This technical information has been contributed by
Precision, Inc.

High-Current Inductors Combine Cost and Space Savings with Reduced Power Losses

MINNEAPOLIS—High-current inductors recently introduced by Precision, Inc., embody a flat-wire, ferrite core construction that is said to generate space and cost savings while reducing power losses. Precision, Inc. offers the new high-current inductors in four standard sizes and a variety of custom formats.

The high-current inductors can be used as a standard part drop-in replacement or as part of a custom technology solution. They also work with power management integrated circuits (ICs) made by major IC manufacturers, such as International Rectifier, Microchip, Texas Instruments, and others. The technology can be easily integrated into a number of key power conversion applications—such as micro-inverters, battery chargers, and AC-DC / DC-DC converters—for a wide array of industries, including solar, medical device, industrial control, and lab/test equipment.

The high-density construction of the Precision High-Current Inductors incorporates what the manufacturer calls “an innovative flat-wire, edge-wound copper coil that generates significant efficiency gains and space savings" over alternative round-wire or Litz wire technologies. It is said to maximize form capabilities and generate up to 33 percent space savings compared to round-wire alternatives. This high-density construction allows for 50 to 60 percent copper utilization compared to just 35 to 40 percent for round wire or 25 to 30 percent for Litz wire, according to Precision representatives. Higher copper utilization reportedly reduces power losses up to 25 percent compared to alternative round wire and Litz wire technologies because of the reduced resistance. The single-layer winding also reduces parasitic, leading to lower switching losses and higher efficiency.

Higher copper utilization also means that higher inductance can be achieved at a given volume. This not only generates potential space savings, but also leads to lower ripple current, which, in turn, reduces stress on other circuit components, such as EMI filters and output capacitors. Overall system component pricing can be reduced as design engineers no longer need pricier, more durable EMI filters and output capacitors.

Precision's new high-current inductors embody a cost-effective and efficient ferrite core construction. Ferrite is more cost-effective than metal alloy powder material, such as Sendust, and enhances performance by allowing up to 50 to 90 percent lower core loss, representatives said. Ferrite is also resistant to thermal aging, ensuring a long operational life. The ferrite core shape is carefully designed to allow for optimal surface area-to-volume ratio for efficient heat dissipation in high-current applications. The Precision family of high-current inductors features four standard, RoHS compliant and halogen-free technologies that can serve as immediate drop-in replacement parts. For custom and semi-custom applications, complimentary design engineering support is provided for small- , mid- , and high-volume orders.

Precision, Inc. (www.precision-inc.com) is an ISO 9001 and ISO 13485 certified and ITAR registered designer and manufacturer of custom and standard magnetic components and assemblies. The company has more than 40 years of design experience and specializes in the creation of innovative and sophisticated solutions for solving customer's magnetic technology needs. The company serves a broad range of industries, including renewable energy, medical device, aerospace/aviation/automotive, electronics, food processing, instrumentation, industrial control, telecommunications, and HVAC applications.