
July 1996
TOPSwitch
Flyback
Transformer Construction
Guide
Application Note AN-18
Introduction
This application note is a design and construction guide for
margin wound or triple insulated wire wound flyback
transformers suitable for use with
TOPSwitch
. Margin wound
and triple insulated wire transformer designs are derived in
Appendix B for a 12 V, 15 W universal input power supply with
secondary regulation, using the step-by-step procedure
developed in application note AN-16. It is assumed that the
reader is already familiar with
TOPSwitch
and the fundamental
principles of flyback power supplies. This information can be
found in the
TOPSwitch
data sheets, and application notes
AN-14 and AN-16. More details on flyback transformer theory
and design can be found in AN-17.
Required Reference Materials:
This application note, AN-16, and AN-17 provide the necessary
techniques for design and construction of flyback transformers
for
TOPSwitch
applications. In addition, the following reference
materials are required to provide dimensional and electrical
data for cores, bobbins, and wire. Sources for these reference
materials are listed in Appendix A.
Ferrite Core Manufacturer’s Catalogs
Ferrite core manufacturers publish catalogs supplying core
dimensions and electrical characteristics used in transformer
design. Some manufacturers also provide additional engineering
information for the more popular core sizes, such as A
vs. gap
and core loss curves. The catalogs for the manufacturers listed
in Appendix A supply basic electrical data for common US,
Asian, and European core types. For core sizes common to
several manufacturers, the electrical characteristics given by
one core manufacturer can be used for a core of the same
physical dimensions from another manufacturer.
Bobbin Manufacturer’s Catalogs
Bobbin manufacturer's catalogs are used to provide mechanical
dimensions for transformer design. The bobbin manufacturers
in Appendix A offer a wide variety of bobbin styles for standard
ferrite core sizes in materials suitable for high volume production.
Many ferrite core manufacturers also carry bobbins for their
standard core sizes.
PI-1907-061896
PRIMARY
SECONDARY
BIAS
Figure 1. Typical Flyback Transformer Using EE Core.