Report

New high permeability materials for EMI suppression leticia.leon@ferroxcube.com February 2011 ‹#› Contents High permeability materials evolution What is improved? What is new in 3E10 & 3E12? 3E10 3E12 Standard range in 3E10 &3E12 Applications ‹#› High permeability materials evolution Permeability 12000 3E12 10000 3E5/6 Tighter tolerance 7000 3E26 6000 3E25/3E27 4300 3C11 3E10 ‹#› What is improved in the common mode filter ? Higher permeability Increase coupling between windings the differential mode impedance is decreased Reduce the size of the toroid and/or the number of turns of winding less DC resistance cheaper BOM cost Larger bandwidth Extended dumping bandwidth Lower electric losses Better frequency stability Lower signal distortion Tighter inductance tolerances Less variation due to external stresses from winding and potting Better predictability More robust process and improved repeatiblity ‹#› Tighter tolerance (±20%) 3E6 20% Higher permeability ‹#› 3E10: Process control with extended bandwidth Tighter tolerance in AL Lower electric losses More stability with frequency Impedance Vs Frequency Impedance (Ω) 30 3E6 25 Property 3E10 Permeability 10000 ± 20% tan δ/μi @ 30 kHz, 25ºC, 0.25mT < 5x 10-6 tan δ/μi @ 100kHz, 25ºC, 0.25mT < 20 x 10-6 3E10 20 15 We can observe that despite 3E6 higher initial permeability , from 300 kHz upwards, thanks to 3E10 better stability with frequency, extended impedance bandwidth and higher amplitude are achieved 10 5 100 1000 Frequency (kHz) Measured on a coated toroid of Ø25xØ15xh10 10000 Less influence of winding and potting operations on permeability Broad damping characteristics Better process control thanks to the improvement in impedance stability with frequency and tolerance reduction ‹#› 3E12: 20% permeability rise Permeability in product increases up to 20% compared to 3E6 and market equivalents Property Permeability 3E12 12000 ± 30% Reduction of negative impact of high number of turns like DC resistance and parasitic capacitance Higher permeability leads to core size or number of turns reduction Cost savings either in ferrite material or in copper ‹#› 3E10 & 3E12 performance overview Impedance Vs Frequency 3E10 and 3E12 Impedance Vs Frequency 30Graphs 600 show how impedance vary 3E12 as aachieves the highest impedance function of number of turns Impedance (Ω) 25 In all cases we observe similar in 3E10 and 3E12: 3E12 higher Z at lower 15frequencies, whereas lower electric losses of 3E12 lead to wider bandwidth 10with high impedance in 3E10 20 3E6 3E10 Impedance (Ω) up 500 to 300kHz 3E10 achieves the most behavior extensive widthband 400 300 200 100 3E12 3 turns 3E10 0 100 5 100 1000 Frequency (kHz) 10000 5 turns 3E10 5 turns 3E12 1000 10000 Frequency (kHz) Impedance Vs Frequency 3E10 and 3E12 Impedance Vs Frequency 3E10 and 3E12 18000 3000 15000 Impedance (Ω) 2500 Impedance (Ω) 3 turns 3E12 2000 1500 1000 12000 9000 6000 3000 3E10 10 turns 3E12 10 turns 3E10 25 turns 500 3E12 25 turns 0 100 1000 10000 100 Frequency (kHz) 1000 Frequency (kHz) 10000 Measured on coated toroids of Ø25xØ15xh10 ‹#› Range in 3E10 & 3E12 Standard cores in 3E10 and 3E12 are all toroid´s tools from 2.5mm to 63mm Rings are the optimal shape in high permeability to reduce leakage losses Gapped shapes reduce effective permeability, therefore the advantages obtained for these shapes in 3E10 and 3E12 materials are negligible However, shapes can be manufactured in these materials upon request Samples available ‹#› Applications The main applications are interference suppression and wideband transformers: Wideband transformers Impedance transformation over a broad frequency range. Applications include impedance matching, voltage or current transformation, DC isolation, balanced/unbalanced mixing, power splitting, coupling, and signal inversion. Telecommunications devices Pulse transformers Communication systems and digital networks Ground fault interruptors (GFI) Home and industrial Interference suppression Common mode choke. Mains filters in all type of electronic equipment. ATTENTION TO HIGH GROWTH INVERTERS MARKET!!!!!!! ‹#› Summary Property Property 3E6 Permeability 10000 ± 30% tan δ/μi @ 30 kHz, 25ºC, 0.25mT < 10x 10-6 tan δ/μi @ 100kHz, 25ºC, 0.25mT < 30 x 10-6 Resistivity 0.1 Ohm x m 3E10 Permeability 10000 ± 20% tan δ/μi @ 30 kHz, 25ºC, 0.25mT < 5x 10-6 tan δ/μi @ 100kHz, < 20 x 10-6 25ºC, 0.25mT Resistivity Property 0.5 Ohm x m 3E12 Permeability 12000 ± 30% tan δ/μi @ 30 kHz, 25ºC, 0.25mT < 7x 10-6 tan δ/μi @ 100kHz, 25ºC, 0.25mT < 25 x 10-6 Resistivity 0.5 Ohm x m ‹#› Benchmarking Looking at competitors’ highest permeability products we find… Asian 2 Asian 1 American Permeability 10000 Permeability 12000 Permeability 10000 Tolerance ±30% Tolerance ±30% Tolerance ±30% Max size Electric losses 63 7 Max size 65 Max size 38 Electric losses 30 Electric losses 10 Ferroxcube 3E10 Ferroxcube 3E12 FXC offers the tightest tolerance in high permeability 12000 10000 12000 Permeability Taking all these factors into account, itthe islargest difficult to the find size with maximum permeability in the market ±20% ±30% Tolerancesuch high ±20% quality product Max size 63 63 Electric losses 55 77 and the lowest electric losses ‹#› ‹#›