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Mark A. Swihart
VP – Technology and Product Development
Magnetics’ Powder Core Materials
Kool Mµ 75 Series XFlux® Kool Mµ® MAX High Flux MPP
6.5% Silicon
Type Sendust Blend Sendust High Flux MPP
Iron
µ vs. DC Bias High Flux XFlux 75 Series Kool Mµ MAX MPP Kool Mµ
AC Core Loss MPP Kool Mµ MAX Kool Mµ 75 Series XFlux High Flux
µ vs. Temp Stability MPP Kool Mµ MAX Kool Mµ High Flux 75 Series XFlux
Range of Available
MPP High Flux Kool Mµ Kool Mµ MAX XFlux 75 Series
Perms
Inherent Advantages of Powder Cores
1. Soft Saturation Curve
0.9
60 permeability
Kool Mµ
Per Unit of Initial Permeability
0.8
0.7
0.6
0.5
0.4
Ferrite gapped to an
effective permeability of 60
0.3
0.2
0.1
0.0
1 10 100 1000
DC Magnetizing Force (Oersteds)
6
Operating Design Point
The gapped ferrite must be kept a safe distance away
from the sudden rolloff. Small shifts in the rolloff
curve, or in the operating point, could have a
FERRITE disastrous effect. This curve shifts to the left with
increasing temperature.
POWDER CORE
INDUCTANCE
7
Magnetization Curves
No Gap Bsaturation
Distributed Gap
Discrete
No Gap
Gap
Bsaturation
8
Comparison of 60µ Cores
9
Inherent Advantages of Powder Cores
2. Temperature Stability
Discrete Gap Distributed Gap
(Ferrite) (Powder Core)
10
Alloy Saturation Curves vs. Ferrite
16
HIGH FLUX
14
12
10
Saturation
Flux 8
MPP
Density 6
in kG
4
FER
RITE
2
0
-50 0 50 100 150 200
Temperature °C
11
DC Bias and Temperature
1.0
MPP, 250C
0.9
Per Unit of Initial Permeability
0
and 75 C
0.8
0.7
0.6
0.5 Ferrite
750C
0.4
0.3 Ferrite
250C
0.2
0.1
0.0
1 10 Hdc (Oersteds) 100
12
Inherent Advantages of Powder Cores
13
Fringing Flux / Leakage Flux
Ferrite Powder Core
14
Fringing Losses
Flux bowing into the space
occupied by copper conductor
generates eddy current losses in
the coil.
15
Inductor Core Loss Comparison
16
Steinmetz Equation for General Magnetic Loss
a b
Pv = k f B
Pv is core loss density
f is frequency
B is flux density
17
Improved High Flux
• Cores with 58+ properties manufactured beginning January 2018
• No change to existing High Flux part numbers
100 kHz
Dimensions (after finish) Magnetic Data
Size
OD max (mm) ID min (mm) HT max (mm) Wa (mm2) Ae (mm2) Le (mm) Ve (mm3)
050 13.5 6.98 5.52 38.3 10.9 31.2 340
Kool Mµ MAX - Core Sizes
120 17.3 9.52 7.12 71.2 19.2 41.2 791
380 18.1 9.01 7.12 63.8 23.2 41.4 960
206 21.1 12 7.12 114 22.1 50.9 1,120
310 23.7 13.3 8.3 139 31.7 56.7 1,800
350 24.4 13.7 9.66 149 38.8 58.8 2,280
930 27.69 14.1 12 156 65.4 63.5 4,150
548 33.66 19.4 11.5 297 65.6 81.4 5,340
585 35.18 22.5 9.78 399 46.6 89.5 4,150
324 36.71 21.5 11.4 364 67.8 89.8 6,090
254 40.77 23.3 15.4 427 107 98.4 10,600
438 47.63 23.3 19 427 199 107 21,300
089 47.63 27.88 16.2 610 134 116 15,600
715 51.69 30.93 14.4 751 125 127 15,900
195 58.0 25.6 16.2 514 229 125 28,600
109 58.0 34.7 14.9 948 144 143 20,700
620 62.9 31.7 25.9 789 360 144 51,800
740 75.0 44.4 35.9 1,550 497 184 91,400
866 78.9 48.2 13.9 1,820 176 196 34,500
906 78.9 48.2 17.1 1,820 221 196 43,400
102 103.0 55.75 17.9 2,470 358 243 86,900
337 134.0 77.19 26.8 4,710 678 324 220,000
XFLUX
• 0078xxx-A7 series
• Cost 40-50% less than High Flux
• Applications:
• Low & medium frequency chokes, where
inductance at peak current is critical.
• Where High Flux would be used but cost is a
constraint.
• Where iron powder would be used but iron
powder losses are unacceptably high, or the
design cannot tolerate thermal aging.
XFlux – 75µ and 90µ
Now available in 050 (13.5mm OD) to 337 (134mm OD) size toroids.
Custom Blending
• Powder blends give intermediate performance for permeability,
saturation, and losses.
• Blending can be useful for:
• Fine tuning a material’s performance
• Decreasing overall cost (in trade for some performance)
• Making a powder better to work with, especially at pressing
• Arriving at a target particle size distribution
75 (Blended) Material
• Customized by customer
and application.
• Target bias, inductance and
loss defined in special
specs.
Thank you!
Planning to attend PCIM 2019? We will be discussing this same topic in the
Exhibitor Forum on Wednesday, 8 May from 14:00-14:20. Hope to see you there!