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Tape-Wound Soft Magnetic Cores

Magnetic cores up to 2.1m x 2.1m, 1800kg and strip widths up to 0.6m. Strip widths of 25mm, 33mm, 45mm are more cost effective because there is no slitting process or slitting scrap. There is virtually no limit on maximum strip width with stacked assemblies.

Cores can be supplied as an assembly of multiple cores stacked and bonded together. Stacked cores actually perform better because the voltage per lamination supported is divided by the number of cores stacked together. Thin epoxy layer can be applied to minimise sloughing of the outer layer, this is important in high voltage and oil applications.

Please call 01793 784389 and speak to a member of our technical sales team to discuss your requirements.

 

Materials

  • Nanocrystalline
  • 3% Grain-Oriented Silicon Steel (GOS)
  • 50% & 80% Nickel
  • Amorphous
  • Supermendur®, Cobalt-Iron High Flux
  • 6.5% Non-Oriented Silicon Steel
  • Other Specialised Materials

Geometry

  • C-cores
  • E-cores
  • Uncased toroids including machined nylon, injection moulded, Aluminium and more
  • Pie type 3-phase cores, D-cores, bars and other custom shapes
  • Custom configurations
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Case Studies

Ultra Low-Loss Amorphous Cores

  • Low-loss cores for inverters, energy storage application
  • Metglas 2605SA1 alloy in cut C-core geometry
  • Over 30% lower loss than other suppliers
  • Optimized annealing & bonding process
  • 3 weeks from engineering to delivery

Custom Pulsed Cores

  • Pulse power transformer for medical imaging equipment
  • Special coating for high insulation resistance & breakdown voltage
  • 30kV high power pulse test, pulse waveforms & data supplied
  • Custom tools for stacked assemblies

Energy Harvester Cores

  • Power harvesting for smart grid monitoring application
  • Tape wound technology for most efficient, cost effective solution
  • Specialised testing needed for qualification
  • 3 weeks from engineering to delivery

Advanced Nanocrystalline Cores

  • High frequency applications utilising a variety of nanocrystalline materials
  • Custom computer controlled atmospheric conditions to optimise annealing
  • Large core sizes up to 2.1 metres
  • Typically 3-5 weeks with expedite available

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Magnetic Core Performance

The tables below show the performance of various magnetic core materials.
B (kG) is flux density in units of kilo-Gauss. Watts/lb and VA/lb are power loss and excitation VA when measured at the indicated flux (B) and frequency under sine wave excitation.

C Cores

Material Description Thickness (inches) Space Factor (Minimum) Maximum Watts/lb Maximum VA/lb Test Flux Density (kG) Test Frequency (Hz) Maximum Gap VA/inch2 @ .001″
3% Silicon Steel Silectron®1 .001 .83 12.0 20.3 12.5 400 16.3
.002 .89 10.0 15.0 15.0 400 29.2
.004 .90 10.0 13.1 15.0 400 29.9
.004 .90 15.0 39.5 17.6 400 41.1
.007 .90 15.0 39.5 17.6 400 43.0
.009 .92 0.89 1.7 15.0 60 5.0
.009 .95 0.89 1.5 17.6 60 6.9
.011 .95 0.89 1.7 15.0 60 5.0
.011 .95 0.89 1.5 17.6 60 6.9
.012 .95 0.89 1.7 15.0 60 5.0
80% Nickel-Iron Supermalloy®2 .0005 .65 12.0 18.0 5.0 10000 57.7
.001 .83 14.0 21.0 5.0 10000 70.6
.002 .89 20.0 30.0 5.0 10000 81.2
.004 .90 15.0 22.0 5.0 5000 41.5
50% Nickel-Iron Deltamax®3 .0005 .65 30.0 40.0 10.0 5000 115.3
.001 .83 37.0 47.0 10.0 5000 141.2
.002 .89 55.0 70.0 10.0 5000 162.4
.004 .90 3.5 6.0 10.0 400 13.0
50% Cobalt-Iron Supermendur®4 .002 .89 20.0 72.0 20.0 400 52.0
.004 .90 19.0 66.0 21.0 400 58.6
Metglas®5 2605SA1 .001 .82 16.5 N/A 2.0 20000 N/A
Nanocrystalline Prime .0007 & .0005 .78 5.5 N/A 2.0 20000 N/A
Nanocrystalline FT3-W .0007 .78 5.5 2.0 20000 N/A

 

E Cores

Material Description Thickness (inches) Space Factor (Minimum) Maximum Watts/lb Maximum VA/lb Test Flux Density (kG) Test Frequency (Hz) Maximum Gap VA/inch2 @ .001″
3% Silicon Steel Silectron®1 .004 .90 12.0 22.7 15.0 400 51.8
.004 .90 18.0 68.4 17.6 400 71.0
.007 .92 18.0 68.4 17.6 400 74.0
.009 .95 1.1 4.0 17.6 60 11.9
.012 .95 1.1 2.9 15.0 60 8.7
.011 .95 1.1 2.9 15.0 60 8.7
.011 .95 1.1 4.0 17.6 60 11.9
50% Cobalt-Iron Supermendur®4 .004 .90 22.0 120.0 21.0 400 101.0

 

 Datasheets

 

 

 

 

 

More Information?

Telephone +44 (0)1793 784389 or email: sales@ppm.co.uk