A successful mass production case of the industry's smallest 65W AC/DC Power Adapter for the consumer market.

E-Power Solutions' "DAC (Dual Active Clamp) technology" brings new innovation to the power supply industry. UNIFIVE has successfully brought this groundbreaking circuit technology to market as high-quality mass-produced Products. Since its founding in 1989, our company has specialized in the development and manufacturing of compact power supplies. Here, we introduce a case study in which our technical expertise transformed an innovative idea into a reliable reality.

Products Overview: The Remarkable Miniaturization Achieved by ADAMON 65W Gen2

Proprietary Technology Achieving One of the World's Smallest Classes

ADAMON 65W Gen2 has achieved astonishing miniaturization and weight reduction, with a volume of just 46cc and a weight of 65g. This breakthrough was made possible by combining the Dual Active Clamp Technology (DAC Technology) developed by E-Power Solutions with UNIFIVE's many years of power supply manufacturing expertise.

Technical Features and Solutions for Mass Production Challenges

The core of DAC Technology lies in the combination of a voltage clamp circuit that limits the input voltage to 250V or less and a highly efficient active clamp DC-DC converter. This innovative circuit configuration makes it possible to replace the conventionally required large 400V-class electrolytic capacitors with smaller components rated at 250V or less.

UNIFIVE addressed the following technical challenges in designing this groundbreaking circuit technology into a mass-producible Products:

1. Optimization of PCB design for high-speed switching circuits
2. Thorough noise countermeasures to comply with EMI standards (CISPR 32 Class B)
3. Efficient thermal design within a compact enclosure
4. Compliance with stringent safety standards (PSE/IEC 62368-1)

As an example of a Products leveraging this technological advantage, a commercial model under the ADAMON brand developed by E-Power Solutions is also available (ADAMON 65W Gen2 One of the World's Smallest Class USB-C Charger (Amazon Sales Page)).

Innovative Differences Between GaN AC/DC Power Adapter and DAC Technology

A Different Concept from Conventional GaN Approaches

GaN (gallium nitride)-based AC/DC Power Adapter, which currently dominate the market, achieve miniaturization through the approach of "enhancing high-voltage MOSFET performance using GaN." In contrast, the ADAMON 65W Gen2 achieves equivalent or greater miniaturization through an innovative circuit design that enhances MOSFET performance by lowering voltage resistance, while utilizing existing highly reliable Si devices.

Comparison of Technical Approaches

Performance Advantages Achieved by DAC Technology

By adopting DAC technology, the following advantages have been achieved:

• Power Efficiency: Achieves high efficiency of 94% (equivalent to or better than GaN-based products)
• Size: Industry-leading compact size of 46cc (smaller than GaN-based products)
• EMI Performance: Secures a -6dB margin against CISPR 32 standard
• Reliability: High reliability through proven Si devices

UNIFIVE Manufacturing Solutions

Manufacturing Capabilities Backed by 35 Years of Experience

Since our founding in 1989, we have specialized in the development and manufacturing of compact power supplies. Our track record of developing over 1,500 new Products annually and shipping more than 15,000 sample units demonstrates our technical expertise and production capacity.

Particularly in mass production, we thoroughly implement Design for Manufacturing (DfM) from the design stage to establish a stable production system. Through inspection processes essential for safe and reliable power supplies and multi-stage quality control by skilled technicians, we achieve manufacturing quality highly valued by global companies.

Comprehensive Support System for Fabless Companies

We provide the following comprehensive services to fabless companies with innovative circuit technologies and ideas:

Features of Our Manufacturing Solutions

1. Design for Manufacturability from the Initial Stage

• Mass production optimization through DfM (Design for Manufacturing)
• Thorough efficiency improvements in component layout and PCB design
• Achieving both cost reduction and quality improvement

Turning your Products ideas into a "mass-producible reality."

We thoroughly implement DfM from the early stages of development with mass production in mind. By eliminating waste in component placement and optimizing PCB design, we achieve the optimal balance between cost and manufacturing quality. We propose improvements in manufacturability to ensure that your ideas become successful Products in the market.

2. Advanced Quality Assurance System

• Comprehensive testing systems
• Fully implemented traceability system
• Established long-term supply and maintenance structure

High quality as a given. The quality of UNIFIVE is protected by our systems.

At the mass production stage, we conduct rigorous inspections on all Products. With a comprehensive testing framework in place, we have established a system capable of producing safe and reliable power supplies. Furthermore, through a fully implemented traceability system and long-term supply structure, we continue to provide highly reliable Products.

3. Flexible Customization Support

• Enclosure design and logo modifications
• Support for unique specifications
• Production available from small lot sizes

Can you meet this specification? Our answer is yes.

UNIFIVE has established a production system capable of responding quickly not only to mass production but also to small-lot custom orders. From changes in Products exterior design and brand logo printing to connector and cable customization, we support Products development that highlights your company’s uniqueness. Feel free to consult with us even at the idea stage.

Summary of Manufacturing Partner Proposal Supporting Global Brands

UNIFIVE has been continuously chosen by brands around the world, built on over 35 years of experience in power supply manufacturing. We have established a system that consistently supports everything from Products development to mass production, quality assurance, and after-sales support, strongly assisting our customers' businesses from the manufacturing side. Here, we summarize the reasons why we are highly regarded as a manufacturing partner and the services we provide. Whether you are working on commercialization for the first time or aiming to further evolve your existing brand, you can rely on us with confidence.

UNIFIVE

1. Extensive Mass Production Experience
   • Over 1,500 new developments annually
   • Proven track record with global manufacturers
2. One-Stop Solutions
   • Integrated support from design assistance to mass production
   • Comprehensive support for safety certification acquisition
   • Established after-sales service system
3. Advanced Technical Expertise
   • Over 35 years of power supply development know-how
   • State-of-the-art manufacturing and inspection equipment
   • Quality control by skilled engineers

Available Services

• Mass production design support
• Prototyping and evaluation
• Safety certification acquisition
• Mass production manufacturing
• Quality assurance
• After-sales support