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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.
Winding Cross Sections
20/32 Litz Solid Wire400/40 Litz
Full Foil Long Cut
50/40 Litz
Prototype Cut
Solid Wire20/32 Litz
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
Total Loss Comparison
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
Temperature Rise Measurement – Results at 15% Ripple
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 [email protected] 800-628-1123
Thank you for your time
Weyman Lundquist, PresidentWest Coast Magnetics4848 Frontier Way, Ste 100Stockton, CA 95215
www.wcmagnetics.com800-628-1123