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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 and PC40 materials having superior magnetic characteristics.
APPLICATIONS
High frequency inductive heater EE320x250x20
Transformer
Reactor choke
Uninterruptible Power Supply System(UPS)
CATV’s power supply
Photovoltaic power generation
Power supply of communications station
Electrical vehicle
Automated warehouse, conveyor machine
Current sensor
General purpose inverter • Air conditioner
• Fun
• Pump
• Printing press
• Packing machine
• Machines for food industry
• Drier
• Compressor of freezer
• Textile machine
• Woodworking machine
• Medical machine
Trains
EC70,90,120
PQ78,107
UU79x129x31
UU79x129x31
• All specifications are subject to change without notice.
002-01 / 20071116 / 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 PE22 PC40
Initial permeability µi [23°C] 1800 2300
Curie temperature Tc °C >200 >200
Saturation magnetic flux density
H=1194A/m
Remanent flux density Br [23°C] mT 140 125
Coercive force Hc [23°C] A/m 16 15
Core loss
25kHz, 200mT
100kHz, 200mT
Electrical resistivity ρΩ • m 3 6.5
Approximate density dapp kg/m
Thermal expansion coefficient α 1/K 12×10–612× 10
Thermal conductivity κ W/mK 5 5
Specific heat C
Bending strength δb3 N/m
Young’s modulus E N/m
Magnetostriction λs–0.6× 10–6–0.6× 10
• 1(mT)=10(G),1(A/m)=0.012566(Oe)
[23°C]
Bs
[100°C]
mT
Pcv [100°C] kW/m
p J/kg • K 600 600
510
410
80
3
520
3
4.8× 1034.8× 10
2
9× 10
2
1.2× 10111.2× 10
7
500
380
70
420
9× 10
3
–6
7
11
–6
(2/6)
CORE LOSS vs. TEMPERATURE CHARACTERISTICS
200
150
)
3
100
kW/m
(
cv
P
PE22
PC40
50
0
Temperature(˚C
25kHz-200mT
)
800
)
3
600
kW/m
(
cv
P
400
120100806040200
0
PE22
PC40
Temperature(˚C
100kHz-200mT
)
120100806040200
• All specifications are subject to change without notice.
002-01 / 20071116 / e16_1.fm
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CORE LOSS vs. FREQUENCY CHARACTERISTICS
MATERIAL:PE22
5
10
10
(3/6)
5
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
1
10
10
300mT
150mT
250mT
100mT
200mT
50mT
Material : PE22
Temp.23˚C
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
250mT
300mT
200mT
150mT
100mT
50mT
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
1
10
10
300mT
150mT
250mT
100mT
200mT
50mT
Material : PE22
Temp.40˚C
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
300mT
250mT
200mT
150mT
100mT
50mT
(kW/m
cv
P
2
10
1
10
Material : PE22
Temp.60˚C
10
1
10
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
10
1
10
2
300mT
250mT
200mT
150mT
10
100mT
50mT
Material : PE22
Temp.100˚C
3
10
4
Frequency (kHz)
(kW/m
cv
P
2
10
1
10
Material : PE22
Temp.80˚C
10
1
10
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
1
10
10
300mT
250mT
150mT
200mT
100mT
50mT
Material : PE22
Temp.120˚C
2
10
3
10
4
Frequency (kHz)
• All specifications are subject to change without notice.
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MATERIAL:PC40
5
10
10
(4/6)
5
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
1
10
10
300mT
150mT
250mT
200mT
100mT
50mT
Material : PC40
Temp.23˚C
2
10
3
10
4
Frequency (kHz)
5
10
4
10
300mT
250mT
150mT
200mT
100mT
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
10
1
10
2
300mT
250mT
200mT
150mT
10
100mT
50mT
Material : PC40
Temp.40˚C
3
10
4
Frequency (kHz)
5
10
4
10
300mT
250mT
200mT
150mT
3
3
)
3
10
50mT
)
3
10
100mT
50mT
(kW/m
cv
P
2
10
(kW/m
cv
P
2
10
1
10
Material : PC40
Temp.60˚C
10
1
10
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
1
10
10
300mT
2
250mT
150mT
200mT
10
100mT
50mT
Material : PC40
Temp.100˚C
3
10
4
Frequency (kHz)
1
10
Material : PC40
Temp.80˚C
10
1
10
2
10
3
10
4
Frequency (kHz)
5
10
4
10
3
)
3
10
(kW/m
cv
P
2
10
1
10
10
1
10
2
300mT
250mT
200mT
150mT
10
100mT
50mT
Material : PC40
Temp.120˚C
3
10
4
Frequency (kHz)
• All specifications are subject to change without notice.
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SATURATION MAGNETIC FLUX AMPLITUDE PERMEABILITY vs. MAGNETIC PERMEABILITY vs.
DENSITY vs. TEMPERATURE SATURATION MAGNETIC FLUX FREQUENCY CHARACTERISTICS
CHARACTERISTICS DENSITY CHARACTERISTICS
700
600
5000
3000
Material: PE22
Temp.: 23
˚C
(5/6)
500
)
400
mT
(
s
B
300
200
100
0
Temperature(˚C
PE22
PC40
)
INITIAL MAGNETIC PERMEABILITY vs.
TEMPERATURE CHARACTERISTICS
6000
5000
PC40
PE22
f=1kHz
H
=0.4A /m
m
Temperature(˚C
)
3002001000
i
µ
4000
3000
2000
1000
0
4000
120˚C
100˚C
a
80˚C
µ
60˚C
3000
40˚C
23˚C
Material: PE22
150100500
2000
Flux density(mT
5000
f=16kHz
)
3002001000
2000
µ′, µ′′
1000
3000
0
1
10
Material: PC40
Temp.: 23
µ′
2
10
Frequency(kHz
˚C
µ′′
3
10
)
4
10
µ′
120˚C
a
µ
4000
3000
2000
100˚C
80˚C
60˚C
40˚C
23˚C
Flux density(mT
Material: PC40
f=16kHz
)
3002001000
µ′, µ′′
2000
1000
µ′′
0
1
10
2
10
Frequency(kHz
3
10
)
4
10
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
λ=
f ×
µrεr×
λ.
C: Electromagnetic wave speed in a vacuum(3.0× 108m/s)
r: Relative magnetic permeability
µ
r: Relative permissivity
ε
f: Frequency of the applied magnetic field(electromagnetic wave)
As µe 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
3
10
)
mm
(
2
10
Resonant dimension
1
10
10
PE22
PC40
1
2
10
Frequency(kHz
)
3
10
• All specifications are subject to change without notice.
002-01 / 20071116 / e16_1.fm
Page 6
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.
(6/6)
• All specifications are subject to change without notice.
002-01 / 20071116 / e16_1.fm
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