Digital technologies boost performance of DC-DC converters amid miniaturization

China makers of DC-DC converters rely mainly on PFM and PWM, while some employ MCUs and DSPs to achieve high power density and reliability in small sizes.

As electronics applications become increasingly smaller but more powerful, components develop in the same way. In DC-DC converters, which are widely used in consumer electronics, computers, office automation, remote communication, instruments, military and aviation, the trend is toward greater power density and longer operating life even in smaller sizes.

To realize these characteristics, makers of the component in mainland China use digital management technologies. Some have turned to employing MCUs and DSPs to push efficiency past 95 percent. For the majority, pulse-frequency modulation or PFM and pulse-width modulation or PWM are mainly employed.

Shenzhen Deshi adopted a double-sided PCB, imported aluminum electrolytic capacitors and high-Q value power inductors in a model measuring 43x20x15mm only. The unit has 3.2 to 40VDC input voltage, 1.2 to 35VDC output voltage, 3A maximum output current and more than 95 percent efficiency.

Acquiring more product certification is also an objective across the local DC-DC converter manufacturing segment. Most suppliers have obtained approval from CE, FCC and UL, and meet RoHS. There are others such as Beijing V-Young Tech Development Co. Ltd that have ensured RCM compliance as well.

In addition to industry trends, customization continues to drive R&D efforts. To the majority of manufacturers, orders based on this still represent the bulk of shipments, with shares ranging from 50 to as much as 90 percent. Interviewed maker Ligao (Zhongshan) Electrical Appliance Co. Ltd has always emphasized flexibility to any requirement when developing products. Over 70 percent of its total deliveries are in buyers' specifications.

The mainland's DC-DC converters market is expected to keep growing, especially as applications such as green vehicles and drones have emerged. These new sectors are forecast to have a combined expansion rate surpassing 10 percent in the next two years. The domestic new energy automotive industry, in particular, will be in the scale of $920 million in 2022 from $230 million in 2016, according to projections by local market research company YLZ Information Consulting. In past years, the power supply category already benefited from established markets with a 5 to 10 percent increase in sales value.

The mainland accounts for 30 percent of the world's DC-DC converters shipments. More than 400 makers gather there, including companies with investment from Hong Kong, Taiwan, the US and Japan. Emerson, Artsyn, TDK-Lambda, Murata, Mornsun, Suplet and Huizhong are among the major players.

Most local enterprises in this line have small and midsize operations. They turn out other types of power supplies, with the featured category making up 20 to 70 percent of their shipments. Companies export 30 to 80 percent of total output mainly to the US, Europe and the Asia-Pacific region.

Over 80 percent of the maker pool is in the Pearl River Delta and the Yangtze River Delta regions, and the Bohai Bay Rim Economic Region. The key locations are Guangdong and Zhejiang provinces, and Beijing.

Modular, open-frame units

Mainstream DC-DC converters from mainland suppliers come in modular and open-frame configurations, which are classified further into isolated and nonisolated types.

In the isolated subcategory, the selection includes buck, boost, buck-boost and Ćuk units, while forward, flyback, half- and full-bridge kinds are among the common choices in the nonisolated counterpart.

Low-power models are in the 0.1 to 300W range and dominate shipments. Medium- and high-power units are respectively 300 to 500W and above 500W.

The typical product efficiency is between 70 and 90 percent, while those with higher ratings can also be sourced from some makers.

All locally made DC-DC converters come with built-in safety features against short circuits, and overvoltage and -current. These comply with CE, FCC, RoHS and UL requirements.

MOSFETs and ICs used are obtained from foreign providers, including International Rectifier, Fairchild, STMicroelectronics and ON Semiconductor. Diodes, transistors, transformers, passive components, PCBs and cases are purchased locally or imported, depending on buyers' specifications.

The price of DC-DC converters has been stable owing to minimal fluctuations in the cost of production inputs. This trend is forecast to last through 2020.

The products in this gallery have been handpicked by our China-based market analyst for representing current trends in DC-DC converters from China makers.

Isolated DC-DC converter has 4:1 conversion ratio

Beijing V-Young Tech Development Co. Ltd’s model VND5-24S15-W isolated DC-DC converter has 4:1 conversion ratio and 5W power. The single-output unit with a hexahedron metal shield has built-in short-circuit protection and automatic recovery. It meets CE, FCC, RCM and UL requirements.

The minimum order of 100 units is for delivery within 15 days.

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Nonisolated DC-DC converter with up to 90% efficiency

This nonisolated DC-DC converter from Ligao (Zhongshan) Electrical Appliance Co. Ltd, PV2412-6A-2-#3626 model, has 20 to 30VDC input voltage, and 12 to 13.8VDC, 7.5A continuous and 15A maximum output. Its standby current is ≤20mA. The unit with 85 to 90 percent efficiency has reverse-polarity, overheating, -load and short-circuit protection. It operates in 0 to 40 C, and meets CE, E8, EN 61000 and Directive 2006/96/EC requirements.

An order of at least 100 units is for delivery within 25 days.

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DC-DC converter meets EN 55022 Class B

Designed to meet EN 55022 Class B, this DC-DC converter from Shenzhen Qinxinlong Electronic Co. Ltd, QDC-#5190 model, features active current-sharing control and hot-swap functions. The low-ripple and -noise model has reverse-voltage, overcurrent, -voltage, -temperature and short-circuit protection. It operates in -20 to 70 C.

The maker requires a minimum order of 3,000 units. Delivery lead time is 20 days.

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45W DC-DC converter

The model SQD-120C-002 from Shenzhen Saqcn Innovation Technology Co. Ltd is a DC-DC converter with 8 to 36VDC input voltage and 45W power. The 43g unit with 0 to 50 C operating temperature has overcurrent, -voltage and short-circuit protection. Its board measures 144x80mm.

The minimum order of 3,000 units is delivered within 7 days.

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