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Buck converter and Fly-Buck converter design tips
Date:July 4, 2025    Views:4

    Synchronous buck converters have been recognized as isolated bias power supplies in the communications and industrial markets. Isolated buck converters, or Fly-Buck converters as they are commonly called, use a coupled inductor instead of a buck converter inductor to create isolated as well as non-isolated buck outputs. Each isolated output requires only one winding, one rectifier diode and one output capacitor. This topology can be used to generate multiple semi-regulated isolated or non-isolated outputs in a simple and low-cost manner.
    There are some major current differences between buck converters and Fly-Buck converters. We are already familiar with the switching current loop in buck converters, as shown in Figure 1. An input loop containing input bypass capacitors, VIN pins, high-low side switches, and ground return pins carries the switching current. The loop should be optimized for quiet operation to achieve a minimum trace length and a minimum loop area. The output loop containing the low-side switches, inductors, output capacitors, and ground return path actually carries the low-ripple DC current. While it is important to keep all current paths as short as possible to achieve low DC voltage drops, low losses, and low voltage regulation errors, the area of this loop is not as important as the input current loop.


Figure 1. Current loop in buck converter. The VIN loop is a high di/dt loop.
    The primary side of a Fly-Buck converter looks similar to a buck converter, as shown in Figure 2. The VIN loop here, like the buck converter, is also a high di/dt loop. However, the current of the VOUT1 loop is very different from that of the buck converter. In addition to the primary inductor magnetizing current, the loop also contains reflected current from the secondary winding. The reflected current contains only the leakage inductance of the coupled inductor in its path, so the di/dt is significantly higher than the magnetizing current of the inductor. Therefore, it is also very important to minimize the loop area of VOUT1 loop. In the same way, the secondary output loop containing the secondary inductor winding, the rectifier diode, and the secondary output capacitor also needs to be minimized because of the high di/dt current flowing through it.



Figure 2. The Fly-Buck converter has two high di/dt loops on the primary side. All secondary loops are high di/dt.
    Another thing to keep in mind when laying out Fly-Buck converters is that the secondary winding also has a switching node. The secondary switching node (SW2) is a high dv/dt node that supports VIN*N2/N1 voltage conversion. Therefore, it is usually necessary to keep the SW2 trace area small to prevent it from emitting noise.
    Figure 3 is an example of a layout that incorporates the guidance in this article. Like the switching node area, the high di/dt loops on the primary and secondary sides can also be minimized.


FIG. 3. The Fly-Buck layout based on LM5017 minimizes the area of di/dt loops and high di/dt SW1,2 nodes.




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