680uH/12A Plug-in Inductor Design Solutions

Design Requirements

• Inductance: 680μH
• Current: 12A
• Type: Plug-in
• Objective: Minimize size

Solution 1: Powdered Iron Core Inductor

Material Characteristics

• Material: Iron-Silicon-Aluminum alloy powder core
• Permeability: 60-90
• Saturation flux density: ~1.0-1.2T
• Applicable frequency: 10kHz-500kHz

Design Parameters

• Core model: T106-26 (Outer diameter: 26.9mm, Inner diameter: 14.7mm, Height: 11.1mm)
• Number of turns: ~65 turns
• Wire specification: AWG 14 (diameter ~1.63mm)
• Estimated volume: ~11.5cm³

Pros and Cons

• Pros: Low cost, readily available
• Cons: Larger volume, higher high-frequency losses, higher temperature rise

Solution 2: Ferrite Core Inductor

Material Characteristics

• Material: Manganese-Zinc ferrite
• Permeability: 1500-3000
• Saturation flux density: ~0.4-0.5T
• Applicable frequency: 1kHz-200kHz

Design Parameters

• Core model: ETD39/20/13 (Dimensions: 39mm×20mm×13mm)
• Number of turns: ~42 turns
• Wire specification: AWG 14 (diameter ~1.63mm)
• Air gap: ~0.8mm
• Estimated volume: ~10.1cm³

Pros and Cons

• Pros: Smaller volume, lower high-frequency losses
• Cons: Lower saturation flux density, requires air gap

Solution 3: Nanocrystalline Core Inductor

Material Characteristics

• Material: Nanocrystalline alloy
• Permeability: 15000-30000
• Saturation flux density: ~1.2-1.3T
• Applicable frequency: 1kHz-100kHz

Design Parameters

• Core model: C-type nanocrystalline core (Dimensions: 32mm×25mm×10mm)
• Number of turns: ~35 turns
• Wire specification: AWG 14 (diameter ~1.63mm)
• Air gap: ~1.0mm
• Estimated volume: ~8.0cm³

Pros and Cons

• Pros: Smallest volume, low temperature rise, high efficiency
• Cons: Higher cost, may require customization

Comparison of Solutions

Recommendation

Based on the size requirement, the nanocrystalline solution (Solution 3) provides the smallest volume solution while offering the best performance characteristics. If cost is a primary consideration, the ferrite solution (Solution 2) offers a good balance of performance and volume.