference designs are provided:

• DER-1079 – This solution uses the TOP7074K to provide 60W of isolated flyback power for home appliances with a wide voltage input range;
• DER-1019 – This solution is a 356W high-voltage (89V / 4A) isolated flyback industrial power supply using the TOP7078E.
• RDK-1018 – This e-bike charger solution uses a 168W wide-range isolated flyback design based on the TOP7075E.

For more information, please contact a Power Integrations sales representative or one of the company’s authorized global distributors, DigiKey, Newark, Mouser , and RS Components , or visit power.com .

About Power Integrations
Power Integrations, Inc. is a technology innovation company focused on high-voltage power conversion in the semiconductor field. Its products are a key component of the clean energy ecosystem, enabling efficient transmission and use of electrical energy in renewable energy generation and applications ranging from milliwatts to megawatts. For more information, please visit www.power.com .

Power Integrations, the Power Integrations logo, PowiGaN, TOPSwitchGaN, TOPSwitch, TinySwitch, and EcoSmart are trademarks, service marks, or registered trademarks of Power Integrations, Inc. All other trademarks are the property of their respective owners.

Disclaimer: This announcement is a translation of the original official version. This translation is provided for convenience only; please refer to the original version, which is the only legally binding version.

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