A ZVS Flyback DC-DC Converter using Multilayered Coreless Printed-Circuit Board(PCB) Step-down Power Transformer

The experimental and theoretical results of a ZVS (Zero Voltage Switching) isolated flyback DC-DC converter using multilayered coreless PCB step down 2:1 transformer are presented. The performance characteristics of the transformer are shown which are useful for the parameters extraction. The measured energy efficiency of the transformer is found to be more than 94% with the sinusoidal input voltage excitation. The designed flyback converter has been tested successfully upto the output power level of 10W, with a switching frequency in the range of 2.7MHz-4.3MHz. The input voltage of the converter is varied from 25V-40V DC. Frequency modulation technique is employed by maintaining constant off time to regulate the output voltage of the converter. The energy efficiency of the isolated flyback converter circuit under ZVS condition in the MHz frequency region is found to be approximately in the range of 72-84%. This paper gives the comparative results in terms of the energy efficiency of the hard switched and soft switched flyback converter in the MHz frequency region. Keywords—Coreless PCB step down transformer, DC-DC converter, Flyback, Hard Switched Converter, MHz frequency region, Multilayered PCB transformer, Zero Voltage Switching