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13726661550
Flat Wire Inductors
Flat wire increases surface area by up to 60%, supporting better skin effect at higher frequencies. Ideal for high-current solutions in UPS, solar, automotive, and industrial applications.
Powder cores are distributed gap cores with excellent inductance stability under DC/AC conditions, high resistivity, low hysteresis, and eddy current losses.
Material Comparison：
| Traditional EI, EE, C Foil Inductors | Traditional Round Wire Inductors | Flat Wire Inductors | ||||||
| Content | EI, EE, C Core | Toroidal Core | Powder Core | |||||
| Round Wire | Round Wire | Flat Wire | ||||||
| Power Range | 20KVA ~500KVA | 3KVA ~ 100KVA | ||||||
| Material 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 | Poor | High | High | |||||
| High Power Loss (>100kVA) | Good | Moderate | Poor | |||||
| DCR (>100kVA) | Excellent | Good | Poor | |||||
| Fill Factor | Good | Good | Moderate | |||||
| Composition | 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 (mW/cc) 50KHz, 1000G |
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 | |
| Temp. Stability (-60°C 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 (T) | 1 | 1 | 1 | 1.6 | 1.5 | 1.5 | 0.8 | |
| Frequency Response (Flat to) | 5MHz | 15MHz | 30MHz | 3MHz | 3MHz | 20MHz | 6MHz | |
| Relative Cost | 1x* | 2x | 2x | 1.2x | 4x-6x | 5x | 7x-9x | |
Why Toroidal Cores Are Preferred Over EI/EE/C Foil Inductors:
Lower parasitic capacitance
Safer production process
Reduced DC noise and EMI
Lower leakage flux
Main Applications:
Flat wire toroidal inductors are widely used as boost inductors and inverter inductors in:
- New energy vehicles
- Charging stations
- UPS
- Photovoltaic inverters.
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