Magnetics® Powder Cores
Magnetics Powder Core products - Kool Mu® (sendust), MPP (molypermalloy), Kool Mµ® MAX, Kool Mu® Hƒ, EdgeTM, High Flux, XFlux®, and 75-Series materials - are distributed air gap cores that are primarily used in power inductor applications, specifically in switched-mode power supply (SMPS) output filters, also known as DC inductors. Other power applications include differential inductors, boost inductors, buck inductors, and flyback transformers. Notable characteristics of Magnetics’ Powder Core materials are high resistivity, low hysteresis and eddy current losses and excellent inductance stability under both DC and AC conditions. In addition, Magnetics Powder Core materials are not pressed with an organic binder, so there is no thermal aging.
While all six materials are used in power applications, each has its own advantage:
- For the lowest loss inductor, MPP material should be used since it has the lowest core loss.
- For the smallest core size in a DC bias dominated design, High Flux material should be considered.
- For the most efficient design using the smallest core, Edge is the best choice, offering the highest DC bias and approximately 40% lower losses compared to High Flux.
- XFlux can be a lower cost alternative to High Flux, in situations where the higher core losses and more limited permeability availability of XFlux is acceptable.
- Kool Mµ (commonly referred to as sendust) is well known for the moderate cost and has significantly lower losses and substantially better thermal properties when compared to powdered iron cores.
- The combination of high DC bias and low core loss density makes Kool Mµ MAX the optimal solution for high efficiency, high power inductors.
- Kool Mµ Hƒ powder cores, optimized for frequencies 200-500 kHz, are a cost-effective solution for minimizing power losses in high frequency power supplies.
- The relatively high saturation flux density of 75-Series cores makes them a low-cost solution in applications where stable inductance under load is necessary.
Powder Core Shapes
Powder cores are available in a variety of geometries including toroids, E shape, U shape, blocks, rounded blocks, and new EQ, LP, and EER shapes. The material properties of powder cores and the flexibility of these geometries make them ideal for a multiple applications and custom assemblies.
Large Toroid Sizes
Five large sizes have been added to the toroid powder core line, including the massive 165 millimeter core. Large Powder Core toroids are a cost-effective option for high current applications, such as: UPS, large Power Factor Correction (PFC) chokes and inverters for renewable energy.
View Powder Core Material Property Curves including Normal Magnetization curves, Core Loss Density curves, Permeability versus Temperature curves, Permeability versus DC Bias curves, Permeability versus AC Flux, and Permeability versus Frequency curves.
View Property Curves
Designing at High Temperatures
Thermal considerations are a basic part of power electronics design. Having this understanding is vital for selecting the best type of material for each application, and for ensuring that the magnetic device will function safely at its maximum operating temperature.
View Design Guide
Powder Core Materials Comparison
Click on table to zoom