Teardown report: ANKER 65W gallium nitride super charger

ANKER is a well-known 3C e-commerce brand at home and abroad, and one of the first merchants to launch gallium nitride fast charging. On May 25, Anker Innovation held a new product launch conference with the theme of "Charging Life", launching new products such as the "Super Charge" gallium nitride series, the Starry Vast Series, the One Piece Series, and the Shengkuo Limited Edition.

The "Super Charge" gallium nitride series belongs to Anker's second generation gallium nitride fast charger. This series has three powers of 30W, 45W and 65W. In addition to adopting a new appearance design, the 65W charger also debuts PI's latest PowiGaN chip InnoSwitch4 -CZ series. Together, the products are bright and colorful.

1. Appearance of Anker’s 65W gallium nitride super charger

The packaging box is in a classic blue and white color scheme, with the ANKER brand in the upper left corner.

The back is printed with information such as the product's three major characteristics, parameters, and certification.

The package contains charger, instruction manual, certificate of compliance, etc.

The main body shell of this charger is matte-finished, and the surface has a skin-like feel, making it a good hands-on experience. There is a silver-gray decorative panel on the top of the fuselage, making the entire product highly recognizable.

Nano II and 65W are printed on one side of the waist, indicating the product name and maximum output power.

The input end is equipped with foldable national standard pins, and with such a compact body, it is very portable.

The charger parameters are marked on the input terminal shell.

Model: A2663

Input: 200-240V~50/60HZ 1.4A

Output: 5V3A, 9V3A, 15V3A, 20V3.25A (65W Max)

Anker Innovation Technology Co., Ltd.

The product has passed CCC certification. It is worth mentioning that this charger is the National Bank version, and the input voltage of 200-240V is in line with the actual voltage in my country.

The ANKER brand is printed on the top decorative panel.

The USB-C interface tongue is still in the classic blue color, and ANKER's exclusive "IQ 3.0" (full name PowerIQ 3.0) fast charging logo is printed next to the interface.

The actual height of the charger body measured using a vernier caliper is 44.2mm.

Width is 35.97mm.

Thickness is 41.57mm. Through three-dimensional calculation, the volume of the charger is approximately 66.09cm³, and the power density is approximately 0.98W/cm³.

Intuitive comparison with Apple's 61W charger, the size advantage is very obvious.

The intuitive feeling of holding it in your hand.

Net weight is approximately 107g.

Using ChargerLAB POWER-Z KT002, it was measured that the USB-C port supports Apple 2.4A, Samsung 5V2A, DCP protocols, as well as QC2.0/3.0, PD3.0, and PPS fast charging protocols.

In addition, it was also measured that the C port has four fixed voltage levels of 5V3A, 9V3A, 15V3A, and 20V3.25A, as well as a set of PPS voltage levels of 5-21V3.25A.

1. Anker 65W gallium nitride super charger disassembly

Disassemble the input housing and fix the screws and AC wires with glue and insulation.

The charger is filled with thermally conductive glue, and the PCBA module is difficult to take out directly. It can only be taken out by cutting the body shell.

The PCBA module is potted into a whole block, and the overall stability and heat dissipation performance will be better. Two high-voltage filter electrolytic capacitors are coated with black plastic shells for insulation protection.

Clean the potting glue and measure the length of the PCBA module to be 33.95mm.

Width is 30.47mm.

Thickness is 34.5mm. It can then be calculated that the maximum space occupied by the module is approximately 35.69cm³, and the power density is approximately 1.82W/cm³. PI's active clamp architecture effectively compresses the charger volume.

The PCBA module is made of three PCB small boards and is welded together with a U-shaped structure design.

Through observation, we found that this charger uses a PI highly integrated switching power supply solution with a wide range of output, and a design architecture with a protocol chip to control the interface output voltage. Let's learn about each component one by one starting from the input end.

The input fuse and filter inductor jacket are protected by black insulating tubes.

Viewed from the U-shaped notch, the common mode inductor on the input board and the two solid capacitors on the output board are protected by black plastic shells. It can be seen that the internal insulation measures of the charger are well done.

Separate the three PCBA modules.

There are fuses, X capacitors and common mode inductors on the front of the input board.

There are two rectifier bridges on the back to evenly distribute heat.

Close-up of fuse and heat shrink tubing.

The safety X capacitor comes from Dongguan Chengxi Electronics, with a capacity of 0.22μF.

A close-up of the common mode inductor, with a yellow magnetic core and two-wire winding, used to filter out EMI interference.

Close-up of two 8M109 rectifier bridges, chip packaging reduces thickness.

The capacitors, inductors, and Y capacitors on the small connection board have been removed. In addition, there is a transformer on the board.capacitors

The back of the small board is equipped with PI's ClampZero chip and InnoSwitch4-CZ main control chip.

Close-up of filter inductor.

The four high-voltage filter electrolytic capacitors are all from the Yongming（Shanghai Yongming Electronic Co.,Ltd) KCX series, and the two specifications are 400V 33μF.

The other two specifications are 400V 22μF. This series of capacitors is a dedicated product for fast charging sources launched by YMIN in 2019. It has an operating temperature range of -55℃~105℃, a lifespan of 3000 hours, and is lightning-strike resistant, low leakage current (low standby power consumption), and high ripple. Current, high frequency, low impedance and other performance advantages.

With the characteristics of small size, YMIN KCX series electrolytic capacitors are also used by Bull 65W gallium nitride fast charging, Philips 65W gallium nitride fast charging socket, Momis 65W 2C1A gallium nitride fast charging charger, Youbi 30W 1A1C nitride Gallium fast charging charger, Beijing 65W 1A1C gallium nitride fast charging charger, Nubia 65W 2C1A deuterium front gallium nitride fast charging and other products are adopted and have been unanimously recognized by customers.

The switching power supply main control chip uses PI INN4075C. This is PI's new generation InnoSwitch4 series chip that uses PowiGaN technology. It is used in an active clamp flyback architecture to achieve zero-voltage switching of the main switch tube and reduce device temperature rise. At the same time, it optimizes EMI performance and is very suitable for small size, high operating frequency switching power supply design.

InnoSwitch4-CZ is an integrated flyback chip for zero-voltage switching. It integrates a 750V high-voltage PowiGaN switch, active clamp driver, synchronous rectification and FluxLink feedback. It is used in conjunction with the ClampZero active clamp chip to recycle leakage inductance energy and achieve Conversion efficiency up to 95%.

At the same time, its standby power consumption is less than 30mW, it has built-in synchronous rectifier gate open circuit detection, supports fast input under-voltage/over-voltage protection, and has complete and comprehensive protection functions. Suitable for high power density flyback design, high energy efficiency USB PD charger and high energy efficiency constant voltage and constant current charger, etc.

Paired with INN4075C is PI CPZ1062M. This highly integrated device reduces switching losses in the InnoSwitch4 main switch, captures and recycles transformer leakage inductance energy, and significantly improves energy efficiency. PI's ClampZero series products integrate high-voltage switch tubes and controllers and can be seamlessly connected to the InnoSwitch4 main controller to implement a flexible active clamp flyback solution.

PI CPZ1062M data information.
PI's PowiGaN series chips have been adopted by dozens of products from well-known domestic and foreign brands such as Xiaomi, Belkin, NetEase, Anker, SATECHI, Aoji, Lulian, Baseus, OPPO, etc. The quality has been highly recognized by customers, which has greatly Promote the development of gallium nitride fast charging market.

Close-up of the transformer, the secondary output wire is covered with a magnetic ring.

The Y capacitor is also from Chengxi Electronics.

There are two output filter solid capacitors and an output VBUS switch tube on one side of the output board.

The other side is equipped with synchronous rectifiers, diodes and protocol chips.

The synchronous rectifier uses AOS Bandai AON6220, NMOS, withstand voltage 100V, DFN5x6 package.

A Schottky diode is connected in parallel next to it to improve efficiency.

The two output filter solid capacitors are YMIN NPX series, with specifications of 25V 560μF. This series of capacitors has the characteristics of small size, low ESR, high rated ripple current, high reliability, and resistance to switching shock.

YMIN NPX series solid state capacitors have previously been used by Flash 100W 3C1A gallium nitride fast charger, Momis 65W 2C1A gallium nitride fast charger, Baseus 45W 1A1C gallium nitride charger, and Nubia 65W deuterium front nitride It is used in gallium chargers and other products, and has also been used in 20W mini chargers of brands such as Anker, Philips, Xiaoxiaohei, Pinsheng, and Bonkers, and has been unanimously recognized by customers.

The USB PD protocol IC uses Weltrend WT6636F, which is a protocol chip that has passed the USB PD3.0 (PPS) certification of the USB-IF Association (TID number: 1080018). It has also passed Qualcomm QC4+ certification, certification number QC20200316138.

WT6636F supports USB PD3.0 and PPS, has built-in programmable constant voltage and constant current control, integrates a low-side current sampling amplifier, supports line loss compensation, supports multiple protection functions, including overvoltage protection of the data pin, and integrates a 10bit ADC internally for Voltage and current detection, built-in 8051 core microcontroller, built-in discharge MOS tube.

Products using WT6636F include THEONE 65W 1A1C fast charging charger, RedmiBook Pro 15 notebook standard 100W charger, Qingke Mini 45W fast charging charger, LG gram notebook standard 65W gallium nitride charger, Lenovo thinkplus 65W nitride Gallium Lipstick Power Supply Pro, NetEase Intelligent Manufacturing 61W gallium nitride fast charging, etc. At the same time, there are dozens of fast charging products using Weltrend's chips.

The output VBUS switch tube uses AOS Bandai AONR66406, NMOS tube, withstand voltage 40V, DFN 3x3 EP package.

The USB-C female socket is reinforced with a steel sleeve, and there is a rubber ring seal between it and the shell.

Now that everything has been dismantled, let’s take a family photo.
ANKER 65W gallium nitride super charger is equipped with a single USB-C interface, and its shape tends to be square. The black shell and silver-gray decorative plate design on the top make it eye-catching and full of personality. As a 65W super fast charger, the power density is as high as 0.98W/cm³, and it is equipped with foldable prongs, making it compact and portable. In addition, it supports QC and PD universal fast charging protocols, and has a 5-21V3.25A PPS voltage range to meet the fast charging needs of major brands of mobile phones, tablets, and laptops.
On the one hand, the workmanship of the charger is exquisite, which can be seen in all aspects, including connecting wires, gluing screws, capacitor jacket plastic shell, USB socket jacket steel sleeve reinforcement, etc. In addition, the interior is potted with thermally conductive glue to form a whole, ensuring stability and heat dissipation performance.
In terms of materials, the first PI INN4075C+CPZ1062M solution has an active clamp flyback architecture that can recycle leakage inductance energy, allowing the product to have higher efficiency, lower heat generation and achieve miniaturization. In addition, AOS synchronous rectifier and Weltren WT6636F protocol IC are used, and Yongming small-sized PD fast-charging electrolytic capacitors and solid capacitors are used for filtering, further helping the charger become smaller. The overall materials used in the charger are also very reliable.