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    Single-Phase and Three-Phase Input

    D01.7 - Miniaturized Primary-Side Regulated Active Clamp Flyback Converter with Custom IC and Integrated Transformer for High Power Density Applications

    Thursday, March 26, 2026
    12:00 PM - 1:45 PM CT
    Location: Poster 1
    This paper presents a highly compact primary-side regulated (PSR) active clamp flyback (ACF) converter enabled by a custom integrated (IC) controller. The design addresses challenges associated with high-frequency operation, including transformer parasitic capacitances and precise dead-time control for zero-voltage switching (ZVS). A custom IC integrating adaptive frequency modulation, on-chip ZVS detection via the auxiliary winding, and programmable dead-time compensation reduces the need for bulky external components. The transformer is optimized for low parasitic capacitance while maintaining adequate leakage inductance for resonant transitions. Experimental results on a 5 V/5 W prototype confirm reliable ZVS across a wide input voltage range (85–265 VAC), achieving a power density of 16.23 W/in³ and a peak efficiency of 77.1%. Thermal and waveform measurements validate the effectiveness of the co-designed transformer and IC, demonstrating the proposed solution's suitability for space-constrained, next-generation AC-DC power applications.