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(1/72)
003-02 / 20050803 / e140.fm
• All specifications are subject to change without notice.
Ferrite for Switching Power Supplies
INTRODUCTION
Our foremost mission is to develop unique and advanced electron-
ics technologies. As such, ever since TDK was founded in 1935
when its researchers invented ferrite, we have been involved in a
wide range of technological and product development efforts.
Particularly, our high-performance ferrite elements, which result
from our accumulated expertise and excellent microstructure con-
trol technologies, have become essential in reducing the weight
and improving the performance of advanced electronic devices
that are transforming the world around us.
As a result of pursuing the numerous potentials of these ferrite ele-
ments, we have been able to develop high-frequency power ferrite
material that deliver among the world’s highest levels of reliability
and magnetic properties. These products include PC33, PC40,
PC44, PC45, PC46, PC47, and PC50. They contribute to achiev-
ing even greater size reductions and performance improvements
of high-performance switching power supplies and DC to DC con-
verters -- products considered to constitute the heart of microelec-
tronic devices. We have also developed the PC95, which delivers
a saturated magnetic flux density equivalent to that of PC44 and
low loss in a wide temperature range. This materials is expected to
improve the efficiency of power supplies in DC to DC converters
used in electric vehicles.
Additionally, we have been conducting research in ferrite that
delivers permeability close to the theoretical limit in high frequency
ranges. These ferrite materials are designed for EMC solutions.
The materials HS52, HS72, and HS10 deliver frequency
responses with excellent permeability - a prerequisite for EMC
magnetic material such as EMI filters and common mode choke
coils - and higher impedance compared to existing material in the
high frequency ranges.
In parallel with material development, we have been working to
reduce sizes and improve the performance of our switching power
supplies and DC to DC converters. To this end, we have been
developing optimum core shape designs and creating an extensive
line up of these products to accommodate a wide range of specific
needs. We also manufacture peripheral items including bobbins
and various accessories.
(2/72)
003-02 / 20050803 / e140.fm
• All specifications are subject to change without notice.
CIRCUIT EXAMPLE
SINGLE FORWARD CONVERTER
Notes: • LP and EPC cores are ideal for use in thin transformers.
• LP cores are available in .5 and .7 inches in height (when mounted).
• EP cores are available in .5 and .65 inches in height (when mounted).
Current transformer
Common mode choke coil Main power transformerActive filer choke coil Smoothing choke coil
Auxiliary power transformer
Drive Transformer
EMI/RFI filter
PFC Active filter
Output rectifier
smoothing circuit
Auxiliary power
circuit
Power switch
circuit
Control circuit
DC outputAC input
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003-02 / 20050803 / e140.fm
• All specifications are subject to change without notice.
SELECTED ITEMS OF LEGEND
C
1
= Core constant mm
–1
Ae Effective cross-sectional area, mm
2
e Effective magnetic path length, mm
Ve Effective core volume mm
3
Acp Cross-sectional center leg/pole area, mm
2
Acp min. Minimum cross-sectional center pole area, mm
2
Acw Cross-sectional winding area of core, mm
2
Aw Cross-sectional winding area of bobbin, mm
2
w Average length of turns around bobbin, mm
t Minimum thickness of bobbin inside which core is placed, including flanges, mm
W Bobbin-core assembly dimensions
D Bobbin-core assembly dimensions
H Bobbin-core assembly dimensions
Σ
A
H
W
D
H
W
D
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003-02 / 20050803 / e140.fm
• All specifications are subject to change without notice.
MATERIAL CHARACTERISTICS
MATERIAL CHARACTERISTICS
For Transformer and Choke
∗
Average value
∗∗
500kHz, 50mT
Material PC40 PC44 PC47 PC50
Initial permeability µi 2300±25% 2400±25% 2500±25% 1400±25%
Amplitude permeability µa 3000 min. 3000 min.
Core loss volume density
(Core loss)
∗
[B=200mT]
Pcv kW/m
3
25kHz
sine wave
25°C120
60°C80
100°C70
120°C85
100kHz
sine wave
25°C 600 600 600 130
∗∗
60°C 450 400 400 80
∗∗
100°C 410 300 250 80
∗∗
120°C 500 380 360 110
∗∗
Saturation magnetic flux
density
∗
[H=1194A/m]
Bs mT
25°C 510 510 530 470
60°C 450 450 480 440
100°C 390 390 420 380
120°C 350 350 390 350
Remanent flux density
∗
Br mT
25°C 95 110 180 140
60°C 65 70 100 110
100°C 55 60 60 98
120°C 50 55 60 100
Coercive force
∗
Hc A/m
25°C 14.3 13 13 36.5
60°C 10.3 9 9 31.0
100°C8.8 6.5 6 27.2
120°C86726.0
Curie temperature Tc °C >215 >215 >230 >240
Density
∗
db kg/m
3
4.8
×
10
3
4.8
×
10
3
4.9
×
10
3
4.8
×
10
3
Electrical resistivity
∗
ρ
v
Ω
• m 6.5 6.5 4.0 30
Material PC45 PC46 PC33 PC95
Initial permeability µi 2500±25% 3200±25% 1400±25% 3300±25%
Amplitude permeability µa
Core loss volume density
(Core loss)
∗
[B=200mT]
Pcv kW/m
3
100kHz
sine wave
25°C 570 350 1100 350
60°C 250(75°C) 250(45°C) 800
100°C 460 660 600 290
120°C 650 760 680 350
Saturation magnetic flux
density
∗
[H=1194A/m]
Bs mT
25°C 530 520 510 530
60°C 480 470 490 480
100°C 420 410 440 410
120°C 390 380 420 380
Remanent flux density
∗
Br mT
25°C 120 80 220 85
60°C 80 80 150 70
100°C 80 130 100 60
120°C 110 140 100 55
Coercive force
∗
Hc A/m
25°C 12 10 23 9.5
60°C99177.5
100°C 8 10 14 6.5
120°C99146.0
Curie temperature Tc °C >230 >230 >290 >215
Density
∗
db kg/m
3
4.8
×
10
3
4.8
×
10
3
4.8
×
10
3
4.9
×
10
3
Electrical resistivity
∗
ρ
v
Ω
• m 3.0 3.0 2.5 6.0
(5/72)
003-02 / 20050803 / e140.fm
• All specifications are subject to change without notice.
For Common Mode Choke
For Telecommunication
∗
Average value
Material HS52 HS72 HS10
Initial permeability µi 5500±25%
7500±25%
(2000min. at 500kHz)
10000±25%
Relative loss factor
∗
tan
δ
/µi
×
10
–6
10(100kHz) 30(100kHz) 30(100kHz)
Saturation magnetic flux density
∗
[H=1194A/m]
Bs mT 25°C 410 410 380
Remanent flux density
∗
Br mT 25°C7080120
Coercive force
∗
Hc A/m 25°C665
Curie temperature Tc °C >130 >130 >120
Density
∗
db kg/m
3
4.9
×
10
3
4.9
×
10
3
4.9
×
10
3
Electrical resistivity
∗
ρ
v
Ω
• m 1 0.2 0.2
Material H5A H5B2 H5C2 H5C3 H5C4
Initial permeability µi 3300 7500±25% 10000±30% 15000±30%
12000±30%
9000(–20°C)
Relative loss factor tan
δ
/µi
×
10
–6
<2.5(10kHz)
<10(100kHz)
<6.5(10kHz) <7.0(10kHz) <7.0(10kHz) <8(10kHz)
Temperature factor of initial
permeability
α
µir
×
10
–6
–30 to +20°C
0 to 20°C
20 to 70°C
–0.5 to 2.0
–0.5 to 2.0
0 to 1.8
0 to 1.8
–0.5 to 1.5
–0.5 to 1.5
–0.5 to 1.5
–0.5 to 1.5
Saturation magnetic flux density
∗
[H=1194A/m]
Bs mT 25°C 410 420 400 360 380
Remanent flux density
∗
Br mT 25°C 100 40 90 105 100
Coercive force
∗
Hc A/m 25°C 8.0 5.6 7.2 4.4 4.4
Curie temperature Tc °C >130 >130 >120 >105 >110
Hysteresis material constant
η
B
<0.8 <1.0 <1.4 <0.5 <2.8
Disaccommodation factor D
F
×
10
–6
<3 <3 <2 <2 <3
Density
∗
db kg/m
3
4.8
×
10
3
4.9
×
10
3
4.9
×
10
3
4.95
×
10
3
4.95
×
10
3
Electrical resistivity
∗
ρ
v
Ω
• m 1 0.1 0.15 0.15 0.15
Material H5C5 HP5 DNW45 DN40 DN70
Initial permeability µi 30000±30% 5000±20% 4200±25% 4000±25% 7500±25%
Relative loss factor tan
δ
/µi
×
10
–6
25°C, 10kHz <15 <3.5 <3.5 <2.5 <2.0
Temperature factor of initial
permeability
α
µir
×
10
–6
–30 to +20°C
0 to 20°C
20 to 70°C
–0.5
〜
1.5
–0.5
〜
1.5
±12.5%
±12.5%
–0.5 to 2.0
–0.5 to 2.0
–0.5 to 1.5
–0.5 to 1.5
Saturation magnetic flux density
∗
[H=1194A/m]
Bs mT 25°C 380 400 450 405 390
Remanent flux density
∗
Br mT 25°C 120 65 50 95 45
Coercive force
∗
Hc A/m 25°C 4.2 7.2 6.5 8.0 3.5
Curie temperature Tc °C >110 >140 >150 >130 >105
Hysteresis material constant
η
B
<1.5 <0.4 <0.8 <0.8 <0.2
Disaccommodation factor D
F
×
10
–6
<2 <3 <3 <3 <2.5
Density
∗
db kg/m
3
4.95
×
10
3
4.8
×
10
3
4.85
×
10
3
4.8
×
10
3
5.0
×
10
3
Electrical resistivity
∗
ρ
v
Ω
• m 0.15 0.15 0.65 1.0 0.3
+40%
–0%
10
–6
mT
10
–6
mT
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