High-power density 65-W, USB Type-C®, charger using active clamp flyback reference design


Design files


This reference design is a 65-W, high-power density USB charger using the UCC28782 active-clamp flyback controller achieving 30-W/in power density. The maximum power rating is 65-W at 20-V VOUT across a universal AC-input range. VOUT is also adjustable to 20-, 15-, 9-, and 5-V output voltage and 3 A. The design reaches a peak efficiency of 94%. The average efficiency and standby power levels are designed to meet DoE Level VI and CoC Tier 2 limits.

  • High efficiency peak 94%
  • High power density 30 W/in3
  • Meets CoC and DoE efficiency regulations
  • Compatible with USB PD 3.0 standard
Output voltage options PMP40974.1 PMP40974.2 PMP40974.3 PMP40974.4
Vin (Min) (V) 90 90 90 90
Vin (Max) (V) 264 264 264 264
Vout (Nom) (V) 5 9 15 20
Iout (Max) (A) 3 3 3 3.25
Output Power (W) 15 27 45 65
Isolated/Non-Isolated Isolated Isolated Isolated Isolated
Input Type AC AC AC AC
Topology Flyback- Active Clamp Flyback- Active Clamp Flyback- Active Clamp Flyback- Active Clamp
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A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

TIDT245.PDF (1672 K)

Test results for the reference design, including efficiency graphs, test prerequisites and more

TIDM941.PDF (356 K)

Detailed schematic diagram for design layout and components

TIDM942.PDF (129 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDM943.PDF (388 K)

Detailed overview of design layout for component placement

TIDM945.ZIP (3053 K)

Files used for 3D models or 2D drawings of IC components

TIDCG25.ZIP (268 K)

Design file that contains information on physical board layer of design PCB

TIDM944.PDF (927 K)

PCB layer plot file used for generating PCB design layout


Includes TI products in the design and potential alternatives.

Flyback controllers

UCC28782High-density flyback controller for active-clamp (ACF) and zero-voltage switching (ZVS) topologies

Data sheet: PDF | HTML
Digital isolators

ISO7710Robust EMC, single-channel, reinforced digital isolator

Data sheet: PDF | HTML

Technical documentation

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Type Title Date
Test report High Power Density 65-W, USB Type-C® Charger Using Active Clamp Flyback Ref Des PDF | HTML Oct. 26, 2021

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