Design and Implementation of an Air-Cored Fly-back Converter

This paper proposes a miniaturized, light weight design of a fly-back converter based on air cored transformer, suitable for various consumer electronics applications. A method to achieve higher coupling factor in the air-core transformer is also proposed and analyzed. Simulation of the air-core transformer is carried out using ANSYS MAXWELL tool and the design is validated using FEA analysis. A coupling factor of 0.923 between primary and secondary winding of the air-cored transformer is achieved using the proposed method. A fly-back converter is implemented using the air-core transformer and the experimental prototype of the converter is realized using a four layer PCB. Steady state operation of the converter with a switching frequency of 1 MHz is verified using the experimental prototype.