Five new reference designs, spanning 16 W to 120 W and featuring both wound-core and planar transformer options, are set to enhance DC-DC conversion, emergency power, battery management, and auxiliary systems in next-generation 800 V electric vehicles.
Power Integrations introduced five new reference designs for 800 V automotive platforms, built around its 1700 V InnoSwitch 3-AQ flyback switcher ICs. Covering output power levels from 16 W to 120 W, the designs utilize both wound-core and low-profile planar transformers to address critical automotive needs such as DC-DC bus conversion, inverter emergency power, battery management, and auxiliary power supplies.
A key innovation is the new InSOP-28G package, which offers a 5.1 mm drain-to-source creepage distance and supports 1000 VDC primary-side operation. This wide-creepage construction eliminates the need for conformal coating, reducing manufacturing steps, qualification costs, and assembly complexity. The InnoSwitch3-AQ IC integrates a 1700 V silicon-carbide (SiC) primary switch, enabling simplified manufacturing, high efficiency, and long-term reliability for advanced 800 V EV architectures.
The five designs include the RDK-994Q, a 35 W ultra-low-profile supply for traction inverter gate drive or emergency power supply (EPS) with a 40–1000 VDC input and 24 V output; the RDK-1039Q, an 18 W planar transformer-based design for gate driver or EPS applications; and the RDK-1054Q, a 120 W planar transformer solution aimed at reducing or eliminating bulky 12 V lead-acid batteries. Two design example reports complete the lineup: the DER-1030Q, a 20 W four-output supply providing one EPS at 24.75 V and three gate-drive outputs at 25.5 V; and the DER-1045Q, a 16 W four-output supply delivering one 14 V EPS output plus three gate-drive outputs with split +18 V / –5 V rails.
Delivering up to 120 W of output power, these CV/CC flyback ICs can reduce bill-of-materials count by up to 50 percent, saving PCB space and easing component sourcing challenges. Startup is possible from as low as 30 V drain voltage without extra circuitry—an important feature for functional safety. Efficiency exceeds 91 percent, achieved through synchronous rectification and valley switching in both discontinuous and continuous conduction modes. Integrated protection features include input under-voltage, output over-voltage, and over-current limiting, while no-load power consumption remains below 15 mW.
The 1700 V-rated InnoSwitch3-AQ ICs are priced from $6 in 10,000-unit quantities, with reference design kits available for $50 to $100. Full resources, technical documentation, and ordering options are accessible via power.com and authorized distributors. Power Integrations has tested this reference design. It comes with a bill of materials (BOM), schematics, assembly drawing, printed circuit board (PCB) layout, and more. The company’s website has additional data about the reference design. To read more about this reference design, click here.
