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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
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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)
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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
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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
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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
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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.
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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
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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.
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Winding Cross Sections
20/32 Litz Solid Wire400/40 Litz
Full Foil Long Cut
50/40 Litz
Prototype Cut
Solid Wire20/32 Litz
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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
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Total Loss Comparison
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Temperature Rise Measurement – Test Set Up
40 A
20 uF10 Ohms
2.5 Ohms
AmplifierOutput: 6A P-P
Function Generator
Device Under Test
90 uH
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Temperature Rise Measurement – Results at 15% Ripple
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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
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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
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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 [email protected] 800-628-1123
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Thank you for your time
Weyman Lundquist, PresidentWest Coast Magnetics4848 Frontier Way, Ste 100Stockton, CA 95215
www.wcmagnetics.com800-628-1123