TDK Corp.’s Three Pack for Power Ferrite

TDK’s power ferrite, moving into the future, is PC47/PC90/PC95. These materials will offer a lower core loss, higher saturation, and higher efficiency than the PC40/PC44/PC50 materials. What are these ferrite materials and how do you choose which material is the best for your application?

Please check out each criterion below:

• Power Transformer –Conditions - 100°C, 50 KHz – 300 KHz:
  PC47 is the upgrade material improving on the PC40 and PC44 materials. PC47 has the lowest core losses of any ferrite material, TDK, Epcos or competitor. As an alternative, PC90 can be designed in. The core loss graph of the PC90 falls between PC40 and PC44 and the saturation is much higher, providing a more efficient design.
  • Core Loss Primary concern – PC47
  • Saturation Primary concern – PC90

  Please review the graphs @ http://www.mhw-intl.com/products/magnetics/ferrite-cores/tdk-ferrite-cores/

• Power Transformer - Core Loss from -40°C - 120°C:
  PC95 is the champ when it comes to core loss over a wide temperature range. As you can see from the below graph, the core loss remains acceptable down to -40°C and up around +120°C.

• Power Transformer - Frequency >400KHz:
  PC95 is the material to use when the frequency gets above 400KHz. This especially holds true when the operating flux increases above 100mT. (PC50 was an excellent material when operating at 50mT)
• Output Choke:
  PC90 is the material of choice when looking for ferrite to be used in output chokes. This material saturates above 450mT at 100°C. The alternative in order of preference is PC47 and than PC95.

The manufacture of PC40/PC44/PC50 ferrite materials will decrease over time as the better materials are designed in. In many cases, old designs will also be changed over to the new materials to take advantage of the higher efficiency and higher frequency of operation. Over the next few years, the decrease usage in the PC40/PC44/PC50 materials will cause the prices to increase due to the reduced availability and lost economies of scale and eventually result in the materials being discontinued.

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TDK to Discontinue the EE5 Core

As announced last month, TDK will discontinue the EE5 core in all materials effective June, 2012. MH&W does have a suitable replacement. For samples of our replacement core, please contact customer service. The replacement core we are offering has a minimum Al of 270 as compared to the minimum Al of 220 for the PC44EE5-Z.

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Update: TDK Movement of Ferrite Manufacturing to Xiamen, China

2007: TDK made the announcement of a process change whereas the manufacturing of ferrite would move from Japan to China. This movement would be accomplished in three (3) phases.

Phase One, 2008:
The Grinding and Gapping sub-process in Narita, Japan would be moved to Xiamen, China.

Phase Two, 2009–2010:
The Pressing and Sintering sub-process at Narita, Japan would be moved to Xiamen, China.

Phase Three:
The Powder Preparation sub-process and the manufacturing of certain cores located in Ankura plant would be moved to China. TDK has now announced the timeframe for the completion of this process which includes moving the powder preparation sub-process of certain materials from the Anakura Plant in Japan to the Xiamen Plant in China. The powder preparation sub-process of the ferrite materials that are moving are: DN50, DN70, H5A, H5B2, H5C2, H5C3, H5C4, PC33, PC50, PC90 & PC95. Certain cores shapes and sizes located at the Anakura plant will also move to Xiamen, China. The cores to be moved are the cores listed in the high power catalog. There is no change or alteration of the process nor the specification of the materials or cores.

Effective timeframe for the movement of the powder preparation process:
July 1 – September 30, 2012 with completion of the move estimated by year end.

MH&W International, in cooperation with China Manufacturing Technology (CMT), has released a suitable replacement for the EE5 core such that our customers can continue to design in and purchase the EE5 core. The power material that we are purchasing will be the FP3H material.

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