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New high permeability materials for EMI suppression

leticia.leon@ferroxcube.com February 2011

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High permeability materials evolution What is improved? What is new in 3E10 & 3E12? 3E10 3E12 Standard range in 3E10 &3E12 Applications

Contents

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Permeability

High permeability materials evolution

7000 3E26

10000 3E5/6

4300 3C11

6000 3E25/3E27

3E10

12000 3E12

Tighter tolerance

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What is improved in the common mode filter ?Higher permeabilityIncrease 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 bandwidthExtended 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

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3E10

3E123E6

Tighter tolerance (±20%)

20% Higher permeability

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3E10: Process control with extended bandwidthProperty 3E10Tighter tolerance in AL

Lower electric losses

More stability with frequency

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

tan δ/μi @ 30 kHz, 25ºC, 0.25mT

< 5x 10-6

tan δ/μi @ 100kHz, 25ºC, 0.25mT

< 20 x 10-6

Permeability 10000 ± 20%

100 1000 100005

10

15

20

25

30 Impedance Vs Frequency

3E6

3E10

Frequency (kHz)

Imp

edan

ce (

Ω)

Measured on a coated toroid of Ø25xØ15xh10

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

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Permeability in product increases up to 20% compared to 3E6 and market equivalents

3E12: 20% permeability rise

Property 3E12

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

Permeability 12000 ± 30%

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3E10 & 3E12 performance overview

100 1000 100005

10

15

20

25

30Impedance Vs Frequency

3E6 3E10 3E12

Frequency (kHz)

Imp

edan

ce (

Ω)

100 1000 100000

100

200

300

400

500

600

Impedance Vs Frequency 3E10 and 3E12

3 turns 3E10 3 turns 3E12 5 turns 3E10

Frequency (kHz)

Imp

ed

an

ce

(Ω

)

100 1000 10000500

1000

1500

2000

2500

3000Impedance Vs Frequency 3E10 and 3E12

3E10 10 turns 3E12 10 turns

Frequency (kHz)

Imp

edan

ce (

Ω)

100 1000 100000

3000

6000

9000

12000

15000

18000Impedance Vs Frequency 3E10 and 3E12

3E10 25 turns 3E12 25 turns

Frequency (kHz)

Imp

edan

ce (

Ω)

3E12 achieves the highest impedance up to 300kHz3E10 achieves the most extensive widthband

Graphs show how impedance vary as a function of number of turns

In all cases we observe similar behavior in 3E10 and 3E12: 3E12 higher Z at lower frequencies, whereas lower electric losses of 3E12 lead to wider bandwidth with high impedance in 3E10

Measured on coated toroids of Ø25xØ15xh10

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Range in 3E10 & 3E12

Standard cores in 3E10 and 3E12 are all toroid´s tools from 2.5mm to 63mm

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

Rings are the optimal shape in high permeability to reduce leakage losses

Samples available

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ApplicationsThe 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!!!!!!!

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Summary

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

Resistivity 0.5 Ohm x m

Property 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

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

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Benchmarking

American

Permeability 10000

Tolerance ±30%

Max size 63

Electric losses 7

Asian 1

Permeability 10000

Tolerance ±30%

Max size 65

Electric losses 30

Looking at competitors’ highest permeability products we find…

Asian 2

Permeability 12000

Tolerance ±30%

Max size 38

Electric losses 10

Ferroxcube3E10

Ferroxcube 3E12

Permeability 10000 12000

Tolerance ±20% ±30%

Max size 63 63

Electric losses 5 75 7

±20%

FXC offers the tightest tolerance in high permeability

the largest size with the maximum permeability

12000

63 63 and the lowest electric losses

Taking all these factors into account, it is difficult to find such high quality product in the market

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