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Powder cores are distributed air gap cores made from ferrous alloy powders for low losses at high frequencies. Small air gaps distributed evenly throughout the cores increase the amount of DC that can be passed though the winding before core saturation occurs. Molybdenum permalloy powder (MPP) cores are excellent as low loss inductors for switch-mode power supplies, switching regulators and noise filters. High Flux and Sendust powder cores are better choice for the power factor correction (PFC), switching regulator inductors, in-line noise filters, pulse and flyback transformers, and many other application required for low losses at high frequencies.
MH&W International offers many types of soft magnetic powder cores of the Molybdenum Permalloy(MPP), High Flux, Sendust and the new Mega Flux core materials, which are mainly used for inductors and transformers requiring the low losses and inductance stability under high DC bias conditions. The fully standardized production under strict quality control from raw materials (nickel, iron, molybdenum, aluminum and silicon) to finished products enables MH&W to reduce the variations in product quality making it possible to maintain a guaranteed level of quality.
MPP | High Flux |
Ni-Fe-Mo alloy powder cores are made from alloy powders of nickel, iron and molybdenum.MPP cores exhibit a highly sustainable stability in temperature and inductance under high DC magnetization or high DC Bias conditions. They offer the highest permeability among our materials and the lowest core loss compared to any other core material. MPP cores are also considered to be a premium material for direct current output inductors for SMPS including high Q filters, loading coils and EMI/RFI filters. Finished toroid cores are coated with a gray epoxy to provide dielectric protection and added physical strength. | Ni-Fe alloy powder cores are made from alloy powders of nickel and iron.The 15,000 Gauss saturation level of High Flux cores has a higher energy storage capability and more effective permeability when compared to the performance of gapped ferrite or powdered iron cores of a similar size. The excellent DC bias characteristics and low core losses of High Flux cores offer a reduction in size and the number of winding turns as well as superior magnetic properties. CSC High Flux cores are excellent choices for applications such as PFC reactors, switching regulator inductors, in-line noise filters, pulse transformers and flyback transformers. Finished High Flux cores are coated with a Khaki epoxy and come in a variety of shapes and sizes. |
Sendust | Mega Flux |
Fe-Si-Al alloy powder cores are made from alloy powders of iron, silicon and aluminum.Near-zero magnetostriction makes Sendust cores ideal for eliminating audible noise in filter inductors. Core losses of Sendust cores are significantly lower than those of powdered iron cores. Especially Sendust E shapes provide a higher energy storage capability than gapped Ferrite E cores. Gap losses and eddy current losses are minimized with Sendust E cores compared to gapped ferrite E shapes. Sendust cores are a smart choice for PFC circuits. Other major applications include switching regulator inductors, In-line noise filters, pulse transformers and flyback transformers. Finished Sendust cores are coated in a black epoxy. | Fe-Si alloy powder cores are made from an alloy of iron and silicon.CSC has developed new magnetic alloy powder cores for the first time in the world under the name of Mega Flux . The innovative design of these unique cores includes a smaller size, higher current and higher energy storage capability. Mega Flux cores have higher flux density than any other magnetic material, 16,000Gauss compared to 15,000Gauss for High Flux cores and 10,000 Gauss for Sendust cores. The extremely good DC bias characteristics provide the best solution for high end applications such as buck/boost inductors for high power supply systems, smoothing chokes for inverters and reactors for electric vehicles. Mega Flux cores pressed with no organic binder have significantly lower core losses than powdered iron cores and Fe-Si strip cores. They also present excellent thermal properties with no thermal aging effects. Finished Mega Flux cores are coated with a dark brown epoxy. |
Core Descriptions
| MPP | High Flux | Sendust | Mega Flux | |
|---|---|---|---|---|
| Materials | Ni-Fe-Mo alloy | Ni-Fe alloy | Fe-Si-Al alloy | Fe-Si alloy |
| Color | Yellow | Green | Blue | Dark Brown |
| Finish | Epoxy, Parylene-C, Plastic Case | |||
| Sizes | From 3.5mm OD to 77.8mm OD | |||
| Permeabilities (µ) | 26, 60, 125, 147, 160, 173, 200 | 26, 60, 125, 147,160 | 26, 60, 75, 90, 125 | – |
| Break-Down Voltage | 500V min. | 500V min. | 500V min. | – |
| Magnetic Characteristics | Relatively high saturation flux density Low residual flux density Excellent temperature stability Low core losses Excellent inductance stability under high DC bias conditions | Highest biasing capability High saturation flux density of 15,000G compared to 7,000G for MPP and 10,000G for Sendust Relatively low core losses | Core losses significantly lower than powdered iron Good DC bias characteristics Cost between powdered iron and MPP | Bsat : 1.6 Tesla High energy storage capacity Low core losses compared to Fe-Si Laminations Low relative cost Block assembly available Good candidate for high-end applications |
| Major Applications | Direct current output inductors for SMPS High Q filters Loading coils EMI/RFI filters Many other precision applications | Power factor correction(PFC) circuits Switching regulator inductors In-line noise filters Pulse and flyback transformers | Power factor correction(PFC) circuits Switching regulator inductors In-line noise filiters Pulse and flyback transformers | Output Chokes Line filters PFC reactors Flyback transformers Examples: |
Material Characteristics
| Core Materials | Core Loss | Perm. vs DC Bias | Relative Cost | Frequency Range | Flux Density (Sat.) | Temp. Stability |
|---|---|---|---|---|---|---|
| MPP | Lowest | Better | High | 1MHz | 7,000G | Best |
| High Flux | Low | Best | Medium | 1MHz | 15,000G | Better |
| Sendust | Medium | Good | Low | 2MHz | 10,000G | Good |
| Mega Flux | Medium | Best | Low | 1MHz | 10,000G | Best |
| Iron | Highest | Poor | Lowest | 100KHz | 10,000G | poor |
| Amporphous (gapped) | Medium | Better | Highest | 300KHz | 6,500G | poor |
| Ferrite (gapped) | Lowest | Poor | Low | 1MHZ | 4,500G | poor |
Applications
| Computer | Desk top PC | DC Reactor, Choke Coil for SMPS |
|---|---|---|
| Lap Top PC | DC Reactor, Choke Coil for SMPS | |
| Server PC | DC Reactor, Buck Inductor for SMPS Buck Inductor for VRM | |
| Display | PDP | DC Reactor, Buck Inductor for Pre-regulator |
| LCD TV | Choke Coil for Adapter | |
| Lap Top PC LCD | Choke Coil for LCD Back Light Inverter | |
| PDA | Choke Coil for LCD Back Light Inverter | |
| Mobile Phone | Choke Coil for LCD Back Light Inverter | |
| Home Appliances | Digital Amp(for Home Theater) | Low Pass Filter for Digital Amp |
| Digital Camera/Camcoder | Choke Coil for LCD Back Light Inverter | |
| Inverter Airconditioner | DC Reactor for PFC | |
| Induction Heating | AC Reactor for PFC | |
| Industrial Uses | Elevator | AC Reactor for PFC |
| CNC | AC Reactor for PFC | |
| UPS | DC Reactor for SMPS | |
| Automobile | 42V Power Module | Back-Boost Inverter for DC DC Converter |
| EV, HEA | Back-Boost Inverter for DC DC Converter | |
| Substitutional Energy | Solar Cell Generating System | DC Reactor, AC Reactor for Inverter |
| Fuel Cell Generating System | DC Reactor, AC Reactor for Inverter | |
| Telecommunications | Relay Center of Mobile Devices | DC Reactor for SMPS |
| Mobile Phone | Choke Coil for DC DC Converter | |
| Common Uses | Differential Mode Noise Filter |