I'm designing a DCM flyback converter for the first time and I've encountered a problem where the RMS current through the output capacitors reaches 5.6A. I started looking for suitable capacitors, and found capacitor UPW1V152MHD6 - 35V, low ESR, 1.5mF, maximum RMS 2.51A. To cover the RMS current with a margin, I need to put them 3pcs in parallel. However, this means an output capacitance of 4.5mF which seems extremely high to me, I've never seen a flyback with such an output capacitance. I couldn't find any electrolytic capacitors with the same RMS current but lower capacitance (tme.eu). I found a reference design of a similar power supply, but the manufacturer put a 35V, low ESR, 470uF, maximum RMS 1.5A capacitor on the output.
Power supply parameters:
Input: 190-260 VAC 50 Hz
Output: 24V, 3A, 72W
Fsw 65kHz, DCM, ETD39 with 0.4mm air gap, Primary turns 58, Secondary turns 6, Ipk primary 1.42A, Dmax 0.5
I calculated that the peak current on the primary side should reach 1.42A. Using the formula Ipks = Ipkp * (Np/Ns) I calculated the peak current on the secondary side to be 13.72A. Using the formula Irms = Ipk*SQRT(Dmax/3) I calculated the RMS current on the output to be 5.6A. I verified this with a simulation, which shows that my calculations should be correct, except for the RMS current through the capacitors, which is only 4.47A RMS and not 5.6A RMS.
Where could the error be? Are my calculations correct? Did the designer of the reference design make a mistake by using a capacitor with a maximum RMS current of 1.5A? Or am I missing something?
Additional question, why is the capacitor according to the simulation stressed only with 4.47A RMS and not 5.6A RMS?
Thank you very much :)
(Sorry for any mistakes, my English isn't great)