{
  "schema": "gallery_item_v1",
  "id": "flyback-60w-consumer",
  "title": "Flyback · 60 W · Consumer AC-DC",
  "topology": "flyback",
  "blurb": "Universal 90–264 V AC → 12 V / 5 A DCM flyback, TIW-isolated for IEC 62368-1.",
  "spec": {
    "topology": "flyback",
    "p_out_w": 60,
    "v_in_min": 90,
    "v_in_max": 264,
    "v_out": 12,
    "i_out_max": 5.0,
    "fsw_hz": 65000,
    "delta_t_max_c": 40,
    "isolation_v": 3000,
    "ambient_c": 25,
    "lifetime_years": 7,
    "application": "consumer",
    "rohs": true,
    "notes": "USB-PD 60W universal-input adapter"
  },
  "design": {
    "spec": {
      "topology": "flyback",
      "p_out_w": 60.0,
      "v_in_min": 90.0,
      "v_in_max": 264.0,
      "v_out": 12.0,
      "i_out_max": 5.0,
      "fsw_hz": 65000.0,
      "delta_t_max_c": 40.0,
      "isolation_v": 3000.0,
      "ambient_c": 25.0,
      "lifetime_years": 7.0,
      "application": "consumer",
      "rohs": true,
      "notes": "USB-PD 60W universal-input adapter"
    },
    "core": {
      "pn": "RM_RM8-TDK_PC95",
      "vendor": "TDK",
      "material": "PC95",
      "shape": "RM",
      "ae_mm2": 64.0,
      "ve_mm3": 1810.0,
      "le_mm": 28.3,
      "aw_mm2": 26.0,
      "al_nh": 5158.0,
      "bsat_t_mt": {
        "25": 530.0,
        "60": 470.0,
        "100": 410.0,
        "120": 381.0
      },
      "pcv_steinmetz": {
        "k": 5.118289792176818e-08,
        "alpha": 1.42,
        "beta": 2.88,
        "t_ref_c": 100
      },
      "mu_i": 3300.0,
      "f_max_hz": 500000.0,
      "price_usd": 0.9,
      "rohs": true
    },
    "n_pri": 33,
    "n_sec": 6,
    "wire_pri": {
      "pn": "AWG30_PEI200",
      "vendor": "Elektrisola",
      "type": "solid",
      "awg": 30,
      "bare_d_mm": 0.2546,
      "od_mm": 0.2946,
      "insulation": "polyimide",
      "class_c": 200,
      "breakdown_v": 3600.0,
      "litz_n": 1,
      "litz_strand_d_mm": 0.0,
      "price_usd_per_m": 0.122
    },
    "wire_sec": {
      "pn": "AWG22_PEI200",
      "vendor": "Elektrisola",
      "type": "solid",
      "awg": 22,
      "bare_d_mm": 0.6438,
      "od_mm": 0.7038,
      "insulation": "polyimide",
      "class_c": 200,
      "breakdown_v": 4240.0,
      "litz_n": 1,
      "litz_strand_d_mm": 0.0,
      "price_usd_per_m": 0.671
    },
    "n_par_pri": 7,
    "n_par_sec": 7,
    "fringing_factor": 1.206,
    "air_gap_mm": 0.571,
    "b_peak_t": 0.3,
    "b_peak_safe": true,
    "pcv_w": 0.535,
    "pcu_w": 0.302,
    "p_total_w": 0.864,
    "eta_est": 0.9858,
    "delta_t_c": 18.3,
    "hotspot_c": 43.3,
    "lk_uh": 9.25,
    "lm_uh": 185.1,
    "cps_pf": 4.7,
    "mtbf_h": 1044067660.0,
    "pdiv_v": 558.0,
    "pdiv_margin_ok": true,
    "fill_factor": 1.234,
    "bom": [
      {
        "item": "Core",
        "pn": "RM_RM8-TDK_PC95",
        "vendor": "TDK",
        "qty": 1,
        "price_usd": 0.9,
        "alternatives": []
      },
      {
        "item": "Wire-PRI",
        "pn": "AWG30_PEI200",
        "vendor": "Elektrisola",
        "length_m": 7.74,
        "price_usd_per_m": 0.122
      },
      {
        "item": "Wire-SEC",
        "pn": "AWG22_PEI200",
        "vendor": "Elektrisola",
        "length_m": 1.41,
        "price_usd_per_m": 0.671
      },
      {
        "item": "Bobbin",
        "pn": "BOB-RM-PBT",
        "vendor": "Pretak",
        "qty": 1,
        "price_usd": 0.6
      },
      {
        "item": "Tape",
        "pn": "3M-1350F",
        "vendor": "3M",
        "length_m": 0.5,
        "price_usd_per_m": 0.2
      },
      {
        "item": "Air-gap shim",
        "pn": "SHIM-0.57mm",
        "vendor": "internal",
        "qty": 1,
        "price_usd": 0.1
      }
    ],
    "warnings": [
      "Using 7 parallel strands of AWG30_PEI200 for I_rms=1.3A.",
      "Using 7 parallel strands of AWG22_PEI200 for I_rms=7.9A.",
      "Solid AWG22_PEI200 d=0.64mm > 2δ=0.58mm; AC loss high.",
      "Loss breakdown: Pcv=0.54W (iGSE asym-tri), Pcu=0.30W, Extras=0.03W",
      "Window overfilled: used_Ku=1.23 > target=0.30 (manual)",
      "§17 Window overfilled (effective): used_Ku=3.47 > target=0.40 (round_wire_manual, eff_area=9mm² of core.aw=26mm² — 64% lost to bobbin/margin/pins).",
      "§11.7 Thermal cycling dominates: ΔT=18.3°C/cycle. Reduce ΔT via better thermal management or pick more compliant potting."
    ],
    "citations": [
      "McLyman, T&I Design Handbook Ch.16 (Flyback)",
      "Self-study_Hoang.docx §2 Practices — Flyback",
      "Gemini_Claude.md §99.5"
    ],
    "trust_score": 59.5,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 20.0,
      "reference_benchmark": 7.5,
      "datasheet_match": 12.0,
      "lab_measurement": 0.0
    },
    "trust_grade": "B",
    "reliability_matrix": {
      "Lm_pct": 10.0,
      "Lk_pct": 20.0,
      "Pcv_in_range_pct": 25.0,
      "Pcv_dc_bias_pct": 50.0,
      "Rac_near_gap_pct": 50.0,
      "T_hotspot_C": 5.0,
      "EMI_Cps_pct": null,
      "PDIV_margin_pct": null,
      "lifetime_factor": 3.0
    },
    "not_valid_for": [
      "UL 1446 insulation system certification",
      "IEC 61558 / 62368 transformer certification",
      "AEC-Q200 automotive component qualification",
      "CISPR 22/32 EMI compliance claim",
      "Lifetime claim > 5 years without HALT calibration"
    ],
    "uncertainty_envelope": {
      "Lm_uH": {
        "value": 185.1,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 148.08,
        "ci_high_2sigma": 222.12,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 9.25,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 5.55,
        "ci_high_2sigma": 12.95,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 0.535,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 0.2675,
        "ci_high_2sigma": 0.8025,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 0.302,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 0.604,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 43.3,
        "uncertainty_pct": 11.55,
        "ci_low_2sigma": 33.3,
        "ci_high_2sigma": 53.3,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 558.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 279.0,
        "ci_high_2sigma": 837.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 4.7,
        "uncertainty_pct": 531.91,
        "ci_low_2sigma": -45.3,
        "ci_high_2sigma": 54.7,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 1044067660.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 981423600.4,
        "ci_high_2sigma": 1106711719.6,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 300,
        "mean": 5740.353,
        "stdev": 848.1904,
        "p5": 4360.5126,
        "p50": 5746.0165,
        "p95": 6963.9912,
        "cpk_lower": 2.19,
        "cpk_upper": -2.176
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 300,
        "mean": 0.5386,
        "stdev": 0.0522,
        "p5": 0.4541,
        "p50": 0.5354,
        "p95": 0.6314,
        "cpk_lower": 0.876,
        "cpk_upper": 0.831
      },
      "eta": {
        "metric": "eta",
        "n_samples": 300,
        "mean": 0.9857,
        "stdev": 0.0008,
        "p5": 0.9842,
        "p50": 0.9858,
        "p95": 0.9871,
        "cpk_lower": 3.865,
        "cpk_upper": 3.906
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 300,
        "mean": 43.2402,
        "stdev": 2.9363,
        "p5": 38.729,
        "p50": 43.2305,
        "p95": 47.8106,
        "cpk_lower": 0.485,
        "cpk_upper": 0.498
      },
      "preset": {
        "al_nh_pct": 25.0,
        "gap_mm_abs": 0.05,
        "b_pk_pct": 5.0,
        "steinmetz_k_pct": 10.0
      }
    },
    "llc_tank": {},
    "inrush": {},
    "advanced_analysis": {
      "bertotti": {
        "P_hysteresis_W_per_m3": 2.3673,
        "P_classical_eddy_W_per_m3": 0.0015,
        "P_excess_W_per_m3": 0.2723,
        "P_total_W_per_m3": 2.6411,
        "fraction_h": 0.8963,
        "fraction_c": 0.0006,
        "fraction_a": 0.1031,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 130000.0,
        "in_audible_band": false,
        "spl_db_estimate": 35.3,
        "lambda_s_ppm": -1.5
      },
      "aging": {
        "L_total_h": 50412.0,
        "L_total_y": 5.8,
        "dominant": "coffin_manson",
        "L_thermal_h": 230760375.0,
        "L_eyring_h": 287969.0,
        "L_coffin_manson_h": 61147.0,
        "L_ipl_h": 177951937.0
      },
      "paschen": {
        "v_breakdown": 12594.0,
        "altitude_derating": 1.0,
        "safe": true
      },
      "humidity": {
        "moisture_uptake_pct": 0.118,
        "pdiv_derate_pct": 0.6,
        "aging_factor": 1.006,
        "safe": true
      },
      "reference_benchmark": {
        "ref_id": "hurley_wolfle_flyback_50w",
        "passed": false,
        "checks": {
          "n_pri_range": {
            "value": 33,
            "min": 40,
            "max": 120,
            "passed": false
          },
          "n_sec_range": {
            "value": 6,
            "min": 4,
            "max": 14,
            "passed": true
          },
          "lm_uh_range": {
            "value": 185.1,
            "min": 400,
            "max": 1500,
            "passed": false
          },
          "eta": {
            "value": 0.9858,
            "min": 0.86,
            "max": 0.94,
            "passed": false
          },
          "p_total_w": {
            "value": 0.864,
            "max": 4.5,
            "passed": true
          },
          "core_shape": {
            "value": "RM",
            "allowed": [
              "EE",
              "EFD",
              "RM",
              "PQ"
            ],
            "passed": true
          }
        },
        "source": "Hurley & Wölfle, Ch.7 Flyback example, DCM design"
      }
    },
    "window_breakdown": {
      "core_window_mm2": 26.0,
      "after_walls_mm2": 38.52,
      "after_margin_mm2": 11.56,
      "after_pin_leadout_mm2": 9.25,
      "deduction_pct": 64.4,
      "wall_loss_mm2": -12.52,
      "margin_loss_mm2": 69.0,
      "margin_note": "margin tape 6.0mm × height=11.5mm",
      "pin_loss_mm2": 1.16,
      "leadout_loss_mm2": 0.58,
      "interleave_loss_mm2": 0.58,
      "bobbin_pn": "TDK_RM10_8pin",
      "ku_target": 0.4,
      "ku_key": "round_wire_manual",
      "used_ku": 3.47,
      "a_winding_mm2": 32.09
    },
    "bobbin_pn": "TDK_RM10_8pin",
    "material_score": {
      "loss": 56.2,
      "saturation": 86.2,
      "freq_fit": 100.0,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 80.0,
      "cost": 100.0,
      "availability": 100.0,
      "ap_fit": 67.1,
      "thermal": 100.0,
      "total": 88.6,
      "rationale": [
        "Pcv≈262 mW/cm³ at design point",
        "Bsat margin=36% at 43°C",
        "fsw/f_res=0.03 (f_res≈2424kHz)",
        "no DC bias requirement",
        "f_acoustic=130000Hz outside audible",
        "consumer-class accepts most materials",
        "$0.90/qty1k",
        "7 cross-vendor equivalents — supply resilient",
        "Ap ratio 3.29 much oversized",
        "Ve=1810mm³ for 60W (ratio=3.77)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "RM_RM8-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 64.0,
        "ve_mm3": 1810.0,
        "score_total": 88.6,
        "score_breakdown": {
          "loss": 56.2,
          "saturation": 86.2,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 80.0,
          "cost": 100.0,
          "availability": 100.0,
          "ap_fit": 67.1,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈262 mW/cm³ at design point",
          "Bsat margin=36% at 43°C",
          "fsw/f_res=0.03 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=130000Hz outside audible",
          "consumer-class accepts most materials",
          "$0.90/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap ratio 3.29 much oversized",
          "Ve=1810mm³ for 60W (ratio=3.77)"
        ]
      },
      {
        "pn": "RM_RM6-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 31.4,
        "ve_mm3": 540.0,
        "score_total": 85.4,
        "score_breakdown": {
          "loss": 56.2,
          "saturation": 86.2,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 80.0,
          "cost": 100.0,
          "availability": 100.0,
          "ap_fit": 43.4,
          "thermal": 85.0
        },
        "rationale": [
          "Pcv≈262 mW/cm³ at design point",
          "Bsat margin=36% at 43°C",
          "fsw/f_res=0.03 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=130000Hz outside audible",
          "consumer-class accepts most materials",
          "$0.48/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap < required (will overfill)",
          "Ve=540mm³ for 60W (ratio=1.12)"
        ]
      },
      {
        "pn": "RM_RM10-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 96.6,
        "ve_mm3": 4310.0,
        "score_total": 82.0,
        "score_breakdown": {
          "loss": 56.2,
          "saturation": 86.2,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 80.0,
          "cost": 93.8,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈262 mW/cm³ at design point",
          "Bsat margin=36% at 43°C",
          "fsw/f_res=0.03 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=130000Hz outside audible",
          "consumer-class accepts most materials",
          "$1.62/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap ratio 8.97 much oversized",
          "Ve=4310mm³ for 60W (ratio=8.98)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 98.58,
    "trust_grade": "B",
    "trust_score": 59.5,
    "core_pn": "RM_RM8-TDK_PC95",
    "bobbin_pn": "TDK_RM10_8pin",
    "n_pri": 33,
    "n_sec": 6,
    "air_gap_mm": 0.571,
    "p_total_w": 0.86,
    "hotspot_c": 43.3,
    "b_peak_t": 0.3
  },
  "screenshot_path": "/marketing/gallery/flyback-60w-consumer.png",
  "deep_link": "/calculator?gallery=flyback-60w-consumer",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}