Single-Stage Single-Switch curved air gap PFC integrated flyback transformer design

This paper introduces a novel design for a power factor correction (PFC) integrated flyback transformer, which aims to enhance line harmonic current and common-mode noise reduction. The design includes two stages, a PFC stage with two boost inductors and a flyback stage utilizing a flyback transformer. The integrated flyback transformer has a curved air gap solution to prevent core saturation and enhance transformer efficiency. The study presents simulation and experimental results obtained from a prototype circuit of 270W (32.5V/8A) with 4 ferrite materials (3C92,3F35, 3F45 and 4F1).