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Weyman Lundquist
President and CEO
West Coast Magnetics
ISO9001:2015
ISO13485 2016
What Does the Future Hold for Transformers and Inductors in Medium and High Power Applications
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Medium to High Power Magnetics
Highlight challenges
7 kW transformer design example
Ferrites for higher frequencies
Inductors for medium, high power
Power levels increasing to 10 kW and higher.Frequencies increasing beyond 100 kHz to 500 kHzLLC resonant circuits becoming common
OUTLINE
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Larger Geometries Inherently Have Tendency to Higher Temperature Rise
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Higher Currents Require Design for AC Resistance Minimization
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Litz individual Strand Gauge (AWG)
Litz Wire Price/lb versus AWG
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Copper thickness (mil)
Copper foil Price/lb versus thickness
Cost of Litz Wire and Copper Foil
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TRANSFORMER DESIGN EXAMPLE
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Design Elements – 7 kW SMPS Transformer
New WCM410-88 core
Potting to thermally couple bobbin and core
155 C materials
Use of ferrite tape for leakage layer
Shape opt optimization for litz
Investigation of foil
Foil leakage layer
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Loss Measurement for Different Windings
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BF Product for MnZn Ferrites
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Inductors
Must consider saturation in addition to core loss
Inductor size, cost, loss dependent on L value and associated ripple
Most designs are still powdered toroids until power levels are very high.
At high power levels we are seeing more topologies using transformer leakage L for the inductor.
More designs are requiring ferrite cores due to higher frequency and ripple requirements
Gap effects create loss in ferrite based designs
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WCM Shaped Foil Inductors
Low loss gapped ferrite core, shaped foil winding.
Patent pending: Dartmouth and WCM
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WCM Shaped Foil vs. Powdered Toroid
Specs: 50 uH, Max 10 amps RMS
Toroid: Fe Al Si core
WCM319 and WCM318 gapped ferrite
Design toroidal inductor to match inductance of WCM318, 319 and have the same DCR
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ESR vs. Frequency
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Loss vs. Ripple, no DC
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Loss vs. Ripple, Zoom to 5%
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Comparison of 10 uH, 55 amp inductors
ShapedFoil
IronNickelToroid
HighIronToroid
HelicalCoil
Based on 2015 WCM study, copies available
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Winding Loss: Gapped Ferrite
Cutout Patent issued: Dartmouth and WCM
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Thank you for your time
Weyman Lundquist, PresidentWest Coast Magnetics
4848 Frontier Way, Ste 100
Stockton, CA 95215
www.wcmagnetics.com
800-628-1123