Large Size Ferrite Cores for High Power

Summary

Issue date:

November 2010

All specifications are subject to change without notice. Conformity to RoHS Directive: This means that, in conformity with EU Directive 2002/95/EC, lead, cadmium, mercury, hexavalent chromium, and specific bromine-based flame retardants, PBB and PBDE, have not been used, except for exempted applications.

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Large Size Ferrite Cores for High Power Summary

Nowadays, more and more high-frequency circuits are being used in industrial equipment as well as consumer equipment. With the use of higher frequencies, silicon steel sheets have become unsuitable for magnetic material used in transformers. Ferrite, its substitute, delivers reduced core loss at high frequencies and is the optimum material for high-power requirements. To meet these various demands, we at TDK have employed our ferrite development technologies accumulated over the years and advanced production technologies to offer large, high-quality cores for high-frequency, high-power power supplies. In the following information, introduce ferrite cores that used PE22, PC40 and PE90 materials having superior magnetic characteristics. APPLICATIONS
High frequency inductive heater EE320x250x20

Uninterruptible Power Supply System(UPS) CATVs power supply Photovoltaic power generation Power supply of communications station Transformer Electrical vehicle

EC70,90,120

PQ78,107

Automated warehouse, conveyor machine

Current sensor

General purpose inverter

Reactor choke Trains

Air conditioner Fun Pump Printing press Packing machine Machines for food industry Drier Compressor of freezer Textile machine Woodworking machine Medical machine

UU79x129x31

UU79x129x31

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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FEATURES
Large size ferrite cores developed for reactors and transformers used in high power units. Please contact us for machinability of non-standard special forms. MATERIAL CHARACTERISTICS (Typical)
Material Initial permeability Curie temperature Saturation magnetic flux density H=1194A/m Remanent flux density Coercive force Core loss 25kHz, 200mT i Tc Bs Br Hc Pcv dapp Cp b3 E s [23C] C [23C] [100C] [23C] [23C] [90C] [100C] mT mT A/m kW/m3 m kg/m3 1/K W/mK J/kg K N/m2 N/m2 PE22 1800 >200 510 410 140 16 79 80 520 3.0 4.8103 12106 5 600 9107 1.21011 0.6106 PC40 2300 >200 500 380 125 15 64 70 420 6.5 4.8103 12106 5 600 9107 1.21011 0.6106 PE90 2200 >250 530 430 170 13 60 68 400 6.0 4.9103 12106 5 600 9107 1.21011 0.6106

100kHz, 200mT Electrical resistivity Approximate density Thermal expansion coefficient Thermal conductivity Specific heat Bending strength Youngs modulus Magnetostriction

1(mT)=10(G),1(A/m)=0.012566(Oe)

CORE LOSS vs. TEMPERATURE CHARACTERISTICS

200
25kHz-200mT PE22

900

PE22

100kHz-200mT

150
PC40

700
Pcv(kW/m 3)
PC40

Pcv(kW/m 3)

100
PE90

PE90

500 50

20

40 60 80 Temperature(C)

100

120

300

20

40 60 80 Temperature(C)

100

120

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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CORE LOSS vs. FREQUENCY CHARACTERISTICS MATERIAL:PE22

10000
Material : PE22 Temp.23C

10000

Material : PE22 Temp.40C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE22 Temp.60C

10000

Material : PE22 Temp.80C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE22 Temp.90C

10000

Material : PE22 Temp.100C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE22 Temp.120C

1000 Pcv (kW/m3)

100

10

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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MATERIAL:PC40
10000
Material : PC40 Temp.23C

10000

Material : PC40 Temp.40C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PC40 Temp.60C

10000

Material : PC40 Temp.80C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PC40 Temp.90C

10000

Material : PC40 Temp.100C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PC40 Temp.120C

1000 Pcv (kW/m3)

100

10

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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MATERIAL:PE90
10000
Material : PE90 Temp.23C

10000

Material : PE90 Temp.40C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE90 Temp.60C

10000

Material : PE90 Temp.80C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE90 Temp.90C

10000

Material : PE90 Temp.100C

1000 Pcv (kW/m3)

1000 Pcv (kW/m3)

50mT 100mT 150mT 200mT 250mT 300mT

100

100

10

10

1 10

100 1000 Frequency (kHz)

10000

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

10000

Material : PE90 Temp.120C

1000 Pcv (kW/m3)

100

10

1 10

50mT 100mT 150mT 200mT 250mT 300mT

100 1000 Frequency (kHz)

10000

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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SATURATION MAGNETIC FLUX DENSITY vs. TEMPERATURE CHARACTERISTICS

700 600 500
Bs(mT )
PE22 PE90 PC40

INITIAL MAGNETIC PERMEABILITY vs. TEMPERATURE CHARACTERISTICS

5000
PC40

4000

400 300 200

3000

PE22 PE90

i
2000 1000 100 0 0 0 0
f=1kHz Hm=0.4A/m

50 100 Temperature (C)

150

100 200 Temperature (C)

300

AMPLITUDE PERMEABILITY vs. SATURATION MAGNETIC FLUX DENSITY CHARACTERISTICS

7000

7000
Material : PE22 f=16kHz

7000
Material : PC40 f=16kHz

Material : PE90 f=16kHz

6000

6000

6000

5000

5000

5000

4000 120C 100C 80C 60C 3000 40C 23C 2000 0 100 200 Flux density (mT ) 300

120C 4000 100C 80C 60C 40C 3000 23C

80C 60C 40C 100C 4000 23C 120C

a
2000

3000

100 200 Flux density (mT )

300

2000

100 200 Flux density (mT )

300

MAGNETIC PERMEABILITY vs. FREQUENCY CHARACTERISTICS

4000
Material: PE22 Temp.: 23C Hm=0.4A/m

4000
Material: PC40 Temp.: 23C Hm=0.4A/m

4000
Material: PE90 Temp.: 23C Hm=0.4A/m

3000

3000

3000

2000

2000

2000

1000

1000

1000

0 10
0 10 100 1000 Frequency (kHz) 10000

100 1000 Frequency (kHz)

10000

0 10

100 1000 Frequency (kHz)

10000

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

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DIMENSIONAL RESONANCE Dimensional resonance is a phenomenon which increases loss and decreases magnetic permeability by electromagnetic standing waves when the magnetic field of the core frequency is applied. The phenomenon appears when the maximum dimension of the cross section of the core perpendicular to the magnetic field is the integral multiple of about half of the electromagnetic wavelength .
= C f r r

C: Electromagnetic wave speed in a vacuum(3.0108m/s) r: Relative magnetic permeability r : Relative permissivity f: Frequency of the applied magnetic field(electromagnetic wave) As e decreases by inserting into the gap, using the same core enables high frequency wave usage as indicated by the formula above. As dimensional resonance quickly decreases magnetic permeability, design the actual frequency to avoid dimensional resonance. In the case of possible dimensional resonance, it can be protected against by dividing the core in the magnetic circuit direction and bonding them. RESONANCE DIMENSION vs. FREQUENCY CHARACTERISTICS
10 3

PE22 PC40

10 2

101 1 10

10 2 Frequency (kHz)

10 3

GENERAL PRECAUTIONS WHEN USING FERRITE CORE When selecting the material/form of the ferrite core, while considering the margins select from the range in the catalog (product manual) display where factors such as inductance value, maximum saturation flux density, core loss, temperature characteristics, frequency characteristics and Curie temperature are concerned. Select material that does not corrode or react in order to avoid insulation failure or a layer short, and also be careful to avoid loose winding of the core or causing damage to the wire. Be careful that the equipment and tools you use do not strike the core in order to avoid core cracks. Please consider using cases, bobbins or tape for insulation purposes. When using cases and bobbins, select those with a heat expansion coefficient as close to that of the ferrite as possible. When laying out the case, bobbin, coil and the ferrite core, create clearance between each part in order to prevent any core cracks and to assure insulation. Please handle with care, since a ferrite core is susceptible to shock. The outward appearance is determined according to the standard of our company. Do not place close to strong magnets. Be careful not to cause shock by the use of equipment and tools. Be careful not to expose to rapid change in temperature, since it is also susceptible to thermal shock. Careless handling may hurt your skin, since the corners of the polished surface of the ferrite are very sharp, and in some cases, burrs may have formed on the surface. Please be very careful when stacking and handling the containers, since some ferrite cores are heavy, and can cause injury, toppling or back pain. Where inner packaging is concerned, please be careful not to damage the core when taking it out from the container since the packing materials used in order to prevent damage during transportation may make it difficult to take out. Do not reprocess the ferrite core as it can cause problems, such as injury.

All specifications are subject to change without notice. 003-02 / 20101108 / e16_1.fm

Resonant dimension(mm)