For the purpose of designing an intrinsic safety Flyback converter with minimal output voltage ripple based on a specified output current, this paper first classified the energy transmission modes of the system into three sorts, namely, the Complete Inductor Supply Mode-CCM (CISM-CCM), the Incomplete Inductor Supply Mode-CCM (IISM-CCM) and the Incomplete Inductor Supply Mode-DCM (IISM-DCM). Then, the critical secondary self-inductance assorting the three modes are deduced and expressions of the output voltage ripples (OVR) are presented. For a Flyback converter with constant loads and switching frequency, it is shown that the output voltage ripple in the CISM-CCM is the smallest and that it has no relationship with the secondary self-inductance. Otherwise, the OVR of the other two modes are bigger than the previously mentioned one. It is concluded that the critical inductance between the CISM-CCM and the IISM-CCM is the minimal secondary self-inductance to ensure the smallest output voltage ripple. At last, a design method to guarantee the minimum OVR within the scales of the input voltage and load are analyzed, and the minimum secondary self-inductance is proposed to minimize the OVR. Simulations and experiments are given to verify the results.