Finding the solution to challenging high-frequency requirements with established materials

Engineers and designers of power inductors are meeting the demands of delivering more performance and efficiency in a smaller, lighter packages by increasing the frequency of their designs. Higher frequencies enable the use of smaller passive components; however, it pushes the traditional materials used in these applications to their critical point.

At this stage, core losses increase, resulting in higher temperatures inside the core, flux leakage, poor performance and, potentially, the ultimate failure of the design. If engineers and designers are to successfully increase the frequency of their design – and deliver to these more demanding design requirements – they must consider alternative materials.

Using a tried-and-tested material from a different sector

Carbonyl iron powder, available from our partner Micrometals, has long been used in high-frequency applications such as radio frequency and frequency control, where frequencies between 100KHz and 5MHz are not unusual. Although power inductors do not produce radio frequencies, the switching frequency of the latest designs is within a similar range, therefore this well-established material is ideal for designers striving to meet the ever-increasing demands of smaller, lighter, more-efficient products.

Carbonyl iron powder provides many benefits over other material options. With lower permeability, core losses are greatly reduced, which avoids the rapid rise in temperature and resulting loss in overall efficiency and performance. The material remains stable over a wide range of frequencies and is of comparable cost. It is, in some cases, a cheaper alternative to other suitable materials.

Expert support to help you integrate traditional materials in new applications

Acal BFi’s Custom Services for Magnetic Components centre can directly support you with the design and integration of this material into your application. As a partner of Micrometals, one of the leading manufacturers of carbonyl iron powder cores, we are uniquely positioned to provide an outstanding level of service and support.

Micrometals are widely recognised as the expert in producing iron powder alloy materials from either pressing or machining cores in standard, complex and custom shapes for OEM design requirements. Our experience in the magnetics industry and a relationship of more than 30 years means we have exclusive access to their full range of materials. With a complete range of materials, shapes and sizes in stock, we can instantly deliver almost any quantity, from single samples up-to manufacturing production levels, immediately across Europe.

Discover how your magnetic component designs and applications can benefit from carbonyl iron powder with a standard sample, and gain greater overall performance with a custom design from Micrometals and Acal BFi by contacting us today.