The need for reliable and efficient power conversion in all sorts of electronic systems is growing, especially in an expanding variety of applications that must meet low power specifications. To help designers meet these requirements, Bourns has extensive magnetics component customization capabilities that includes flyback transformer technology. The flyback topology is growing in popularity because of its ability to help satisfy compact and cost-effective power supply design goals. This blog post explores how flyback technology can enhance various applications, from LED lighting systems to battery chargers and beyond.

Understanding Flyback Technology

Flyback technology is pivotal for applications requiring voltage and current conversion through an isolated magnetics component. Unlike traditional transformers that focus solely on energy transfer, flyback transformers excel in energy storage and transfer, making them ideal for isolated step-up operations. This dual capability allows for efficient power management in compact spaces.

Key Mechanisms of Flyback Transformers

A flyback transformer functions by storing energy in the primary winding when the switch is ON. Once the switch is turned OFF, this stored energy is transferred to the secondary winding and discharged to the output, providing a controlled and efficient energy supply. This operation not only conserves space, but also enhances the safety and efficiency of the power supply system.

Challenges and Solutions in Magnetic Design

Designing flyback transformers involves addressing several magnetics challenges to maintain signal integrity and minimize parasitic effects. These challenges include managing the distributed capacitance and leakage inductance, which can affect the waveform’s integrity as the power signal passes through the transformer.

Enhancing Signal Integrity

Signal integrity in flyback circuits is critical. The ideal output is a well-defined square wave, but real-world factors such as leakage inductance and interwinding capacitance can alter this. In their custom magnetics designs, Bourns engineers focus on optimizing the placement and winding tightness to reduce leakage and improve the transient response. This design emphasis is crucial for maintaining the quality of the electrical signal.

Balancing Parasitic Components and EMI

The ability to reduce electromagnetic interference (EMI) is a significant consideration in transformer design. Bourns custom flyback transformers are engineered to balance leakage inductance with interwinding capacitance to mitigate EMI effects. This careful balancing ensures that the transformers operate efficiently without compromising the overall system’s performance.

Practical Applications of Flyback Transformers

Flyback transformers are versatile power conversion solutions, which are ideal for applications in several areas:

• LED Lighting Systems: They provide efficient power supply isolation.
• Battery Chargers: They help ensure safe and controlled charging cycles.
• Telecom Systems: They offer reliable power conversion in communication infrastructure equipment.

Conclusion

Bourns® custom flyback transformers enable designers to address the complexities of low-power conversion challenges. With their ability to handle intricate power management tasks efficiently, these transformers are essential for developers looking to enhance the safety, reliability and efficiency of their applications. Whether it’s upgrading an existing system or designing a new one, Bourns’ magnetics custom expertise provides the technology and purpose-built components to meet the industry’s evolving needs.

For a more detailed explanation of Bourns® flyback transformers and the design benefits they provide, please see our Using Flyback Technology for Low Power Conversion Drivers application note.  In it, you will also learn about the magnetics design challenges for this type of transformer along with a comparison of flyback to push-pull operation in regard to isolation and safety performance.