company blog about Recycle Infineon AC-DC Power Conversion:CoolSET™ AC-DC Integrated Power Stage,AC-DC PWM And PFC Controller

Recycle Infineon AC-DC Power Conversion:CoolSET™ AC-DC Integrated Power Stage,AC-DC PWM And PFC Controller

Shenzhen Mingjiada Electronics Co., Ltd. is a globally renowned electronic component recycling company that has long specialised in the recycling of various high-value electronic components. Through our professional recycling channels, we assist clients in optimising their inventory and recovering capital.

Recyclable products include: 5G chips, new energy ICs, IoT ICs, Bluetooth ICs, in-vehicle infotainment system ICs, automotive-grade ICs, communications ICs, artificial intelligence chips, memory ICs, sensor ICs, microcontroller ICs, transceiver ICs, Ethernet ICs, Wi-Fi chips, wireless communication modules, connectors and related products.

Recycling Process

Inventory Classification: Clients need only provide basic information such as model number, brand, date of manufacture and quantity to complete the inventory classification.

Submit Inventory List: Send the inventory list to our valuation team via email or fax.

Professional Quotation: Our valuation team will provide a competitive quotation within 24 hours of receiving the list.

Transaction and Delivery: Once an agreement has been reached, both parties will mutually agree on the delivery method; we provide global logistics support.

I. CoolSET™ AC-DC Integrated Power Stage: Highly Integrated Single-Chip Power Supply Solution

The CoolSET™ AC-DC Integrated Power Stage is a System-in-Package (SiP) solution designed by Infineon specifically for small- to medium-power off-line power supplies. Its key advantage lies in the integration of a high-voltage power MOSFET, PWM control core, high-voltage start-up unit, driver circuitry and protection circuitry onto a single chip, thereby radically simplifying the power supply system architecture, reducing the number of external components, lowering BOM costs and PCB footprint, and significantly shortening the power supply R&D cycle.

1. Core Hardware Integration and Technical Architecture

This series of devices is fully equipped with Infineon’s proprietary high-performance CoolMOS™ super-junction MOSFETs, covering a range of voltage ratings including 650 V, 700 V and 800 V. They are compatible with a wide AC input range of 85–300 V, meeting the requirements of voltage fluctuations in both domestic and industrial power grids worldwide. The devices are available in a variety of proven packages, including DIP-7, PG-DSO-12 and TO220 FulPak, catering to both through-hole and surface-mount production requirements, and are suitable for small-to-medium power supply designs across the full power range from 10W to 100W+.

The new-generation CoolSET™ integrated power stage combines three core switching technologies: fixed-frequency hard switching, quasi-resonant (QR) and ZVS (Zero Voltage Switching) soft switching. The fixed-frequency solution features simple control logic and high stability; the quasi-resonant scheme dynamically adjusts switching timing according to load conditions, reducing light-load losses; the high-side ZVS architecture, combined with CT Link isolated communication technology, significantly reduces switching losses, enabling overall efficiency to exceed 94%, whilst optimising EMI characteristics and simplifying the design of filtering circuits.

2. Core Features and Performance Advantages

- Ultra-low standby power consumption: Integrated active burst mode control automatically reduces the switching frequency and operates intermittently under light load and in standby conditions, keeping standby power consumption below 100 mW and meeting stringent energy efficiency certifications such as the EU’s ErP and the US’s ENERGY STAR.

- Precise power control: Features built-in peak current limiting, adjustable power thresholds and foldback correction technology to precisely lock in the maximum output power, preventing power overshoot caused by abnormal loads, and is suitable for a variety of power supply scenarios, including constant voltage and constant current.

- Comprehensive protection mechanisms: Integrated over-temperature, over-current, over-voltage and short-circuit protection, as well as automatic restart/latch protection functions. The device operates across a wide temperature range of –40°C to 130°C, making it suitable for demanding industrial and outdoor environments and significantly enhancing the robustness of power supply systems.

- Excellent EMI performance: Equipped with frequency jitter modulation technology to disperse the switching noise spectrum, effectively reducing conducted and radiated interference; meets IEC electromagnetic compatibility standards without the need for complex EMI filtering circuits.

- Rapid power-up: An integrated high-voltage start-up unit enables the controller to be powered directly from the rectified high-voltage bus, eliminating the need for additional start-up resistors, thereby simplifying the peripheral circuitry whilst improving start-up response speed.

3. Main Product Models and Suitable Applications

The CoolSET™ integrated power stage has undergone multiple generations of development, from the classic F3 series to the fifth-generation high-frequency series, with continuous performance upgrades: the ICE2QR4780Z (800V withstand voltage, 19W power) is suitable for small household appliances and charger power supplies; the ICE3RBR1765JG (650V, 65kHz fixed frequency) is suitable for small-to-medium power industrial adapters; the ICE3BR1065JF delivers a high output power of 102W, suitable for industrial control auxiliary power supplies; the fifth-generation ICE5AR4770BZS integrates a 700V MOSFET with a maximum switching frequency of 100kHz, specifically designed for lightweight applications such as micro-inverters and off-line UPS systems with power ratings of up to 15W.

II. AC-DC PWM Controllers: The Precision-Controlled Core of Switch-Mode Power Supplies

Infineon’s AC-DC PWM controllers are dedicated control chips designed specifically for AC-DC topologies such as flyback and buck converters. They can be used independently with external power devices to meet the requirements of medium- to high-power, highly flexible power supply designs. Compared to integrated power stage products, PWM controllers retain maximum control flexibility, supporting customisable configuration of frequency, peak current and operating modes, making them the core control solution for industrial power supplies, high-power adaptors and energy storage auxiliary power supplies.

1. Core Operating Mechanism

This series of controllers adopts a current-mode PWM control architecture, enabling precise monitoring of inductor peak current to achieve cycle-by-cycle current-limiting protection, with fast dynamic response and high loop stability. It supports two operating modes: fixed frequency and dynamic frequency reduction. Under full-load conditions, it maintains a fixed switching frequency to ensure output voltage stability; under light-load conditions, it automatically reduces the switching frequency and, in conjunction with burst mode, suppresses light-load losses, thereby addressing the issue of low efficiency under light loads typical of traditional PWM power supplies.

2. Key Technical Highlights

- Wide-range adaptive control: Supports adaptive switching between Continuous Conduction Mode (CCM) and Discontinuous Conduction Mode (DCM). CCM is suitable for high-power output, offering low peak current and excellent EMI performance; DCM simplifies loop design and is suited to lightweight applications requiring medium to low power.

- High-precision voltage regulation: Features a built-in high-precision error amplifier and temperature compensation circuit, ensuring minimal temperature drift in the output voltage and high regulation accuracy, making it suitable for precision electronic equipment with stringent power supply stability requirements.

- Flexible load adaptation: Supports an adjustable dead-time function, enabling rapid adaptation to load transients, suppressing output voltage fluctuations and enhancing the power supply’s dynamic load response performance.

- Low-loss gate drive: Equipped with modulated gate drive technology, which optimises the turn-on/turn-off timing of switching devices, reduces switching and gate losses, and improves the overall conversion efficiency of the unit.

3. Advantages in Typical Applications

AC-DC PWM controllers address the limitation of insufficient power capacity in integrated power stages; by pairing them with external high-voltage MOSFETs, output power can be expanded, making them widely applicable in medium-to-high-power AC-DC conversion scenarios ranging from 100W to 500W. Furthermore, its standardised control logic is compatible with mainstream power supply topologies, offering strong design compatibility. It can be rapidly adapted to the upgrade and iteration of traditional flyback power supplies, helping manufacturers to enhance energy efficiency and stability whilst retaining their existing circuit architecture.

III. AC-DC PFC Controllers: High-Efficiency Power Factor Correction Solutions

In high-power AC-DC power supply systems, low power factor and excessive grid harmonics are key challenges; these not only result in wasted grid energy but also lead to equipment overheating and increased losses. Infineon’s AC-DC PFC controller is specifically designed for front-end power factor correction. When paired with a boost topology, it ensures that the input current tracks the AC mains voltage waveform, effectively improving the power factor and suppressing harmonic distortion, thereby meeting IEC/EN harmonic limits and global energy efficiency regulations.

1. Core Operating Principle

The AC-DC PFC controller primarily operates in continuous conduction mode (CCM) and is suitable for medium- to high-power power supply applications. The chip continuously monitors the input AC voltage, input current and output DC bus voltage. Using a closed-loop control algorithm, it modulates the switching duty cycle to ensure the input current waveform closely matches the voltage waveform, raising the power factor to over 0.95 whilst stabilising the output at a high-voltage DC bus of 380–400 V. This provides a stable input for downstream circuits such as LLC resonant and flyback converters.

2. Core Performance and Technical Advantages

- Ultra-high power factor and low harmonics: Precise current waveform correction technology effectively reduces total harmonic distortion (THD) and eliminates harmonic pollution of the mains supply, making it suitable for applications with stringent compliance requirements, such as industrial power supplies, high-power charging points and server power supplies.

- High-efficiency, low-loss control: An optimised CCM control algorithm significantly reduces peak current and conduction losses in switching devices; the unit’s PFC efficiency reaches over 98% at full load, substantially reducing energy consumption during both standby and operation.

- Comprehensive system protection: Built-in protection against output overvoltage, input undervoltage, overcurrent and overheating, coupled with a soft-start function to prevent inrush current from damaging downstream components at power-up, thereby enhancing system reliability.

- Wide voltage compatibility: Supports a globally standard AC input voltage range, making it suitable for all industrial, commercial and residential power supply environments, offering exceptional design versatility.

3. System Integration Benefits

Infineon’s PFC controllers are frequently used in conjunction with downstream PWM controllers and CoolSET™ integrated power stages to form a complete AC-DC power supply architecture comprising ‘PFC front-end correction + DC-DC back-end conversion’, serving as the standard solution for high-power, high-efficiency power supplies. This combination not only addresses grid compliance issues but also stabilises the bus voltage, reduces design pressures on the downstream power supply, and significantly enhances the overall efficiency and service life of the unit.

IV. Core Advantages of the Full Product Range and Industry Application Scenarios

1. Overall Core Competitiveness

InfiniOn’s full range of CoolSET™ AC-DC devices, based on in-house developed CoolMOS™ power devices and mature control algorithms, achieves a multi-dimensional balance of integration, efficiency, stability and cost. Compared with competing solutions, its multi-generation switching technology, refined power consumption control and comprehensive protection mechanisms can simultaneously meet the low-cost requirements of consumer electronics and the high reliability demands of industrial equipment. Furthermore, the entire product range complies with green and environmental standards and meets global market access requirements.

2. Specific Application Scenarios

- Consumer Electronics Power Supplies: Mobile phone and laptop adapters, power supplies for small household appliances, and smart home power solutions. Leveraging the miniaturised integrated power stage and low standby power consumption of CoolSET™, these solutions enable lightweight, high-efficiency designs.

- Industrial Power Supplies: Auxiliary power supplies for industrial control equipment, industrial adapters and offline UPS systems. With wide operating temperature ranges, high immunity to interference and comprehensive protection features, these solutions are suited to harsh industrial environments.

- New Energy and Energy Storage: Micro-inverters, auxiliary power supplies for energy storage systems, and auxiliary power for charging points. The PFC+PWM combination solution enables highly efficient power correction and stable voltage conversion.

- Commercial Equipment: Server power supplies, lighting power supplies and power supplies for office equipment, meeting commercial compliance requirements for high power factor, low harmonics and high energy efficiency.