Transformer design for low cost battery chargers

Battery chargers for the consumer market must be precise in function and reliable in operation at a reasonable manufacturing cost. A major item within a charger is a transformer. A 60 Hz transformer design methodology which can be used to develop world class devices at modest cost is presented. Specific evaluation techniques include matching application specific bobbins with standard EI and EE laminations, achieving volumetric balance between primary and secondary windings as well as the core, and producing designs that favor automated manufacturing equipment. Safety and cost issues are reviewed