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7/99
AN-23
9
 Calculate secondary number of turns N
S
:
N
N
V
V
V
S
P
O
D
OR
=
×
+
(
)
 Calculate gap length (L
).  Gap length should be larger than
0.1 mm to ensure manufacturability.
L
A
N
L
A
g
e
P
×
P
L
=
×
×
40
1000
1
2
π
 Please refer to Power Integrations Web site
www.powerint.com
for audio noise suppression techniques
applicable to transformer design.
Step 19A, B. Calculate primary RMS current I
and secondary RMS current I
RMS
SRMS
.
 Discontinuous mode:
- Calculate primary RMS current I
RMS
I
D
I
RMS
MAX
P
′
2
3
=
×
where I
’
P
 equals to maximum I
LIMIT
- Calculate secondary RMS current I
SRMS
I
I
D
K
SRMS
SP
MAX
DP
=
×
×
3
1
where 
I
I
N
N
SP
P
S
= ′ ×
and I
’
P
 equals to maximum I
LIMIT
 Continuous mode:
- Calculate primary RMS current I
RMS
I
I
D
K
K
RMS
MAX
RP
3
RP
= ′ ×
×
+
2
1
where I
’
P
 equals to maximum I
LIMIT
- Calculate secondary RMS current I
SRMS
I
I
D
K
K
SRMS
SP
MAX
RP
3
RP
=
×
(
)
×
+
1
1
2
where 
I
I
N
N
SP
P
S
= ′ ×
and I
’
 equals to maximum I
LIMIT
 Choose wire gauge for primary and secondary windings
based on I
 and I
.
 In some designs, a lower guage (larger diameter) wire may
be necessary to maintain transformer temperature within
acceptable limits during continuous short circuit conditions.
 Do not use wire thinner than 36 AWG to prevent excessive
winding capacitance and to improve manufacturability.
Step 20.
Determine output short circuit current I
OS
.
 Calculate maximum output short circuit current I
 from I
’
and N
/N
, where I
’
data sheet and N
P
/N
S
 is the turns ratio from Step 18:
P
P
 is the maximum I
from 
TinySwitch
I
I
N
N
k
OS
P
S
= ′ ×
×
where k is the peak to RMS current conversion factor
 The value of k is determined based on empirical
measurements: k
= 0.9 for Schottky diode and k
= 0.8 for PN
junction diode.
 Check I
 against diode DC current rating I
D.
 If necessary,
choose higher current diode (see Table 3).
Step 21.
Determine Output Capacitor C
OUT
.
 Calculate output ripple current:
I
I
I
RIPPLE
SRMS
O
=
2
2
 Choose output capacitor with RMS current rating equal to or
larger than output ripple current.
 Use low ESR electrolytic capacitor rated for switching
power supply use.
 Examples are LXF series from UCC, PL series from Nichicon,
and HFQ series from Panasonic.