Innovative high-current inductors combine real-estate and cost savings with reduced power losses

October 26, 2012 // By Paul Buckley
Precision, Inc. has launched four new technologies within the company´s family of High-Current Inductors.   The company claims the devices generate up to 33% real estate savings and up to 25% reduction in power losses.

The new high-current inductors, which are available in four standard sizes as well as in a variety of custom formats, feature a flat-wire, ferrite core construction that generates both real estate and cost savings while reducing power losses.
The new Precision High-Current Inductors can be used as a standard part drop-in replacement or as part of a custom technology solution. These inductors also work with power management ICs made by major IC manufacturers such as International Rectifier, Microchip and Texas Instruments. The technology can be easily integrated into a number of key power conversion applications for a wide number of industries.

The high-density construction of the Precision High-Current Inductors features an innovative flat-wire, edge-wound copper coil that generates significant efficiency gains and space savings compared to alternative round-wire or Litz wire technologies.
The high-density inductor construction maximizes form capabilities and generates up to 33% real estate savings compared to round-wire alternatives. This high-density construction allows for 50-60% copper utilization compared to just 35-40% for round-wire or 25-30% for Litz wire. Higher copper utilization reduces power losses up to 25% compared to alternative round-wire and Litz wire technologies due to the reduced resistance. The single-layer winding also reduces parasitics which leads to lower switching losses and higher efficiency.
Higher copper utilization also means higher inductance can be achieved at a given volume. This not only generates potential real estate savings, but also leads to lower ripple current which in turn reduces stress on other circuit components such as EMI filters and output capacitors. Overall system component pricing can be reduced as design engineers no longer need pricier, more durable EMI filters and output capacitors.

Precision´s new High-Current Inductors feature cost-effective and efficient ferrite core construction. Ferrite is more cost-effective than metal alloy powder material such as Sendust and enhances performance by allowing up to 50-90% lower core loss.  Ferrite is also resistant to thermal aging, ensuring a long