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Learn about West Coast Magnetics' innovative inductor technology, featuring low DCR and high window utilization. Find out how this patented technology reduces AC losses significantly, making it ideal for gapped core structures with IDC greater than 10A. Discover how the foil winding design enhances efficiency, comparable to litz wire technology. West Coast Magnetics, a leading manufacturer, guarantees lean operations, on-time delivery, defect-free products, and exceptional customer service. With a history dating back to 1976, West Coast Magnetics continues to pioneer new inductor solutions with a focus on quality and innovation.
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Low AC and DC Resistance Inductor Technology • Weyman Lundquist – President and CEO • West Coast Magnetics • April 4, 2007 • International Patent #WO 2005/09630
Patented Inductor Technology • Very Low DCR, High Window Utilization • Foil winding • AND Low AC Resistance • AC loss reduction comparable to litz wire • SIGNIFICANTLY LOWER TOTAL LOSSES • Applies to: • Gapped core structures • Idc > 10 amps • Ripple > 5% • Inductors (Chokes)
West Coast Magnetics is: • A Manufacturing Driven Organization • Lean since 2005 • 100% on-time delivery • 100% defect free product • A Customer Driven Organization • Service • Engineering Support • A Technology Innovator
West Coast MagneticsCompany History • Founded in 1976 in Silicon Valley • Present Ownership 1993 • Open Stockton facility in 1996 • Acquired Mexico Facility in 1999 • New Inductor Technology 2003
Company Overview • Stockton, CA • Corporate Headquarters and Manufacturing Facility • Tecate, MX • Production Facility • Custom and Standard Products • Power Transformers: 50/60 Hz to 13.56 MHz • Power Transformers: 1 Watt to 15 kW • Power Inductors to 200 amps • Common Mode Chokes to 200 amps • Current Sense Transformers 60 Hz to 13.56 MHz • RF Inductors to 100 MHz
How Does it Work? By cutting away a section of the foil winding in the region of the core gap winding eddy currents are concentrated locally in the region of the cutaway.
Experiment: Is the New Technology Really Better? • Objective: A Conclusive Comparison of the New Technology to Conventional Windings • Step 1: Define the Inductor • Inductance 90 uH • Current 40 Adc • Ripple: Triangle wave at 50 kHz • Core: E70/33/32 Epcos N67 material • Gap: 2.64 mm (1.32 mm each center leg) • Turns: 15
Experiment: Is the New Technology Really Better? • Step 2: Wind Inductors with Conventional Windings Using Best Practices • Full window • Single layer • Step 3: Determine Winding Losses for each Inductor as a Function of Ripple Magnitude • Step 4: Compare Results to Temperature Rise Data Collected under Load.
400/40 Litz 20/32 Litz Solid Wire Long Cut Prototype Cut Full Foil 20/32 Litz Solid Wire 50/40 Litz Winding Cross Sections
Method of Estimating Losses • DCR – Measure voltage drop under 5 Amp DC load. • Core Losses: Derived from Epcos loss curves. • AC resistance – Sweep from 10 kHz to 200 kHz with Agilent 4294A network analyzer • Use Fourier decomposition to translate sinusoidal sweep data to triangular waveform
90 uH 20 uF 10 Ohms 2.5 Ohms 40 A Device Under Test Amplifier Output: 6A P-P Function Generator Temperature Rise Measurement – Test Set Up
Global Market – High Growth Green Energy! • Distributed Power: Wind, Solar and FACTs • Estimated $4.3 Billion in Power Electronic Equipment in 2007 • 15% plus forecasted growth • Hybrid Vehicles • Est. 600,000 in 2007 • 50% plus forecasted growth • Uninterruptible Power Supplies • Estimated $4 Billion in Power Electronic Equipment > 1 kW in 2007 • 7% plus forecasted growth
Design Tools • Code for Winding Loss Simulation • Code for Translation of Winding Cross Section into 2D Foil Shape • Code for Prediction of H vs. L vs. Gap for any Inductor
Licensing Opportunity • Objective: The widest possible application of the technology. • Develop tools for design support. • Maintain license rate at a level which will lead to widespread use. • Contact: Weyman Lundquist wlundquist@wcmagnetics.com • 800-628-1123
Weyman Lundquist, President West Coast Magnetics 4848 Frontier Way, Ste 100 Stockton, CA 95215 www.wcmagnetics.com 800-628-1123 Thank you for your time