Design Considerations for High Temperature Power Inductors

A uniform B-field approximation model is used to develop design formulas for single-layer wound, toroidal core, ac power inductors that must handle a specified current. Such a geometry is well suited for high temperature, high frequency inductors, where removal of heat from the core becomes critical. Explicit expressions are derived for core radii, core and winding volumes, winding turns and core permeability as functions of a dimensional scaling ratio (S). A limit on the maximum allowed core B-field leads to the result that the minimum core volume is proportional to the permeability, which has a lower bound. Plots versus S are provided for a specific case, to show that good designs can be picked in the overlap regions around the minima in mass and overall size, where the mass and size are relatively flat. Data to 250 C are presented for an MPP core based inductor to show that a quasi-linear, high temperature inductor can be constructed with available materials. A similar development is applied to a toroidal air-core geometry, showing that for the same ratings, such an inductor is considerably bigger and more massive, at least in the single-layer version.