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13726661550
Flat Wire Inductor
Featuring a flat wire winding structure, it offers high current handling capability, low DC resistance, and excellent thermal performance. Suitable for high-current DC-DC converters, vehicle power systems, and high-frequency power applications, providing a compact and efficient inductor solution.
Flat wire inductors, with their innovative structural design, comprehensively outperform traditional round wire inductors in performance: The adoption of a flat conductor structure increases current density by 50%–100%, enabling higher current-carrying capacity within the same volume; the optimized geometric design effectively reduces skin effect and proximity effect, lowering high-frequency losses by over 30%; the compact winding layout saves more space while improving heat dissipation efficiency; fully automated precision winding processes ensure product consistency and reliability, coupled with enhanced insulating materials, significantly extending service life. They are particularly suitable for applications with stringent requirements for high efficiency and high power density, such as new energy vehicles and high-end power supplies.
Material Comparison:
| Traditional EI, EE, C Foil Inductor | Traditional Round Wire Inductor | Flat Wire Inductor | |
| Content | Round Wire on EI/EE/C Core | Toroidal Core | Powder Core with Flat Wire |
| Power Range | 20KVA ~500KVA | 3KVA ~ 100KVA | |
| Material Use Efficiency | Poor | Good | Excellent |
| Magnetic Field Uniformity | Poor | Excellent | Excellent |
| Manufacturing Process | Difficult | Simple | Simple |
| Parasitic Capacitance | High | Low | Very Low |
| Insulation Reliability | Poor | High | Very High |
| Heat Dissipation Efficiency | Poor | High | High |
| Coil Loss at High Power (>100 kVA) | Good | Moderate | Poor |
| DCR at High Power (>100 kVA) | Excellent | Good | Poor |
| Fill Factor | Good | Good | Moderate |
For different application requirements, we recommend using different powder cores:
- To achieve inductors with the lowest loss, ultra-low-loss Kool Mµ Hƒ and MPP powder cores should be used.
- For designs dominated by DC bias where minimum core size is essential, HIGH FLUX and EDGE powder cores with the highest flux density are recommended.
- When competitive cost is needed while maintaining reasonably low core loss and high saturation, Kool Mu powder cores are an excellent choice.
- For low- and medium-frequency inductors and chokes, XFlux powder cores offer a cost-effective, high-saturation material solution (1.6 T).
| Component | FeSiAl | FeSiAl | FeSiAl | FeSi | FeNi | FeNi | FeNiMa | |
| Permeability Range | 14-125 | 14-60 | 26,60 | 19-125 | 14-160 | 26,60 | 14-550 | |
| Core Loss 60µ(mW/cc) | 50KHz, 1000G | 215 | 200 | 120* | 575 | 250 | 150 | 165 |
| 100KHz, 1000G | 550 | 550 | 325* | 1280 | 625 | 375 | 450 | |
| Perm vs. DC Bias-60µ (Oe) | 80% of µ1 | 45 | 65 | 60 | 100 | 100 | 130* | 60 |
| 50% of µ2 | 95 | 130 | 115 | 170 | 185 | 205* | 105 | |
| 60µ Temperature Stability - Typical % (-60 to 200°C) | 6% | 3% | 5% | 4% | 4.50% | 2% | 2.50% | |
| Curie Temperature | 500°C | 500°C | 500°C | 700°C | 500°C | 500°C | 460°C | |
| Saturation Flux Density (Tesla) | 1 | 1 | 1 | 1.6 | 1.5 | 1.5 | 0.8 | |
| Frequency Response – 60µ Flat up to | 5MHz | 15MHz | 30MHz | 3MHz | 3MHz | 20MHz | 6MHz | |
| Relative Cost | 1x* | 2x | 2x | 1.2x | 4x-6x | 5x | 7x-9x | |
Comparison of Inductor Advantages:
The replacement of traditional EI, EE, and C foil inductors with toroidal core inductors is becoming increasingly popular, and the reasons are as follows:
Key Applications:
New modes of power consumption and power generation are changing how distribution networks are utilized. Flat wire toroidal inductors are widely used as boost inductors and inverter inductors, finding extensive applications in the following fields:
- New Energy Vehicles
- Charging Stations
- Uninterruptible Power Supplies (UPS)
- Photovoltaic Inverters
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