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1N4004

OFFLINE FLYBACK CONVERTERS DESIGN METHODOLOGY WITH THE L6590 FAMILY

STMicroelectronics 

AN1262 APPLICATION NOTE

(that is a larger input capacitor) is of help. Some iterations, involving a recheck of the points mentioned in "Pre-

liminary Calculations - step 2", may be necessary.

If no solution can be found, either some specification should be relaxed or the power handled by the converter

should be derated.

9 FLYBACK TRANSFORMER DESIGN

To complete the set of data needed to design the flyback transformer, the primary inductance value (Lp) and the

primary-to-secondary turns ratio (n) are still to be defined.

The primary inductance will be chosen so that the converter is operated on the boundary between DCM and

CCM at Vin = Vinmin:

Lp= [---(--V-----i-n---m----i--n-2---–--⋅--V-f--s--D-w--S---⋅-(--Po---n-i--n)--xT---)--)---⋅---D-----X---]---2-

(4)

while the primary-to-secondary turns ratio is defined so as to get the desired reflected voltage VR:

n = V-----o---u-V--t--R+-----V-----F-

(5)

With the complete set of specification, the transformer design can start with the selection of the magnetic core

material and geometry.

Table 9. Ferrite Materials selection

Grade

Saturation flux density

[T]

Specific Power Losses @100 °C [W/cm3]

B2

0.36

PFe = 1.15 ⋅ 10–5 ⋅ ∆B2.26 ⋅ fs1.w11

3C85

0.33

PFe = 1.54 ⋅ 10–7 ⋅ ∆B2.62 ⋅ fs1.w54

N67

0.38

PFe = 8.53 ⋅ 10–7 ⋅ ∆B2.54 ⋅ fs1.w36

PC30

0.39

PFe = 1.59 ⋅ 10–6 ⋅ ∆B2.58 ⋅ fs1.w32

F44

0.4

PFe = 2.39 ⋅ 10–6 ⋅ ∆B2.23 ⋅ fs1.w26

Manufacturer

THOMSON

PHILIPS

EPCOS (ex S+M)

TDK

MMG

As to the magnetic material, a standard soft ferrite for power applications (gapped core-set with bobbin) is the

usual choice: the switching frequency is not so high thus special grades for high frequency operation are not

required. Table 9 shows some suitable materials.

The geometry will be usually a popular E or E-derived type. Other configurations, such as RM or PQ cores, are not

recommended because they are inherently high leakage geometries, since they result in narrower and thicker wind-

ings. Consider that minimizing leakage inductance is one of the major tasks in the design of a flyback transformer.

Among the various shapes and styles offered by manufacturers the most suitable one will be selected with technical

and economic considerations. Table 10 shows some possible choices with the relevant data useful for the design.

The next quantity to be defined is the peak flux density Bmax which the transformer will be operated at. Being

this a DCM design, Bmax will also equal the maximum flux density swing ∆Bmax.

10/42

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