Nanocrystalline Core Material for Modern Power Electronic Designs
Nanocrystalline Core Material for Modern Power Electronic Designs Nanocrystalline Core Material for Modern Power Electronic Designs
Fritz Rauscher MAGNETEC GmbH, Booth 525 in Hall 12 Advanced softmagnetic material for EMI filter chokes MAGNETEC MAGNET-TECHNOLOGIE NANOPERM ® - Advanced softmagnetic material for EMI filter chokes May 21, 2003 PCIM, Nuremberg © MAGNETEC GmbH www.magnetec.de 05/2003/ra 1/15
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Fritz Rauscher<br />
MAGNETEC GmbH, Booth 525 in Hall 12<br />
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
NANOPERM ® - Advanced softmagnetic<br />
material <strong>for</strong> EMI filter chokes<br />
May 21, 2003<br />
PCIM, Nuremberg<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 1/15
Content of presentation<br />
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
• <strong>Nanocrystalline</strong> material NANOPERM®<br />
• Current compensated chokes<br />
• Comparison <strong>Nanocrystalline</strong> and Ferrite<br />
core chokes<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 2/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
<strong>Material</strong> properties of NANOPERM ®<br />
Alloy composition Fe73,5 Cu1 Nb3 Si15,5 B7<br />
Saturation flux density Bsat<br />
1,2 T<br />
Permeability levels µ 20.000 - 200.000<br />
Saturation magnetostriction λs < 0,5 ppm<br />
Specific electrical resistivity σ 115 µΩcm<br />
Density γ 7,35 g/cm³<br />
Curie temperature Tc<br />
~ 600 °C<br />
Max. operational temperature Tmax ~ 120 °C (180°C)<br />
<strong>Core</strong> losses (0,3T, 100kHz, sine) Pv < 110 W/kg<br />
Tape thickness d 17 / 23 µm<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 3/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Choice of softmagnetic material<br />
Main requirement on a EMC filter choke:<br />
High impedance Z(f), f = 150kHz to 30MHz<br />
Z(f) = ω * L(f) = 2π * f * L(f)<br />
L(f) = A L* n 2 with A L = µ 0 * µ r(f) * A fe / l f<br />
Z(f) = 2π * f * n 2 * µ 0 * µ r (f) * A fe / l fe<br />
n: number of turns µ r : permeability A fe : Iron cross section<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 4/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Basic circuitry of a EMI mains filter<br />
230V<br />
mains<br />
L<br />
N<br />
C x<br />
L<br />
PE Cy Cy load<br />
C x: X-capacitor, L: Current compensated choke, C y: Y-capacitor<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 5/15<br />
L´<br />
N´
Principle of a CM choke<br />
RF current<br />
load current<br />
H load = 0<br />
H RF ≠ 0<br />
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
1-phase version<br />
3-phase version<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 6/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Benefits of NANOPERM products<br />
• High insertion losses<br />
• Small build volume<br />
• Low earth leakage currents<br />
• High working temperature<br />
• Best value <strong>for</strong> the money<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 7/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Comparison Ferrite - NANOPERM ®<br />
Ferrite NANOPERM ®<br />
Permeability (@100kHz) 10.000 – 12.000 20.000 – 30.000<br />
Saturation flux density Bsat 230 mT 1180 mT<br />
Curie temperature Tc ~ 130 °C ~ 600 °C<br />
Max. working temperature 95 °C 120 °C (180 °C)<br />
Relative cost 1 < 2<br />
NANOPERM: ⇒ Advanced, smaller and lighter components!<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 8/15
Permeabiliy @ 10kHz / 3mA/cm<br />
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Permeability as a function of<br />
50.000<br />
40.000<br />
30.000<br />
20.000<br />
10.000<br />
0<br />
temperature<br />
NANOPERM<br />
Ferrite<br />
Max. Max. <strong>for</strong> <strong>for</strong><br />
Ferrite: Ferrite:<br />
about about 120°C<br />
120°C<br />
0 50 T [°C] 100<br />
150<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 9/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Saturation flux density as a function<br />
Saturation induction Bsat [T]<br />
1,4<br />
1,2<br />
1<br />
0,8<br />
0,6<br />
0,4<br />
0,2<br />
0<br />
of temperature<br />
NANOPERM<br />
Ferrite<br />
T38<br />
Max. Max. <strong>for</strong> <strong>for</strong><br />
Ferrite: Ferrite:<br />
about about 120°C 120°C<br />
N67<br />
0 100 200 T [°C] 300<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 10/15<br />
400
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Better impedance with same core<br />
Attenuation level [dB]<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
NANOPERM<br />
Ferrite<br />
geometries<br />
Improved<br />
attenuation<br />
below below<br />
400 400 kHz kHz<br />
0<br />
0,01 0,1 1 10 100<br />
Frequency f (MHz)<br />
<strong>Core</strong> geometry:<br />
Ø 30mm, 22 turns<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 11/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Same impedance at smaller volume<br />
Impedance Z [kΩ]<br />
20<br />
16<br />
12<br />
8<br />
4<br />
Volume<br />
reduction<br />
> 50% 50%<br />
10 100 f [kHz]<br />
NANOPERM<br />
∅ = 40 mm<br />
Ferrite<br />
∅ = 63 mm<br />
1.000 10.000 100.000<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 12/15
Build volume - real example<br />
NANOPERM ® choke<br />
I N =3 x25A @ 60°C<br />
L N = 3 x 1,6mH @ 10kHz<br />
m = 120g<br />
25 mm<br />
59 mm<br />
Volume reduction 60%<br />
Weight reduction 65%<br />
73 mm<br />
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Ferrite choke<br />
I N = 3 x 25A @ 40°C<br />
L N = 3 x 1,3mH @ 10kHz<br />
m = 350g<br />
39 mm<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 13/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Available products - cores & chokes<br />
100 mm<br />
Tape wound<br />
cores from ∅<br />
12 ... 300mm<br />
1-phase EMC<br />
chokes up to<br />
I = 2 x 60A<br />
3-phase EMC<br />
chokes up to<br />
I = 3 x 200A<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 14/15
Advanced softmagnetic material <strong>for</strong> EMI filter chokes<br />
MAGNETEC<br />
MAGNET-TECHNOLOGIE<br />
Thank you <strong>for</strong> your attention!<br />
Come and visit us at booth 525!<br />
525<br />
© MAGNETEC GmbH www.magnetec.de 05/2003/ra 15/15
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