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Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 1/15
NANOPERMNANOPERM®® -- Design Considerations Design Considerations for advanced EMI filter chokesfor advanced EMI filter chokes
May 26th 2004PCIM, Nuremberg
Fritz RauscherMAGNETEC GmbH, Booth 525 in Hall 12
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 2/15
Content of presentationContent of presentation
• Nanocrystalline material NANOPERM®• Current compensated chokes• Comparison Nanocrystalline and Ferrite
core chokes
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 3/15
Material properties of NANOPERMMaterial properties of NANOPERM®®
Alloy composition Fe73,5 Cu1 Nb3 Si15,5 B7
Saturation flux density Bsat 1,2 TPermeability levels µ 20.000 - 200.000Saturation magnetostriction λs < 0,5 ppmSpecific electrical resistivity σ 115 µΩcmDensity γ 7,35 g/cm³Curie temperature Tc ~ 600 °CMax. operational temperature Tmax ~ 120 °C (180°C)Core losses (0,3T, 100kHz, sine) Pv < 110 W/kgTape thickness d 17 / 23 µm
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 4/15
Choice of softmagnetic materialChoice of softmagnetic material
Main requirement on a EMC filter choke:
High impedance Z(f), f = 150kHz to 30MHz
Z(f) = ω * L(f) = 2π * f * L(f)
L(f) = AL* n2 with AL = µ0 * µr(f) * Afe / lf
Z(f) = 2π * f * n2 * µ0 * µr(f) * Afe / lfe
n: number of turns µr : permeability Afe : Iron cross section
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 5/15
Basic circuitry of a EMI mains filterBasic circuitry of a EMI mains filter
Cx: X-capacitor, L: Current compensated choke, Cy: Y-capacitor
230Vmains
loadCx
CyL
L
N
PE Cy
L´
N´
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 6/15
Principle of a CM chokePrinciple of a CM choke
1-phase version
3-phase versionload current
RF current
Hload = 0
HRF ≠ 0
load currentload current
RF currentRF current
Hload = 0Hload = 0
HRF ≠ 0HRF ≠ 0
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 7/15
Benefits of NANOPERM productsBenefits of NANOPERM products
•• High insertion lossesHigh insertion losses•• Small build volumeSmall build volume•• Low earth leakage currentsLow earth leakage currents•• High working temperatureHigh working temperature•• Best value for the moneyBest value for the money
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 8/15
Comparison Ferrite Comparison Ferrite -- NANOPERMNANOPERM®®
Ferrite NANOPERM®
Permeability (@100kHz) 10.000 – 12.000 20.000 – 30.000
Saturation flux density Bsat 400 mT 1180 mT
Curie temperature Tc ~ 130 °C ~ 600 °C
Max. working temperature 95 °C 120 °C (180 °C)
Relative cost 1 ~ 2
NANOPERM: ⇒ Advanced, smaller and lighter components!
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 9/15
Permeability as a function of Permeability as a function of temperaturetemperature
0
10.000
20.000
30.000
40.000
50.000
50 100T [°C]
Perm
eabi
lity
@ 1
0kH
z / 3
mA
/cm
0 150
NANOPERM
Ferrite
Max. for Ferrite:
about 120°C
Max. for Ferrite:
about 120°C
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 10/15
Saturation flux density as a function Saturation flux density as a function of temperatureof temperature
0
0,2
0,4
0,6
0,8
1
1,2
1,4
0 100 200 300T [°C]
Satu
ratio
n flu
x de
nsity
Bsa
t [T]
400
Max. for Ferrite:
about 120°C
Max. for Ferrite:
about 120°CFerrite
N67T38
NANOPERM
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 11/15
Better impedance with same core Better impedance with same core geometriesgeometries
0
10
20
30
40
50
60
0,01 0,1 1 10 100
Frequency f (MHz)
Atte
nuat
ion
leve
l [dB
]
Ferrite
NANOPERM
Improved attenuation
below 400 kHz
Improved attenuation
below 400 kHz
Core geometry:Ø 30mm, 22 turns
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 12/15
Same impedance at smaller volumeSame impedance at smaller volume20
10 100 f [kHz]
Impe
danc
e Z
[kΩ
]
4
12
1.000 10.000 100.000
NANOPERM∅ = 40 mm
Ferrite∅ = 63 mm
Volume reduction
> 50%
Volume reduction
> 50%
16
8
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 13/15
73 mm
39 mm25 mm
59 mm
Build volume Build volume -- real examplereal exampleNANOPERM® choke
IN = 3 x 25A @ 60°CLN = 3 x 1,6mH @ 10kHz
m = 120g
Ferrite chokeIN = 3 x 25A @ 40°C
LN = 3 x 1,3mH @ 10kHzm = 350g
Volume reduction 60% Weight reduction 65%
Considearations about softmagnetic material for EMI filter chokes
MAGNET-TECHNOLOGIEMAGNETEC
© MAGNETEC GmbH www.magnetec.de 05/2004/ra 14/15
Available products Available products -- cores & chokescores & chokes
100 mm
Tape wound cores from ∅12 ... 300mm
1-phase EMC chokes up to I = 2 x 60A
3-phase EMC chokes up to I = 3 x 200A
Recommended