External AC-DC Power Supplies: Economic Factors, Application Drivers, Architecture/Packaging Trends, Technology and Regulatory Developments

Summary

Topics Covered:

• Application Segments
• Architecture and Packaging Trends
• Standards and Regulatory Framework for Development
• Advances in Standby Power Management
• Potential Technology Threats
• Advancements in Technology, Components and Materials
• Partnerships and Business Alliances
• Recent Product Developments
• Competitive Environment

Executive Summary

The outlook for the worldwide ac-dc external power supply market is expected to remain strong over the next several years, as evolving power architectures, smaller form factors, more efficient designs and improved power management technology combine with growing application demand to create new opportunities. Led by the communications, computer, consumer, portable medical and lighting segments, the power supply industry will experience a number of significant opportunities and threats, as manufacturers scramble to produce products designed for the latest demanding high tech applications.

A particularly significant technological and architectural challenge for power supply manufacturers includes a growing trend towards smaller configurations that leave room for added functionality and processing power. However, the desire to produce smaller and lighter products often poses serious challenges for the power supply designers, as power supplies must often fit into a standard format already in use in order to avoid the expense of a costly system re-design. Despite this challenge, a number of companies have been quite successful and have introduced new products that are small, more efficient and meet strict regulatory guidelines.

The introduction of light-emitting diode (LED) lighting as an application for external power supplies represents a significant development for the industry. LEDs are growing in popularity because they are following the major trends in the lighting industry, which include a strong demand for lighting equipment which is smaller, smarter and more colorful. Signs present the greatest area of opportunity for LEDs and bring a number of important advantages to the market. The two most obvious are lower energy consumption (up to 80% more efficient than neon) and longer operating lives compared with neon or other illumination alternatives. A specific area of opportunity is in channel letter lighting, as most LED channel letter systems are easily installed and many can be powered from a simple external ac-dc power supply.
 
One of the more important trends examined in the power supply market is the reduction of standby power in consumer products such as appliances, portable electronics and computer systems. End users, assisted by strengthened regulations, are demanding that power supply manufacturers provide products able to achieve the ultra-low standby power performance.  In an effort to address this problem, a number of semiconductor companies have introduced integrated circuit (IC) solutions that enable power supply systems to comply with stringent no-load and standby power requirements. Many of the new IC solutions target chargers and adapters for a broad range of small portable devices, including mobile phones, portable media players, eBook readers and tools. 

Both digital power management and power factor correction (PFC) are starting to make inroads in the external ac-dc power supply market. Several companies have targeted ac-dc adapters/chargers for digital control. Others currently offer controllers for off-line applications such as cordless phones, mini-adapters, routers, wireless modems and other external ac-dc chargers/adapters. In addition, regulatory moves in Europe, the United States, and elsewhere mandate high power factor for many electronic products with power requirements over 75W and for lighting products over 5W. These rules are combined with a number of application-specific standards that require high power supply efficiency across the entire load range, from full load to as low as 10% load.

Although the U.S. Environmental Protection Agency (EPA) announced that the external power adapter market will no longer be eligible for the Energy Star label, there are still a number of voluntary and mandatory programs that are tasked with regulating load power consumption and operating efficiency in external power supplies. In the US, there are three main programs: the California Energy Commission (CEC); US Congress with its Energy Independence and Security Act (EISA), both of which are mandatory; and the Energy Star program, which is voluntary. In Europe there is the Energy-related Products (ErP) Directive formally known as the Energy using Products (EuP) Directive and the European Code of Conduct (CoC). Other parts of the world that are enacting legislation are basing their limits primarily on previous Energy Star requirements.

In a development that could have a significant impact on the manufacturers of external power supplies, the Institute of Electrical and Electronics Engineers (IEEE) has initiated a project to establish a standard smart dc power supply that could eventually eliminate the need to carry around multiple power adapters. In order to see this project through, the IEEE initiated a working group called P1823 whose goal is to develop a specification for what it calls a “universal power adapter for mobile devices” – shortened to UPAMD. Eventually, UPAMDs could be fitted as standard in homes, hotel rooms, trains, aircraft and cars so that a dc supply becomes as ubiquitous as the mains. The establishment of an industry-wide standard is viewed by many as a critical step toward the replacement of brand- and model-specific analog power adapters with digital power supplies that can be used and reused with multiple devices.

One of the more visible threats to the external power supply market comes from the growing use of universal serial bus (USB) power in the consumer electronics market. Examples of this can be seen in cell phones, MP3/MP4 players and ebook reader markets. The USB has effectively replaced a variety of other interfaces such as serial and parallel ports and poses a serious threat to lower wattage external power supplies. In addition, the introduction of wireless charging pads, the growing use of Power-over-Ethernet (PoE) and the eventual emergence of dc power are also expected to provide external ac-dc power supplies with significant competition.

Although the external power supply industry is much too large for any one or two companies to affect the entire industry, there have been a number of recent partnerships and alliances indicating a trend towards cooperation among companies representing complementary areas of interest and expertise. Several of these partnerships have been between power supply manufacturers and consumer/commercial electronics applications manufacturers; others have been between semiconductor manufacturers and power supply manufacturers, while still others have been between companies whose products are in seemingly different areas. The common thread among these partnerships and alliances is that each one was done to further the advancement of a specific technology or product trend.

Among the areas examined in this report are the architecture and packaging trends affecting the industry, as well as a thorough discussion of new and emerging technologies and components, advances in standby power management, relevant business partnerships and alliances, potential threats and the latest regulatory developments and standards. The report also contains over 25 tables and illustrations, depicting a variety of new and emerging technologies, packaging solutions, product introductions, efficiency standards and other relevant information. The focus of this comprehensive analysis provides decision makers with an insightful look into the current and future opportunities and threats available in the external ac-dc market.

Countries Covered

Worldwide

Companies & Organizations Mentioned

ABB, Adranz-Bombardier, Advanced Power Solutions, Alcatel, Alfa Lavel, Amazon, Android, Apex Precision Power, Apple Computer, ARM Holdings, Astrodyne, Atmel, Ault, AU Optronics, Australian Greenhouse Office, Australian National Appliance and Equipment Energy Efficiency Committee, Avnet,  Black & Decker, Bosch, British Telecom, California Energy Commission, CamSemi, Canadian Standards Association, Canon, Chill Semiconductor, China Energy Conservation Project, China National Institute of Standardization, China Standard Certification Center, Cincon Electronics Co. Ltd., Cirrus Logic, Component Distributors, Consumer Electronics Association, Craftec, Data System International, Dell Computer, Delta Electronics, Digital Living Network Alliance, Duracell, Electric Power Research Institute, Emblaze Mobile, Emerge Alliance, Emerson Network Power, Energy Independence and Security Act, Energy Star, European Code of Conduct, European Commission Ecodesign Directive, Fairchild Semiconductor, Flybridge Capital partners, Freescale Semiconductor, Friwo, Fujitsu, Gateway, Green Plug, Hewlett-Packard, HTC, Huawei Technologies, IBM, IEEE, iGo Green Technology, Hakuto Co. Ltd,Highland Capital Partners, iD Soft Capital Group, Imagination Technologies, Infineon, Integrated Device Technology, Intel, International Components Corp., International Electrotechnical Commission, International Energy Agency,  iWatt, Jerome Industries, Korea Energy Management Corp., Korea Ministry of Commerce, Industry and Energy,  Lawrence Berkeley National Laboratories, LG Electronics, Lite-On Technology, Lucent, Lv Jianhua, Makita, Marvell Technology Group, Mean Well, Microsemi, Microsoft, Motorola Mobility, NEC, NetBit, Nexergy, Nintendo, Nokia, Nvidia, Olympus, On Semiconductor, Panasonic, Panorama Capital, Phihong, Philips, Power Box, Power Integrations, Powermat USA, Power Partners, Premier Farnell, Prime View International, Protek Power, Qi Low Power Standard, Qualcomm, Renesas, Research in Motion, Roal Electronics, Rolls Royce, Saab, Salcomp, Samsung, SemiSouth Laboratories, Siemens, Sigma Partners, SL Power Electronics, Sony Ericsson, ST Microelectronics, Standards Institute of Israel, TCT Mobile, TDK Lambda, Texas Instruments, Thomson, Tom Tom, Trueower, Trumbler Technologies, TRUMPower, Underwriters Laboratories, USB Implementers Forum, U.S. Environmental Protection Agency, U.S. Department of Defense, VantagePoint Venture Partners, Volvo, Wal-Mart, Wireless Power Consortium, XP Power

Table of Contents:

Introduction  4
Application Segments 7
Communications 7
Computers 10
Consumer 16
Portable Medical 24
LED Lighting 26

Architecture and Packaging Trends 27
In-line vs. Wall plug 27
Regulation: Switchmode vs. Linear  31

Standards and Regulatory Framework for Development 32
Changes to the Energy Star Program 33
Energy Independence and Security Act (EISA) of 2007  34
European Union (EuP) Initiative, Directive 2005/32/EC  36
European Union (CoC) on Efficiency of External Power Supplies 37
China – (CNIS) and (CSC) Standards  38
Korea – e-Standby Program 39
Additional Foreign Government EPS Standards 39
International Electrotechnical Commission (IEC) 62684 Standard 40
Internationally Recognized Safety Standards and Certifications 41

Advances in Standby Power Management 42
One Watt Initiative  42
Advances in IC Technology and Standby Power Management  43

Potential Technology Threats 45
Universal Serial Bus (USB) Power 45
Universal Serial Bus (USB) Wall Charging 49
Universal Power Adapters for Mobile Devices 51
Green Plug Participation  54
Power-over-Ethernet (PoE) 55
Wireless Charging Pads 59
Wireless Power Consortium 62
The Emergence of DC Power 63

Advancements in Technology, Components and Materials 67
Digital Power Components  67
Power Factor Correction  69

Partnerships and Business Alliances 71
Recent Product Developments 73

Competitive Environment 78
Power Supply Companies 78
Advanced Power Solutions 78
Astrodyne 78
Cincon Electronics Co. Ltd. 79
Delta Electronics 79
Emerson Network Power 80
International Components Corp. 80
Jerome Industries. 81
Lite-On Technology 81
Mean Well USA 81
NetBit 82
Phihong 82
Power Box 83
Protek 84
Salcomp 84
SL Power Electronics 85
TDK Lambda 85
XP Power 86

Semiconductor Companies 86
Chil Semiconductor 86
Cirrus Logic 87
Fairchild 87
Infineon 87
iWatt 88
On Semiconductor 88
Power Integrations 89
Renesas America 90
ST Microelectroncis  90
Texas Instruments 90

List of Tables

Table 1 – In-line vs. Wall Plug Power Supply by Application 28
Table 2 – Energy Star Minimum Energy Performance Classification 35
Table 3 –. Department of Energy Proposed Product Classifications. 36
 
List of Figures

Figure 1 – Apple’s iPad 12
Figure 2 – Integrated Device Technology IDT P95020 17
Figure 3 – Example of HB-LEDs for Channel Lighting 26
Figure 4 – External In-line Power Supply (TDK Lambda)  29
Figure 5 – External Wall Plug Power Supply (Phihong) 30
Figure 6 – NetBit Folding AC Plug and USB Outlet 31
Figure 7 – Power Integrations LinkZero-LP 44
Figure 8 – Standard USB Plug 46
Figure 9 – Combination USB Port / AC-DC Power Supply 47
Figure 10 – SuperSpeed USB  48
Figure 11 – USB Wall Socket 50
Figure 12 – Friwo UP-USB Solution 50
Figure 13 – TruePower Socket Solution 51
Figure 14 – UPAMD Universal Power Adapter Arrangement 53
Figure 15 – Green Plug Greenwire System 55
Figure 16 – PoE Midspan 56
Figure 17 – Microsemi Single Port PoE Midspan Extender 57
Figure 18 – Phihong 2 Port 95 per Port PoE Ethernet Mega Midspan 59
Figure 19– Powermat Wireless Charger 60
Figure 20 – Duracell myGrid 61
Figure 21 – Consumer Products Using DC Power 63
Figure 22 – EMerge Alliance Standard 1.0 65
Figure 23 – Examples of DC Power in a Commercial Facility  66