Ferrite for Switching Power Supplies Summary

Transcription

1 (/6) Ferrite for Switching Power Supplies Summary Our foremost mission is to develop unique and advanced electronics technologies. As such, ever since TDK was founded in 935 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 control 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 elements, 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, PC4, PC44, PC45, PC46, PC47, and PC5. They contribute to achieving even greater size reductions and performance improvements of high-performance switching power supplies and DC to DC converters -- products considered to constitute the heart of microelectronic 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 HS 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. -3 / 27 / e4_.fm

2 (2/6) CIRCUIT EXAMPLE SINGLE FORWARD CONVERTER Common mode choke coil Active filer choke coil Main power transformer Smoothing choke coil AC input EMI/RFI filter PFC Active filter Output rectifier smoothing circuit DC output Auxiliary power circuit Power switch circuit Control circuit Auxiliary power transformer Drive Transformer Current transformer 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). -3 / 27 / e4_.fm

3 H H (3/6) SELECTED ITEMS OF LEGEND C= Σ Core constant mm A 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 D D W W -3 / 27 / e4_.fm

4 (4/6) MATERIAL CHARACTERISTICS MATERIAL CHARACTERISTICS For Transformer and Choke Material PC4 PC44 PC47 PC5 Initial permeability 23±25% 24±25% 25±25% 4±25% Amplitude permeability µa 3 min. 3 min. 25 C 2 25kHz 6 C 8 sine wave C 7 2 C 85 Core loss volume density (Core loss) [B=2mT] Saturation magnetic flux density [H=94A/m] Pcv kw/m 3 Bs mt Remanent flux density Br mt Coercive force Hc A/m khz sine wave 25 C C C C C C C C C C 65 7 C C C C C C Curie temperature Tc C >25 >25 >23 >24 Density db kg/m Electrical resistivity ρv Ω m Material PC33 PC9 PC95 Initial permeability 4±25% 22±25% 33±25% Amplitude permeability µa Core loss volume density (Core loss) [B=2mT] Saturation magnetic flux density [H=94A/m] Pcv kw/m 3 khz sine wave Bs mt 25 C C 8 47 C C C C C C C Remanent flux density Br mt 6 C C C C Coercive force Hc A/m 6 C C C Curie temperature Tc C >29 >25 >25 Density db kg/m Electrical resistivity ρv Ω m Average value 5kHz, 5mT -3 / 27 / e4_.fm

5 (5/6) For Common Mode Choke Material HS52 HS72 HS Initial permeability 55±25% 75±25% (2min. at 5kHz) ±25% Relative loss factor tanδ/ 6 (khz) 3(kHz) 3(kHz) Saturation magnetic flux density [H=94A/m] Bs mt 25 C Remanent flux density Br mt 25 C Coercive force Hc A/m 25 C Curie temperature Tc C >3 >3 >2 Density db kg/m Electrical resistivity ρv Ω m.2.2 For Telecommunication Material H5A H5B2 H5C2 H5C3 H5C4 Initial permeability +4% 2±3% 33 75±25% ±3% 5±3% % 9( 2 C) Relative loss factor tanδ/ 6 <2.5(kHz) <(khz) <6.5(kHz) <7.(kHz) <7.(kHz) <8(kHz) 3 to +2 C.5 to 2. to.8.5 to.5.5 to.5 Temperature factor of initial αr permeability to 2 C 2 to 7 C.5 to 2. to.8.5 to.5.5 to.5 Saturation magnetic flux density [H=94A/m] Bs mt 25 C Remanent flux density Br mt 25 C Coercive force Hc A/m 25 C Curie temperature Tc C >3 >3 >2 >5 > Hysteresis material constant ηb 6 mt <.8 <. <.4 <.5 <2.8 Disaccommodation factor DF 6 <3 <3 <2 <2 <3 Density db kg/m Electrical resistivity ρv Ω m Material H5C5 HP5 DNW45 DN4 DN7 Initial permeability 3±3% 5±2% 42±25% 4±25% 75±25% Relative loss factor tanδ/ 6 25 C, khz <5 <3.5 <3.5 <2.5 <2. Temperature factor of initial permeability.5 to.5.5 to 2..5 to.5 Average value αr 6 to 2 C 3 to +2 C 2 to 7 C ±2.5% ±2.5%.5 to.5.5 to 2..5 to.5 Saturation magnetic flux density [H=94A/m] Bs mt 25 C Remanent flux density Br mt 25 C Coercive force Hc A/m 25 C Curie temperature Tc C > >4 >5 >3 >5 Hysteresis material constant ηb 6 mt <.5 <.4 <.8 <.8 <.2 Disaccommodation factor DF 6 <2 <3 <3 <3 <2.5 Density db kg/m Electrical resistivity ρv Ω m / 27 / e4_.fm

6 (6/6) vs. Frequency Characteristics tanδ/ vs. Frequency Characteristics 5 3 HS52 PC4 PC44 4 H5C3 HS HS72 4 H5C3 HS HS72 PC5 3 HS52 PC44 PC4 PC5 PC95 PC46 PC45 PC47 tan δ/ Frequency(kHz) Frequency(kHz) Magnetization Curves (Typical) Material: PC4 Material: PC44 Material: PC5 5 6 C C 4 2 C C C 4 2 C C 8 C C 2 C Material: PC45 Material: PC46 Material: PC C 8 C C 2 C C 8 C C 2 C C 8 C C 2 C Material: PC C C 2 C / 27 / e4_.fm

7 (7/6) Core Loss (Typical) Material: PC4 Material: PC44 5 (Sine wave data) 5 (Sine wave data) 5kHz 4 3kHz 2kHz 4 5kHz 3kHz 2kHz khz Core loss Pcv(kW/m 3 ) 3 2 5kHz 25kHz Core loss Pcv(kW/m 3 ) 3 2 khz 5kHz 25kHz 6 C C Test core: EI C C Test core: T Material: PC5 Material: PC45 5 (Sine wave data) 5 (Sine wave data) 4 MHz 5kHz 3kHz 2kHz 4 3kHz 2kHz khz 5kHz 6 C C 7kHz Test core: T2X5X Flux density Bm(mT) 6 C C Flux density Bm(mT) -3 / 27 / e4_.fm

8 (8/6) Core Loss (Typical) Material: PC46 Material: PC47 5 (Sine wave data) 5 (Sine wave data) 4 3kHz 4 3kHz 2kHz 2kHz 3 2 khz 5kHz 3 2 khz 4 C 8 C Flux density Bm(mT) 6 C C Flux density Bm(mT) Material: PC33 Material: PC95 5 (Sine wave data) 5 (Sine wave data) 4 3kHz 4 2kHz 3kHz 3 2 khz 5kHz 3 2 2kHz khz 5kHz 6 C C Flux density Bm(mT) C Flux density Bm(mT) -3 / 27 / e4_.fm

9 (9/6) Temperature Dependence of Core Loss (Typical) Material: PC4 (Frequency: khz) Material: PC44 (Frequency: khz) mT 6 4 2mT 2 5mT 2 5mT Material: PC5 MHz mt Material: PC47 Test core: Toroidal OD=3mm TH=8mm ID=9mm khz/2mt 8 Core loss Pcv(kW/m 3 ) 5kHz mt MHz 5mT 5kHz 5mT Material: PC33 Material: PC95, PC45, PC46 2 khz/2mt khz/2mt 8 PC PC45 PC / 27 / e4_.fm

10 (/6) Magnetization Curves (Typical) HS52 HS72 HS C C C C C C Test core OD: 3mm TH: 8mm ID: 9mm 5 Test core OD: 3mm TH: 8mm ID: 9mm 5 Test core OD: 3mm TH: 8mm ID: 9mm 5 vs. Temperature Characteristics (Typical) PC HS PC HS / 27 / e4_.fm

11 (/6) vs. Temperature Characteristics (Typical) PC HS Test core: OD=3mm TH=8mm ID=9mm PC PC PC PC / 27 / e4_.fm

12 (2/6) MAXIMUM NUMBER OF TURNS ON BOBBINS EI and EE Series EER Series ETD Series PQ Series LP Series EP Series RM Series SMD Series EPC and EEM Series Wire Table -3 / 27 / e4_.fm

13 (3/6) EI and EE Series (without terminal pin) EER Series BE62.3-2CPHFR BE-6-52 BE-5-52 BE-4-52 BE5.3-2CPHFR 3 BEER49 BEER42/2 BEER4 BEER28L BEER35 BE-3-52 BEER28 BEER25.5 BE BE EI and EE Series (with terminal pin) BE6-2CPFR BE5-2CPFR BE4-2CPFR BE33-2CPLFR BE35-2CPLFR ETD Series BE3-CPFR BE25-8CPFR BES6-CPSFR BE9-6CPFR BE28-CPLFR 3 BE22/9/6-8CPFR 2 BE3-CPSFR 2 BETD24-2CPHFR BE6-6CPFR BETD9-CPHFR BE22-8CPFR BE2.5-CPFR BE-8CPSFR / 27 / e4_.fm

14 (4/6) PQ Series EP Series BPQ5/5 BPQ4/4 2 BPQ35/35 BPQ32/3 2 BPQ26/25 BPQ32/2 BPQ2/2 BPQ26/2 BPQ2/6 BEP BEP3 BEP7 BEP2 BEP LP Series RM Series BLP32/3-8CPLFR BLP32/3-CPLFR BLP22/3-CPLFR BLP22/3-8CPLFR 3 BLP23/8-8CPLFR 2 2 BRM4 BRM2 BRM BRM5 BRM4 BRM8..5. BRM6.5-3 / 27 / e4_.fm

15 (5/6) SMD Series BER4.5/6-GAFR 2 BER9.5/5-8GAFR BER/5-GAFR BE8.9/8-GFR BE5-96FFR BER/3.9-GAFR EPC and EEM Series BEPC3-2CPHFR BEPC27-CPHFR BEPC25-CPHFR 3 BEPC25B-GAFR BEPC27N-4CPHFR BEPC9-CPHFR BEPC9-GAFR BEPC9-SAFR BEPC7-CPHFR BEPC7-9GAFR 2 BEM2.7-8GAFR BEPC-8GAFR BEPC3-CPHFR BEPC3-GAFR..5-3 / 27 / e4_.fm

16 (6/6) Wire Table AWG AWG dia. AWG area Single dia. Single area Heavy dia. Heavy area (mm) (mm 2 ) (mm) (mm 2 ) (mm) (mm 2 ) / 27 / e4_.fm