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Advancements in a Low Input Voltage Monolithic Ceramic Flyback Transformer for High Voltage Output Applications
Keywords: Ceramic, Flyback, Transformer
This presentation will present progress on development of very low voltage input flyback transformers targeted to generate in excess of 800 Volts output from an under 3 Volt input using miniature monolithic ceramic flyback transformers a fraction of the volumetric size of their wire-wound counterparts. Flyback voltage converters are used in a wide variety of applications, including important medical devices, to convert a low voltage to a high voltage with galvanic isolation between the input and any outputs. Traditionally, wire-wound transformers are used for this purpose and have been available for decades. A new multi-layer ferrite technology has been invented that has drastically reduced the size of these flyback transformers by using a multi-layer ferrite tape based approach to construct a monolithic ceramic flyback transformer structure with thick film printed windings and energy storage materials within the sintered multi-layer structure allowing the ferrite to become the transformer core and package all in one integrated unit but in a drastically smaller volumetric size. Volume reductions down to 1/3 to 1/4 of the wire-wound package size have been realized in these new multi-layer ceramic flyback transformer designs. First, a description of a generic flyback converter operation will be discussed. From this, important circuit design considerations for extreme low voltage to high voltage conversion will be presented. Next, a description of the construction and geometry of these new multi-layer ferrite ceramic transformers will be briefly summarized in comparison to traditional wire-wound transformer technology. Finally, actual test data from recent multi-layer ferrite ceramic flyback transformers used in a representative low voltage input medical flyback circuit will be presented, including actual data generated from an existing prototype ceramic transformer circuit that generates 800 Volts output from a 2 Volt input with galvanic isolation. Performance data such as peak input current, frequency of operation, and output charge time to meet the required output voltage level will be presented.
Daryl Schofield, VP/GM
NASCENTechnology Manufacturing, Inc.
Watertown, SD

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