POWDER CORES - Magnetics

POWDER CORESMolypermalloy High Flux Kool Mµ XFlux Kool Mµ MAX

We offer the confidence of over sixty years of expertise in theresearch, design, manufacture and support of high quality magneticmaterials and components.A major manufacturer of the highest performance materials in theindustry including: MPP, High Flux, Kool Mµ , Kool Mµ MAX,XFlux , power ferrites, high permeability ferrites and strip woundcores, Magnetics’ products set the standard for providing consistentand reliable electrical properties for a comprehensive range of corematerials and geometries. Magnetics is the best choice for a varietyof applications ranging from simple chokes and transformers usedin telecommunications equipment to sophisticated devices foraerospace electronics.Magnetics backs it products with unsurpassed technical expertiseand customer service. Magnetics’ Sales Engineers offer theexperience necessary to assist the designer from the initial designphase through prototype approval. Knowledgeable Sales Managersprovide dedicated account management. Skilled Customer ServiceRepresentatives are easily accessible to provide exceptional salessupport. This support, combined with a global presence via aworldwide distribution network, including a Hong Kong distributioncenter, makes Magnetics a superior supplier to the internationalelectronics industry.

ContentsContentsIndexCore Locator by Part NumberCore Index and Unit Pack Quantities. . . . . . . . 2General Information Click the page nameor page number to godirectly to the pageIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . 8Applications and Materials . . . . . . . . . . . . . . . 9Material Properties . . . . . . . . . . . . . . . . . . . . 10Core Weights and Unit Conversions . . . . . . . 11Core Identification. . . . . . . . . . . . . . . . . . . . . 12Inductance and Grading . . . . . . . . . . . . . . . . 13Core Coating . . . . . . . . . . . . . . . . . . . . . . . . 14Core SelectionInductor Core Selection Procedure. . . . . . . . 15Core Selection Example . . . . . . . . . . . . . . . . 16Toroid Winding . . . . . . . . . . . . . . . . . . . . . . . 17Powder Core Loss Calculation . . . . . . . . . . . 18Core Selector Charts . . . . . . . . . . . . . . . . . . 23Wire Table. . . . . . . . . . . . . . . . . . . . . . . . . . . 28Material DataPermeability versus DC Bias Curves . . . . . . . 29Core Loss Density Curves. . . . . . . . . . . . . . . 35DC Magnetization Curves. . . . . . . . . . . . . . . 47Permeability versus Temperature Curves. . . . 51Permeability versus Frequency Curves . . . . . 55Core DataToroid Data. . . . . . . . . . . . . . . . . . . . . . . . . . 58E Core Data . . . . . . . . . . . . . . . . . . . . . . . . . 96Block Data . . . . . . . . . . . . . . . . . . . . . . . . . . 97U Core Data . . . . . . . . . . . . . . . . . . . . . . . . . 98MPP THINZ Data. . . . . . . . . . . . . . . . . . . . . 99HardwareE Core Hardware . . . . . . . . . . . . . . . . . . . . 100Toroid Hardware. . . . . . . . . . . . . . . . . . . . . 101Winding TablesWinding Tables. . . . . . . . . . . . . . . . . . . . . . 103www.mag-inc.com1

IndexCore Locator & Unit Pack QuantityMPP Toroids2P/N PAGE BOX QTYP/N PAGE BOX 8080801,600P/N PAGE BOX 8,0008,0001,0001,0001,000P/N PAGE BOX QTYP/N PAGE BOX 00400400400400

IndexCore Locator & Unit Pack QuantityHigh Flux BOX 280808080806363636363636666666666666767676767BOX 777777777878787878BOX 191917676767676www.mag-inc.comBOX 201,60045454545400404040404004004004004003

IndexCore Locator & Unit Pack QuantityKool Mµ Toroids4P/NPAGEBOX 79797979696994BOX 777777787878787878878787878787878484848484BOX 739090909090636366667691919191917676767676BOX 010,0008,0008,0004004040404040400400400400400

IndexCore Locator & Unit Pack QuantityKool Mµ Blocks, E Cores, and U 96969696BOX 797969696989696969797BOX .mag-inc.comBOX 8484863636363305

IndexCore Locator & Unit Pack QuantityXFlux 1818181939393938585717171938686BOX 797979799494947575757575BOX 87878878787878784848484848383BOX EBOX 4040400400400400PAGEBOX QTYXFlux Blocks and E GEBOX 97969696BOX 484636363454545484848636363

IndexCore Locator & Unit Pack QuantityKool Mµ MAX 9192707074778888798081819393858571718686BOX 679717738074799475757272828277787887878484BOX g-inc.comBOX QTY707024241,600454540040404007

General InformationIntroductionMagnetics Molypermalloy Powder (MPP) cores aredistributed air gap toroidal cores made from a 81% nickel,17% iron, and 2% molybdenum alloy powder for the lowestcore losses of any powder core material. MPP cores (and allpowder cores) exhibit soft saturation, which is a significantdesign advantage compared with gapped ferrites. Also,unlike ferrites, the MPP saturation curve does not need tobe derated with increasing device temperature.MPP cores possess many outstanding magneticcharacteristics, such as high resistivity, low hysteresis andeddy current losses, excellent inductance stability after highDC magnetization or under high DC bias conditions andminimal inductance shift under high AC excitation.MPP THINZ , or washer cores, put the premiumperformance of Magnetics’ superior MPP material intorobust, low height toroid form, for low profile inductors.With MPP THINZ, exact permeability and height areeasily adjusted to result in the optimum design for eachapplication.Magnetics High Flux powder cores are distributed airgap toroidal cores made from a 50% nickel - 50% iron alloypowder for the highest biasing capability of any powdercore material. High Flux cores have advantages that resultin superior performance in certain applications involving highpower, high DC bias, or high AC excitation amplitude. TheHigh Flux alloy has saturation flux density that is twice thatof MPP alloy, and three times or more than that of ferrite. Asa consequence, High Flux cores can support significantlymore DC bias current or AC flux density.High Flux offers much lower core losses and superior DCbias compared with powdered iron cores. High Flux coresoffer lower core losses and similar DC bias compared withXFlux cores. Frequently, High Flux allows the designer toreduce the size of an inductive component compared withMPP, powdered iron, or ferrite.Magnetics Kool Mµ , XFlux , MPP, High Fluxand Kool Mµ MAX are true high temperaturematerials with no thermal aging.8MAGNETICSMagnetics Kool Mµ powder cores are distributed airgap cores made from a ferrous alloy powder for low lossesat elevated frequencies. The near zero magnetostrictionalloy makes Kool Mµ ideal for eliminating audible frequencynoise in filter inductors. In high frequency applications, corelosses of powdered iron, for instance, can be a major factorin contributing to undesirable temperature rises. Kool Mµcores are superior because their losses are significantlyless, resulting in lower temperature rises. Kool Mµ coresgenerally offer a reduction in core size, or an improvement inefficiency, compared with powdered iron cores.Kool Mµ is available in a variety of core types, for maximumflexibility. Toroids offer compact size and self-shielding. Ecores and U cores afford lower cost of winding, use of foilinductors, and ease of fixturing. Very large cores and structuresare available to support very high current applications. Theseinclude toroids up to 102 mm, 133 mm and 165 mm; large Ecores; U cores; stacked shapes; and blocks.Magnetics Kool Mµ MAX powder cores are distributedair gap cores made from a ferrous alloy powder offering50% better DC bias performance than standard Kool Mµmaterial. Use of copper wire is minimized by maintaininginductance using less turns, resulting in savings in overallcomponent cost. With its super low losses, Kool Mµ MAXdoes not mimic the same temperature rise problems foundin iron powder cores. Inductors built with Kool Mµ MAX donot have several of the disadvantages that are inherent withgapped ferrite cores, including low saturation flux densityand fringing losses at the discrete air gap.Magnetics XFlux distributed air gap cores are made from6.5% silicon iron powder. XFlux offers lower losses thanpowdered iron cores and superior DC bias performance.The soft saturation of XFlux material offers an advantageover ferrite cores. XFlux cores are ideal for low and mediumfrequency chokes where inductance at peak load is critical.Magnetics is committed to meeting globalenvironmental standards and initiatives. Magnetics’REACH and RoHS compliance statements and reportsare available on our website: www.mag-inc.com

General InformationApplications and MaterialsMagnetics powder cores are most commonly used in powerinductor applications, specifically in switch-mode powersupply (SMPS) filter inductors, also known

2 MAGNETICS Core Locator & Unit Pack Quantity 55014 61 10,000 55015 61 10,000 55016 61 10,000 55017 61 10,000 55018 61 10,000 55019 61 10,000 55020 61 10,000 55021 61 10,000 55022 61 10,000 55023 61 10,000 55024 65 10,000 55025 65 10,000 55026 65 10,000 55027 65 10,000 55028 65 10,000 55029