The flyback transformer internally functions a little different than most true transformers. This transformer temporarily stores energy that it gets from the input voltage and current. In this respect, flyback transformers are a multi-winding coupled inductor. The energy from the inputs is stored in a magnetic field to be released to the outputs at a slightly later time. The flyback transformer utilizes a “kickback” action to transform the inputs to a needed output voltage and current.

Today most flybacks operate at frequencies from 20KHz to 100KHz. At these frequencies ferrite cores seem to be the core of choice for flyback transformers, especially when the flyback transformer is operating in a discontinuous mode. Ferrite cores are easily custom gapped for each application and come in many different geometries. Transformers of different wattages can use ferrite cores from really small geometries like E16 and P11 Potcores up to very large U64 and U9316 cores. Due to their high voltage nature, most of the flyback transformers built at Custom Coils are encapsulated. We use several different types of epoxy compounds and silicone based compounds to isolate and protect the high voltage windings of our transformers.

A flyback transformer is very flexible and can be run in different modes and used in different applications.  Flybacks are used in a wide variety of industries such as telecommunications, biomedical, and aerospace. In these industries they make up a portion of the communication and power application transformers. Other types of flyback transformer applications include but are not limited to switching power supplies, converters and inverters.

A flyback transformer also lends itself to designs that require high switching frequencies often up to 500MHz. Other types of switch mode transformers are the preferred choice for lower frequency applications. Some of these applications include RFI filters, switching regulators, and low power isolation power supplies.

The flyback transformer is ideal for use in DC/DC converters for industrial controls and all types of test equipment. They work great in various modes such as continuous or discontinuous modes.  The unlimited number of applications continuously challenges us to come up with creative custom designs that can be economically manufactured and tested.