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PMP41013: USB PD DRP 60W controller for 3S Li-ion (powerbank application)

Part Number: PMP41013
Other Parts Discussed in Thread: PMP41062, BQ25731, TPS25750, TPS25751

Tool/software:

Hi TI team,

I hope you all are doing well. I have a few questions about PMP41013, or alternative reference designs / controllers if they are available, for a powerbank application.

For said powerbank, the Li-ion cells I'm getting are 32Wh each, so I'm limited to just 3 cells in series (3S1P config). At a 60W output and minimum battery voltage of 2.9V/cell, that is a ~7.5A input current assuming 90% efficiency. At a 100W output, that is a >14A input current, and I already know that efficiency would inevitably be closer to about 80% at this point.

Ideally, the power circuitry could allow the battery to output 60W - 100W through the USB-C port in source mode, the higher the better. For sinking (charging the battery) 45W is ok.

Now, I would like to ask - PMP41013 claims to be able to output up to 60W, however the graphs and thermal views are only shown at a battery voltage of 18V, or the nominal voltage of a 5S pack. The efficiency would only get worse as the difference between the input and output voltage got larger, so can the system still output that 60W in USB-C source mode from a battery voltage as low as 8.4V?

Of course, a 100W output would be preferred, but PMP41062 is only compatible with 4 - 10 cell batteries. I do not mind what sort of heatsinking I might have to do, or how wide the PCB traces have to be - could I create a powerbank based on PMP41062 that would be compatible with 3 cell batteries with an 100W output, 45W input?

If either are true, please let me know what modifications I would need to make to component values (I would imagine the inductor would need to be bigger?), PCB layout, and/or thermal considerations to get started with this design.

Thank you very much. Have a great week.

Kind regards,

Rain

  • Hi, Rain

    PMP41062 can support wide range of battery cell, but as you said the lower voltage on battery side, the lower efficiency as the voltage difference between input and output, and this design is mainly for power tools charger with high cell battery application, so we only tested with 4-10s, for lower battery cell, BQ25731 might be better as it is designed for lower cell voltage application, for power stage such as inductor, follow the basic formula in DS. and for the firmware, I suggest you to raise a new E2E ticket for TPS25750 GUI with detail power specification, a firmware application engineer will help you on that.

      

    BR

    Max

  • Hi Max,

    Thank you very much for your response. So, in this case, I should aim for a design with TPS25751 + BQ25731, for a 60W output, using the datasheet formulas to calculate values for the power stage Slight smile I will contact a firmware applications engineer through a new E2E ticket if I end up going through with this solution.

    Before I do that, though, I just have one additional question - does this mean that even though the results in the test reports of PMP41062 only cover testing with almost the maximum input voltage (40V) in detail (thermals, efficiency, etc), it can output 100W in OTG mode all the way down to an 11.6V input, as this is the fully drained voltage of a 4S pack? I would assume this is true, but I am not entirely sure, given that the cut-off voltage per cell is not stated.

    If so, I may have to look for alternative cell solutions in order to create a 4S pack that stays under the 100Wh limit, as this powerbank will be designed to charge laptops for thousands of cycles and last 10+ years, and it would be good for some future-proofing as more devices adopt 100W USB-C charging. Sorry, I don't mean to seem indecisive here.

    That's all I would like to ask, and then I will close this case. Thank you so much for your quick reply! Have a great week!

    Kind regards,

    Rain

  • Hi Rain

    in OTG mode, we basically implement USB PD protocol, for 100W, it should be 20V/5A power contract here, for battery side, you can change the charger current limit in GUI for different battery cell condition as you have lower cell voltage here

    BR

    Max

  • Hi Max,

    Thanks, that solves my question. I hope you have a great day!

    Kind regards,

    Rain