Wireless data transmission has been around for quite some time now, and today, consumers are increasingly interested in wireless charging capabilities. Tech providers are stepping up to meet this demand. In this article, Infineon will explore and compare the latest advancements in wireless charging methods and technologies, highlighting the advantages of integrated wireless charging solutions.
Background
Every electronic device needs power, yet most rely on wired connections, often via wall outlets and adapters. While "wireless" has become synonymous with data transmission, magnetic fields can also be harnessed to deliver power, offering users greater convenience. Without cables, compatibility issues are minimized, and the safety and reliability of devices improve. Additionally, sealing devices becomes simpler, protecting them from accidental damage like drops into liquids. One major perk of wireless charging is eliminating the bulkiness of traditional adapters.
As industries move toward universal charging solutions, we’ll likely see more public charging stations popping up in places like airports, hotels, events venues, and cafes.
Design Challenges
Most chargers are switch-mode power supplies, requiring engineers to master electromagnetism—a subject many find challenging. Wireless charging operates similarly, except the transformer is split between the charger and the device being charged. Thus, the terms change: the primary side becomes the "transmitter," and the secondary side becomes the "receiver."
In wireless charging, coils and their coupling significantly influence overall performance more so than in SMPS. Since the windings are independent, their coupling is looser. However, with careful design, transmitters and receivers can achieve good coupling coefficients, allowing for efficient wireless power transfer.
Beyond magnetism, efficiency, mechanical packaging, electromagnetic interference (EMI), thermal management, and the presence of metallic foreign objects (like coins or keys) pose additional challenges for designers.
Wireless Topology and Technology
Wireless charging systems generally consist of three main components: an adapter/charger, a transmitter, and a receiver.
The adapter converts standard mains electricity into a regulated 5-20 VDC power supply for the primary/transmitter. These adapters can either be standalone units connected via wires or integrated directly into the transmitter.
The transmitter uses a MOSFET-based half-bridge or full-bridge inverter to convert DC into AC, creating an alternating magnetic field. Controlled by a microcontroller and MOSFET drivers, the inverter provides the flexibility and functionality needed for wireless inductive charging.
Class D and Class E are two popular topologies for resonant applications. While similar in many ways, each has distinct advantages, making them suitable for different applications.
Class D topologies, represented by a full-bridge topology, offer a nearly flat efficiency curve across a wide load range, making them ideal for general-purpose wireless charging stations in public spaces. This method supports a variety of power levels.
Class E topologies, optimized for specific parameters, exhibit peak efficiency at certain points but drop off rapidly elsewhere. They are better suited for higher power levels and scenarios involving near-empty or fully discharged devices. The Class E bill of materials (BOM) costs slightly less than Class D, though the difference isn’t significant.
Infineon provides comprehensive solutions for wireless charging transmitters and switch-mode power supplies, converting mains AC to inverter input DC.
The selection of wireless charging products empowers design engineers with confidence in using components and subsystems that ensure compatibility.
At the heart of the transmitter design lies the microcontroller, responsible for system control and intelligence. Infineon’s XMC™ microcontroller family offers numerous options, with the XMC1100, 1402, and XMC4108 being ideal for Class D and Class E topologies.
The EiceDRIVERTM gate driver converts microcontroller signals to drive MOSFETs directly. The new 2EDL71 is best suited for Class D designs, while the proven 1EDN is preferred for Class E applications.
Infineon offers a wide range of MOSFETs, with specific specifications differing in package size and critical parameters like RDS(ON) and Qg. Infineon leads the industry with an industry-leading figure of merit (FoM). Voltage levels range from 30V to 250V, giving designers flexibility to design wireless chargers of various power levels. Infineon’s market-leading OptiMOS™ MOSFETs are used in Class D or Class E inverters (and synchronous rectification), while the CE and P7 versions of CoolMOSTM devices provide switching for ACDC adapters.
Infineon also provides a range of flyback controllers for power adapters, along with CoolSETTM units that integrate controllers and power stages.
To support component solutions, Infineon’s newly developed Class D power amplifier transmitter test board enables designers to quickly start designing efficient and compact solutions.
This test board allows designers to evaluate the functionality and performance of Infineon MOSFETs in Class D power amplifiers. It consists of two half-bridges made up of an 80V 2x2 Infineon MOSFET (IRL80HS120) and associated drivers, enabling operation in both single-ended (one half-bridge) and differential (both half-bridges active) configurations.
An embedded oscillator ensures precise 6.78 MHz operation and provides a pin to set the switching frequency with an external waveform generator (via the BNC connector).
All necessary components are included to design a zero voltage switching (ZVS) power solution for maximum efficiency. The onboard linear regulator provides a stable supply voltage for the board logic.
A second BNC connector can connect to an external transmit coil for wireless energy transmission. Adding a wireless charging receiver completes the design.
Conclusion
Wireless charging offers the same conveniences as wireless data transmission. As standards and methods integrate, increased interoperability between chargers and portable devices will bring greater convenience to users. Ongoing integration and innovation will make "true" wireless charging a reality, enabling more types of devices to be charged without wires.
As a leading provider, Infineon offers a wide range of products covering all key components of AC adapters and transmitters. Each component boasts high performance, including low switching/conduction losses, minimal parasitics, and a high figure of merit (FoM), allowing designers to build wireless charging solutions using proven silicon MOSFET technology. Infineon’s extensive expertise in power semiconductors and microcontrollers has established it as a technology and quality leader.
Test boards that accelerate product evaluation and development support a broad portfolio of products, covering all aspects of wireless charging designs. Infineon provides advanced products and valuable ecosystem support for current and future wireless charging solution designers.
Author:
Stephan Schächer, Head of Technology and Systems Marketing, Infineon Technologies DCDC
Milko Paolucci, Senior Application Engineer, Infineon Technologies
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