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VIN=180-240VDC (out of interest what is this from?)
VOUT=12V
IOUT=10A
FSW=100KHZ
DCM or CCM, see whats best
Isolation ..not full mains isolation
Prefer single switch flyback
less than 5W of loss in the RCD clamp.
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BJTpower I take it the above is your spec?
If so I will have a look whilst im doing the laundry if you can confirm the above……we need to look through all core sets and find which are pre-gapped and work with those….getting cores grinded is too expensive, and polyester film gapping is too hit and miss
Please confirm your spec
(by the way, as you know, my earlier excel sheet, in post #25, was just for the parameters BJTpower gave, and wasn't me trying to do ccm or dcm, it came out ccm with the high LP , as Easy Peasy noted, but that was just from the parameters that bjtpower gave. I appreciate it wasn't DCM, but at that stage, there was no stipulation that it had to be dcm, it was just a case of wapping BJTpower's parameter's in and showing BJTpower how it came out)
Let us please ask OP what the real requirements are and get it cracked. Can you please confirm?