Power inductors

Custom Power Inductors – design and poduction of dedicated chokes to meet the requirements of non-Standard applications

Modern power electronics require components with increasingly higher efficiency, higher power density, and improved EMI performance. Therefore, more and more device manufacturers are opting for custom power inductors designed specifically for specific applications.

Producing custom inductors allows for optimization of:

DC/DC converter efficiency,
operating temperature,
system size,
EMI level,
resistance to high pulse currents,
core saturation characteristics.

Production of dedicated, custom power chokes

Modern power chokes are a fundamental element of buck converters, boost converters, flyback circuits, LLC converters, PFC circuits, SMPS (switched-mode power supplies), industrial inverters, automotive systems, EV chargers, power supply systems in FPGA applications and VRMs for CPU processors.

Power inductors: coils and chokes - Most important technical parameters

The production of dedicated power chokes typically includes design, core selection, winding design, thermal optimization, prototyping, electrical testing, and environmental qualification. Various designs are available: SMD chokes, THT chokes, high-current chokes, common-mode chokes, coupled chokes, planar inductors, and toroidal chokes.

Below are the approximate ranges of electrical and mechanical parameters:

PARAMETER	POWER INDUCTORS
Wire type	Solderable and non-solderable: CuL 155 – 200, Gr.1 – 2 (typically) Selfbonding: FSP 18, STP 18, PSP 15 and etc.
	CuAg silver-plated wires for HF applications
Other types of wires are available on request.
Wire diameter	Min	0.1 mm
	Max	2.10 mm
	Other wire diameters are available on request.
Winding direction	Left, Right
Number of winding layers	Min	1
	Max	TBD
Coil shape	Depends on the shape of the ferrite core. Cylindrical, spool, bar, and others.
	Possibility of placing a UV glue point for automatic assembly (Pick & Place machines).
	Unusual, non-typical shapes or requirements – Possibility of individual arrangement upon request.
Types of Cores Used	Ferrite Cores, Powder Core, Metal Composite
Typical Saturation Current Ranges (Isat)	0.1 A (100 mA) 1 A 5 A 10 A
Typical DC Resistance (DCR)	Below 1 mΩ (in VRM and Automotive), 2 – 100 mΩ for medium power
Typical Operating Frequency	Depends on the application and on the material selection (especially the ferrite core hysteresis) 100 kHz 250 kHz 500 kHz 1 MHz
Leads	Typically – soldered to the core.
	Compression-welded.
	Metalized with silver wire for reinforcement.
	Other designs are available upon request.
Lead Location and Shape	Typically – wrapped around specific points on the core.
	Depends on the core shape – lead layout according to the core and customer requirements.
Soldering	Pb Free
	Pb (on request)