I took a DIY approach using a regular boost converter and adding my flyback pulse sensing circuit. The flyback pulse is rectified across C2. Q1 is a current source that is used to translate the voltage to the feedback pin across resistor R2 thus regulating the voltage across C2. The current source is also a dummy to keep the boost converter running.
D1, C2 and R3 looks similar to the snubber used in a typical flyback converter and also functions as one.
I noticed negative high voltage spikes during startup in LTSpice simulation. These spikes goes away as the secondary side load increases as voltage ramps up.
I use a clamping diode on the switch pin to ground. The BAV99 diode comes with a second diode and is used for that purpose in my design.
The output has a PI filter consists of a small ceramic capacitor, a ferrite bead and a bulk tantalum capacitor. At1.2MHz switching frequency, the ferrite does a good job of filtering out these ripples.
Green trace: voltage across ceramic capacitor before the ferrite bead Red trace: voltage across tantalum capacitor after the ferrite bead |
This circuit isolation is limited by the PCB spacing as well as the enamel on the magnetic wires between the primary and secondary side. Here is the layout on a 0.8" x 0.815" (20.3mm x 20.7mm) single sided PCB.
No load voltage: 7.45V. Full load (40 ohms) voltage: 6.51V +/- 0.01V between input voltage of 12V to 18V. The wall wart that this module is replacing has a no load voltage 7.8V and 6.74V at 40 ohms load.
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