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
| Parameter | Solution 1: Powdered Iron | Solution 2: Ferrite | Solution 3: Nanocrystalline |
|---|---|---|---|
| Volume | ~11.5cm³ | ~10.1cm³ | ~8.0cm³ |
| Temperature Rise | High | Medium | Low |
| Efficiency | Medium | High | Highest |
| Cost | Low | Medium | High |
| Frequency Range | 10-500kHz | 1-200kHz | 1-100kHz |
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.
