Design

Inputs

kcu
0.67

Ta (C)
24

Ts (C)
93

Freq. [kHz]
101

67

Material
3C94

Vpri,rms
107

Ipri,rms
10.0
100

3C94

Design
Core Type
E-core
EC-core
EFD-core
EP-core
ER-core
ETD-core
PM-core
Potcore
PQ-core
RM-I core
U-core

Core #
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

V-A Rating

Jrms

Bac

Npri

[watts]

[A/mm ]

[mT]

[#]

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Notes

Any row having a cell entry of #N/A indicates t

core in that row cannot meet the input specific

Throughput

Vsec,rms
110

[cm]

Isec,rms
9.73

Power
2140

0.023482564

Nsec

Acu,pri

Acu,sec

Skin, Prox.
Effects?

[#]

[mm ]

[mm ]

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Outputs

Vc+Vw

[nH]
Lleakage

[cm ]

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504

Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

Efficiency
[%]
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504
Err:504

ntry of #N/A indicates that the

meet the input specifications.

MANUFACT.
SUGGESTED
MIN FREQ. MAX. FREQ.

10
10
20

100
100
200

20

1000

500
3000

3000
10000

C(T)
0.9034283
0.9203004
0.9278937
0.955259
0.9905975
0.9175383
0.9185379
1.0215842
1.003176
0.904462
1.028636
0.87609
1.08121
1.20923
0.981933
0.899158
1.008659
1.070295
1.080913
0.976477
1.008763
0.948655
0.9398

MATERIAL
SIEMENS
N27
N41
N49
N53
N59
N61
N62
N63
N67
N72
N87
PHILLIPS
3B8
3C15
3C30
3C80
3C81
3C85
3C90
3C94
3F3
3F35
3F4
4F1

21

Kc

3.0672E-005
1.89E-04
1.1184E-006
1.6E-06
2.54E-06
1.22E-05
1.95E-06
3.0E-06
2.4326E-006
1.07E-06
2.33E-06

1
1
1
1
1
1
1
1
1
1
1

2.45
2.14
2.98
2.860
2.9511
2.585
2.713
2.714
2.756
2.865
2.76

8.76E-07
1.08E-07
3.63E-07
9.43E-06
1.08E-06
4.54E-07
5.35E-07
1.51E-07
1.46E-06
1.31E-08
2.35E-07
1.68E-05

1.6
1.7
1.5
1.42
1.56
1.6
1.5
1.6
1.3
1.5
1.35
1.35

2.5
2.8
2.7
2.2
2.55
2.6
2.6
2.7
2.5
3.45
3.09
2.25

Transfer Data
1.5133E-007

1.6

2.7

Transfer

Data

Core Rating

Core #

Err:504

Err:504

Criteria
TestE

Jrms
Err:504

Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

Phillips Designation

(mm)

Core Type/Number Dim. A

E5.3/2.7/2
5.25
E6.3/2.9/2
6.3
E13/6/6
12.7
E13/7/4
12.95
E/16/8/5
16
E19/8/5
19.05
E19/8/9
19.1
E20/10/5
20.7
E20/10/6
20
E25/9/6
25.4
E25/10/6
25.4
E25/13/7
25
E25/16/6
25.4
E30/15/7
30.8
E30/15/13
30.8
E31/13/9
30.9
E32/16/9
32
E34/14/9
34.3
E36/21/15
36
E41/17/12
40.6
E42/21/15
43
E42/21/20
43
E42/33/20
42
E46/23/30
46
E47/20/16
46.9
E50/27/15
50
E55/28/21
56.2
E55/28/25
56.6
E56/24/19
56.1
E65/32/27
65
E71/33/32
70.5
E80/38/20
80

E Core Dimensions

(mm)

(mm)

Dim. B
2.65
2.9
5.7
6.5
8.2
8.05
8.1
10
7
9.45
9.65
12.8
15.85
15
15.2
13.1
16.4
14.1
21.8
16.6
21
21
32.8
23.2
19.6
27.2
27.8
27.8
23.6
32.8
33.2
38.1

Dim. C
2
2
6.4
3.7
4.7
8.7
8.7
5.3
5.9
6.3
6.35
7.5
6.3
7.3
12.6
9.4
9.5
9.3
15.5
12.4
15.2
20
20
30
15.6
14.6
21
25
18.8
27.4
32
19.8

Mean turn length = lw

No coil former : lw = 2(F+C)+0.5(E-F)

radius =
1
(E-F)
4
C
Winding Volume Vw = Awlw

Surface Area of assembled transformer

As = surface area of assembled core plus
Core surface area = 4AB + 4BC + 2AC

Surface area of winding not included in co

4E{0.5}(E-F)+ 4{2D(0.5)(E-F)} = 2E(E-F)
As = 4AB + 4BC + 2AC + 2(E-F)(E+2D)

2B

Ro
ign
are

1
2
2D

(E-F

Calculated
w/bobbin
(mm)

(mm)

(mm)

(mm)

(mm2)

(mm3)

(mm)

Dim. D
1.9
1.85
4.1
4.5
5.7
5.7
5.7
6.3
7
6.5
6.4
8.7
12.9
9.7
9.7
8.6
11.2
9.8
15.75
10.4
14.8
14.8
26
15.8
12.1
18.6
18.5
18.5
14.6
22.2
21.9
28.2

Dim. E
3.8
3.6
9.5
8.95
11.3
14.3
14.3
12.8
14.1
19.3
18.8
17.5
19.3
19.5
19.5
21.9
22.7
25.5
24.5
28.6
29.5
29.5
29.5
31.5
32.4
34.1
37.5
37.5
38.1
44.2
48
59.1

Dim. F
1.4
1.4
3.2
3.7
4.7
4.75
4.75
5.2
5.9
6.35
6.35
7.5
6.35
7.2
7.2
9.4
9.5
9.3
10.2
12.45
12.2
12.2
12.2
14.2
15.6
14.6
17.2
17.2
18.8
20
22
19.8

Lm
12.3
13.8
27.7
29.5
36.8
39.8
39.9
45.2
45.5
48.5
48.4
56.6
74.1
68.8
68.8
61.0
72.6
69.2
95.4
76.6
97.7
97.7
140.9
103.3
88.0
118.9
123.7
124.3
106.0
145.7
148.9
184.9

Ac
2.8
2.8
20.5
13.7
22.1
41.3
41.3
27.6
34.8
40.0
40.3
56.3
40.0
52.6
90.7
88.4
90.3
86.5
158.1
154.4
185.4
244.0
244.0
426.0
243.4
213.2
361.2
430.0
353.4
548.0
704.0
392.0

Vc
34.4
38.7
567.8
404.3
812.4
1645.0
1648.3
1245.8
1582.6
1941.3
1952.1
3182.3
2965.5
3618.3
6245.3
5392.6
6552.2
5986.5
15075.6
11824.0
18116.6
23837.6
34385.7
43990.9
21407.2
25336.8
44665.6
53443.4
37450.5
79819.5
104843.2
72493.3

Lw
14.5
14.1
33.0
26.9
33.1
45.8
45.8
36.8
40.4
49.5
48.8
49.6
49.5
52.2
62.8
61.1
62.6
66.5
77.7
78.9
85.8
95.4
95.4
119.4
92.7
92.9
112.2
120.2
109.4
136.7
152.7
144.8

2D
radius =
1
(A - E)
2
1
2

(E-F)

2D
radius =
1
(A - E)
2
1
2

(E-F)

With coil former lw = 2(F+C+3.2mm)+0.5(E-F-1.6mm)

embled transformer As

f assembled core plus surface area of winding not included in core surface area.
4AB + 4BC + 2AC

ding not included in core surface area =

D(0.5)(E-F)} = 2E(E-F) + 4D(E-F) = 2(E-F)(E+2D)
2AC + 2(E-F)(E+2D)

2B

1
2

C
(E-F)

Rounded corners
ignored in surface
area estimate

1
2
2D

(E-F)

ius =

(A - E)

F)

Calculated
w/bobbin
(mm2)

(mm3)

(mm2)

C/W]

Aw

Vw
12.7
8.9
511.5
363.7
809.7
1783.4
1783.4
1215.1
1651.6
3203.7
2967.2
3290.7
6800.8
4970.9
5980.3
5195.8
7553.5
8741.0
14759.9
11026.8
18869.6
20979.7
37763.4
28130.2
15916.0
29600.8
37123.5
39771.4
26719.4
66104.9
78620.2
149564.1

As
134.3
153.6
821.1
717.2
1129.0
1715.9
1723.9
1645.5
1422.0
2354.9
2335.0
2737.0
3497.9
3692.6
4371.8
3670.1
4521.0
4558.3
7208.4
6121.7
8240.9
9056.9
12634.3
11996.1
8265.0
11269.2
13969.7
14928.6
11777.7
19973.1
22897.6
27455.8

R
992.6
868.1
162.4
185.9
118.1
77.7
77.3
81.0
93.8
56.6
57.1
48.7
38.1
36.1
30.5
36.3
29.5
29.3
18.5
21.8
16.2
14.7
10.6
11.1
16.1
11.8
9.5
8.9
11.3
6.7
5.8
4.9

0.9
0.6
15.5
13.5
24.5
39.0
39.0
33.0
40.9
64.7
60.8
66.4
137.3
95.2
95.2
85.0
120.6
131.4
189.9
139.7
219.8
219.8
395.6
235.5
171.8
318.6
331.0
331.0
244.3
483.6
514.8
1033.0

[mW/cm3]
Psp @ T
1476
1668
394
483
360
259
260
346
228
237
246
219
185
222
185
179
166
160
125
139
115
105
91
86
115
106
88
83
95
71
65
64

[A/mm2]

[mT] @ freq.

Jrms
10.0
10.6
5.2
5.7
4.9
4.2
4.2
4.8
3.9
4.0
4.1
3.9
3.5
3.9
3.5
3.5
3.4
3.3
2.9
3.1
2.8
2.7
2.5
2.4
2.8
2.7
2.4
2.4
2.5
2.2
2.1
2.1

Bpeak
325.1
340.1
199.2
215.0
192.8
170.6
170.9
189.9
162.6
165.1
167.3
160.3
150.7
161.3
150.6
148.9
144.7
142.8
130.3
135.4
126.4
121.9
115.6
113.5
126.1
122.6
114.6
111.9
117.7
105.6
102.0
101.7

ius =

(A - E)

F)

Magnetic path length lm = 4D +(E-F) + (0.5)(A-E)

Core Area Ac = FC
Core Volume Vc = Aclm = FC(4D +(E-F) + E)

e surface area.

[watts]

[#]

[nH]

[watts]

E_rating
2.4
1.9
97.4
67.8
153.6
342.8
343.9
249.2
271.0
509.9
498.2
686.4
874.4
933.8
1373.0
1162.0
1573.1
1592.8
3391.3
2665.4
4291.5
5186.7
8241.7
8189.9
4377.5
6654.3
9987.7
11242.2
7678.2
18259.8
23043.9
25538.2

Npri
262.08
250.49
58.46
81.06
56.01
33.83
33.78
45.57
42.14
36.12
35.36
26.46
39.56
28.14
17.45
18.13
18.27
19.31
11.58
11.41
10.17
8.02
8.45
4.94
7.77
9.13
5.76
4.96
5.74
4.12
3.32
5.99

Lleakage
13127.98
11044.69
1812.58
2160.58
1256.70
918.87
916.34
965.29
878.63
1347.45
1243.16
417.55
814.19
548.58
253.92
305.54
257.84
429.33
99.08
167.18
108.72
75.06
47.51
33.34
81.30
84.91
42.79
33.93
49.79
26.52
20.94
75.66

Pwr Loss
0.07
0.08
0.42
0.37
0.58
0.89
0.89
0.85
0.74
1.22
1.21
1.42
1.81
1.91
2.26
1.90
2.34
2.36
3.73
3.17
4.26
4.69
6.54
6.21
4.28
5.83
7.23
7.73
6.09
10.34
11.85
14.21

Calculated

Calculated

w/bobbin

w/bobbin

lw
14.456
14.142
32.979
26.9305
33.05
45.7815
45.7815
36.82
40.362
49.5195
48.8345
49.588
49.5195
52.199
62.799
61.113
62.612
66.522
77.739
78.9435
85.849
95.449
95.449
119.449
92.664
92.903
112.159
120.159
109.389
136.682
152.708
144.789

Aw
0.88
0.63
15.51
13.505
24.5
38.955
38.955
33
40.92
64.695
60.76
66.36
137.335
95.23
95.23
85.02
120.64
131.4
189.865
139.68
219.8
219.8
395.64
235.5
171.76
318.62
330.99
330.99
244.26
483.64
514.84
1032.98

From Ferroxcube CD
lw

Aw
12.6
12.8
32
24
33
33.7
47.6
38.7

1.5
1.62
16.8
11.6
21.6
40
35.9
28.6

53.1
49

47.4
56

56

80

60
69

97
102

81.2
93
78.5

114
178
255

94.7

131

119

278

114
150

205
394

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestEC

Core #
EC35
EC41
EC52
EC70

Dim. A
35.3
41.6
52.2
71.7

Dim. B
17.3
19.5
24.2
34.5

Dim. C
9.5
11.6
13.4
16.4

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

Dim. D
22.8
27.1
33
44.5

Dim. E
9.5
11.6
13.4
16.4

Dim. H
12.3
13.9
15.9
22.8

Lm
77.4
89.3
105
144

Ac
84.3
121
180
279

Vc
6530
10800
18800
40100

Lw
53.1
62.4
74.9
97.3

EC Core Formulas

Magnetic parameters (mean path length lm, core area Ac, and core volume Vc) given in m
Winding parameters:
Mean turn length lw = 2 (D/2 + E/2)/2 = 0.5 (D + E) ; No coil former
lw = 0.5 (D + E+1.6) ; with coil former having walls 0.8 mm thick
Winding window area Aw = 2H (D-E)/2 = (D-E)H ; no bobbin
Aw = (D-E-1.6)(H-0.8) ; with bobbin having walls 0.8 mm thick
Winding volume Vw = Awlw = (D + E) H (D-E) = (D2 - E2)
Surface area of assembled core and winding As
Exposed core surface area:
Front and back = 2(A2B) - 2(2HD) = 4AB - 4DH
Top and bottom = 2AC
Left and right = 2(2BC) = 4BC
Total exposed core surface area = 4AB - 4DH + 2AC + 4BC
Exposed winding surface area:
Vertical surface = 2HD - 2(2HC)
Horizontal surface = 2(0.5D)2 - 2CD

As = 4B(A+C) + 2AC - 4DH + 2H(D - 2C) + 0.5D2 - 2CD

Ferroxcube
w/bobbin
[mm2]
Aw
102.5
137.5
212.0
465.0

Ferroxcube
w/bobbin
[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

Vw
5442.8
8580.0
15878.8
45244.5

As
4327.1
5854.7
8921.0
16981.4

R
30.8
22.8
14.9
7.9

Psp
187.0
156.3
133.1
103.0

Jrms
3.6
3.3
3.0
2.6

Bpeak
151.2
141.5
133.3
121.2

ore volume Vc) given in manufacturer's catalog.

[watts]

[#]

[nH]

[watts]

EC_Rating
1386.0
2283.2
4553.1
12378.5

Npri
18.71
13.93
9.94
7.05

Lleakage
210.37
141.32
95.45
62.41

Pwr Loss
2.24
3.03
4.62
8.79

Calculated
w/bobbin
Lw
53.2
63.3
75.4
98.1

Calculated
w/bobbin
Aw
134.6
182.1
271.8
583.0

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

Lw
53.1
62.4
74.9
97.3

Aw
102.5
137.5
212.0
465.0

Calculated
No bobbin
Lw
50.7
60.8
72.8
95.6

Calculated
No bobbin
Aw
163.6
215.5
311.6
640.7

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestEFD

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Core #
EFD10
EFD12
EFD15
EFD20
EFD25
EFD30

Dim. A
10.5
12.5
15.0
20.0
25.0
30.0

Dim. B
5.2
6.2
7.5
10.0
12.5
15.0

Dim. C
2.7
3.5
4.7
6.7
9.1
9.1

Acore
Err:504

Vc + Vw
Err:504

Ferroxcube
w/bobbin
[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

Dim. D
7.7
9.0
11.0
15.4
18.7
22.4

Dim. E
4.6
5.4
5.3
8.9
11.4
14.6

Dim. F
1.5
2.0
2.4
3.6
5.2
4.9

Dim. H
3.8
4.6
5.5
7.7
9.3
11.2

Lm
23.7
28.5
34.0
47.0
57.0
68.0

Ac
7.2
11.4
15.0
31.0
58.0
69.0

Vc
171.0
325.0
510.0
1460.0
3300.0
4700.0

Lw
14.8
18.6
25.6
34.1
40
52.9

EFD Core Formulas

Magnetic parameters (mean path length lm, core area Ac, and core volume Vc)
Winding parameters:
Mean turn length lw

lw = 2(E+F) +2(0.25)(D - E) = 2(E+F) +0.5(D-E) ; no coil former

lw = = 2(E+F+3.2 ) +0.5(D-E-1.6) ; with coil former having wall thickness 0.8 mm

Winding window area Aw = 2H (D-E)/2 = (D-E)H : no coil former
Aw = (D-E-1.6)(H-.8) ; with coil former having wall thickness 0.8 mm
Winding volume Vw = Awlw
Surface area of assembled core and winding As
Exposed core surface area:
Front and back = 2(A2B) - 2(2HD) = 4AB - 4DH
Top and bottom = 2AC
Left and right = 2(2BC) = 4BC
Total exposed core surface area = 4AB - 4DH + 2AC + 4BC
Exposed winding surface area:
Vertical surface = 2DH - 4CH
Horizontal surface = 4(D-E)E + 4F(D-E) +2EF +2(D-E)2 - 2DC
Total surface area As = 2H(D-2C) + 4(D-E)(E+F) + 2EF +2(D-E)2 - 2CD
= 4(D-E)(E+F) + 2EF +2(D-E)2 - 2CD

Ferroxcube
w/bobbin
[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

[watts]

Aw

Vw
62.2
120.9
427.5
944.6
1840.0
2766.7

As
251.0
342.3
578.5
986.9
1352.0
1894.7

R
531.1
389.5
230.5
135.1
98.6
70.4

Psp
557.2
397.3
319.3
212.4
136.1
131.3

Jrms
6.1
5.2
4.7
3.8
3.0
3.0

Bpeak
226.6
199.9
184.4
158.5
134.4
132.7

EFD_Rating
12.5
22.9
64.0
153.9
324.6
425.5

4.2
6.5
16.7
27.7
46
52.3

and core volume Vc) given in manufacturer's catalog.

wall thickness 0.8 mm

D-E)2 - 2CD

[#]

[nH]

[watts]

Npri
146.21
104.67
86.25
48.54
30.59
26.06

Lleakage
2701.37
1669.10
2065.81
709.81
307.51
261.82

Pwr Loss
0.13
0.18
0.30
0.51
0.70
0.98

Calculated
w/bobbin
Lw
20.955
24.3
28.2
39.1
48.5
55.1

Calculated

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

w/bobbin

No bobbin

Aw

Lw

Aw

Lw

4.5
7.6
19.3
33.8
48.5
64.5

14.8
18.6
25.6
34.1
40
52.9

4.2
6.5
16.7
27.7
46
52.3

Calculated

17.1
20.5
24.3
35.2
44.7
51.2

Calculated
No bobbin
Aw
11.8
16.6
31.4
50.1
67.9
87.4

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestEP

Core #
EP7
EP10
EP13
EP17
EP20

Dim. A
9.4
11.5
12.8
18.0
24.0

Dim. B
7.5
10.2
13.0
16.8
21.4

Dim. C
5.0
7.4
9.0
11.4
14.4

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

Core dimensions:

Ferroxcube
w/bobbin
[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

Dim. D
6.5
7.6
9.0
11.0
15.0

Dim. E
7.2
9.4
9.7
12.0
16.5

Dim. F
3.4
3.3
4.5
5.7
8.8

Dim. G
1.7
1.8
2.4
3.3
4.5

Lm
15.5
19.3
24.2
29.5
41.1

Ac
10.7
11.3
19.5
33.7
78.7

Vc
165.0
215.0
472.0
999.0
3230.0

Lw
17.7
21.7
23.0
28.9
40.8

EP Core Formulas
Magnetic dimensions (lm, Ac, Vc) given on core spec sheets.
Winding dimensions:
Mean turn length lw = 2(E+F)/2 = (E + F) ; no bobbin
lw = (E + F+1.6) ; bobbin with 0.8 mm thick walls
Winding window area Aw = C(E-F)/2 ; no bobbin
Aw = (C-1.6)(E-F-1.6)/2 ; bobbin with 0.8 mm thick walls
Winding volume Vw = lw Aw
Surface area As:
Exposed core surface:
Vertical surface area = 2BD + AB + AB - EC = 2B(D+A) - EC
Top and bottom surface = 2AD
Exposed core surface area = 2AD + 2B(A+D) - EC
Exposed winding surface = CE/2
Total surface area = 2AD + 2B(A+D) - EC + 0.5CE = 2AD + 2B(A+D) + 0.57CE

Ferroxcube
w/bobbin
[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

[watts]

Aw

Vw
76.1
247.4
310.5
537.5
1370.9

As
381.2
604.1
847.0
1448.4
2524.6

R
349.8
220.7
157.4
92.1
52.8

Psp
818.2
676.1
560.1
487.8
284.0

Jrms
7.5
6.8
6.2
5.8
4.4

Bpeak
261.2
243.4
227.0
215.7
176.5

EP_Rating
26.7
63.2
109.7
231.6
610.1

4.3
11.4
13.5
18.6
33.6

2B(A+D) + 0.57CE

[#]

[nH]

[watts]

Npri
85.33
86.72
53.88
32.81
17.17

Lleakage
2050.50
2815.91
807.56
360.00
134.63

Pwr Loss
0.20
0.31
0.44
0.75
1.31

Calculated

Calculated

Ferroxcube

Ferroxcube

Calculated

w/bobbin

w/bobbin

w/bobbin

w/bobbin

No bobbin

Lw

Aw

Lw

Aw

Lw

19.2
22.5
24.8
30.3
42.2

3.7
13.1
13.3
23.0
39.0

17.7
21.7
23.0
28.9
40.8

4.3
11.4
13.5
18.6
33.6

16.6
19.9
22.3
27.8
39.7

Calculated
No bobbin
Aw
9.5
22.6
23.4
35.9
55.4

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestER

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

Core #
ER9.5
ER11
ER14.5
ER28
ER28L
ER35
ER40
ER42
ER42A
ER48
ER54

Dim. A
9.5
11.0
14.5
28.6
28.6
35.0
40.0
42.0
42.0
48.0
53.5

Dim. B
5.0
6.0
6.8
11.4
11.4
11.4
13.4
15.6
15.6
21.0
18.0

Dim. C
2.5
2.5
3.0
14.0
16.9
20.7
22.4
22.4
21.8
21.2
18.3

Calculated
w/bobbin
[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

Dim. D
7.1
8.0
11.8
21.8
21.8
26.2
29.6
30.1
30.4
38.0
40.7

Dim. E
3.5
4.3
4.8
9.9
9.9
11.3
13.3
15.5
15.0
18.0
17.9

Dim. F
1.6
1.5
1.6
9.8
12.7
14.8
15.5
15.5
15.6
14.7
11.1

Dim. G
7.5
8.7
11.8
21.8
21.8
26.2
29.6
30.1
30.4
38.0
40.7

Lm
14.2
14.7
19.0
64.0
75.5
90.8
98.0
98.8
99.0
100.0
91.8

Ac
8.5
11.9
17.6
81.4
81.4
107.0
149.0
194.0
170.0
255.0
250.0

Vc
120.0
174.0
333.0
5260.0
6140.0
9710.0
14600.0
19200.0
16800.0
25500.0
23000.0

Lw
19.8
22.9
28.6
52.3
52.3
61.4
69.9
74.1
73.8
90.4
94.5

ER Core Formulas
Magnetic dimensions (mean path length lm, core area Ac, and core volume Vc)
Winding dimensions:
Mean turn length lw = 2 (G+E)/2 = (G+E) ; no bobbin
lw = (G+E+1.6) ; bobbin with 0.8 mm thick walls
Winding area Aw = 2F(G-E)/2 = F(G-E) ; no bobbin
Aw = (F-0.8)(G-E-1.6) ; bobbin with 0.8 mm thick walls
Winding Volume Vw = lwAw = F(G2 - E2)
Surface area As:
Exposed core surface: front and back = 2(2CA) - 2(2FD) = 4AC-4DF
Left and right = 2(2CB) = 4BC
top and bottom = 2AB

Total exposed core surface = 4AC -4DF+4BC+2AB = 4C(A+B)+2AB-4DF

Winding surface:
Vertical surface = G2F - 2(2FB) = 2FG - 4BF
Horizontal surface = 2(G/2)2 - 2BG
Total winding surface = 2FG-4BF + 0.5G2 -2BG = G(2F-0.5G) - 2B(2F+G)
As = 4C(A+B)+2AB-4DF + G(2F-0.5G) - 2B(2F+G)

Calculated
w/bobbin

Calculated
w/bobbin

[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

[watts]

Aw

Vw
38.0
44.9
123.4
4846.4
6408.1
11430.3
15097.1
14161.3
15070.9
23128.9
20638.1

As
71.7
76.7
73.2
1689.4
2165.5
3174.7
3903.8
4207.1
4042.3
4043.6
3324.9

R
1859.6
1738.3
1821.8
78.9
61.6
42.0
34.2
31.7
33.0
33.0
40.1

Psp
234.9
181.3
83.0
86.5
89.3
77.7
68.0
65.3
65.6
43.0
39.4

Jrms
4.0
3.5
2.4
2.4
2.5
2.3
2.1
2.1
2.1
1.7
1.6

Bpeak
164.5
149.5
111.9
113.7
115.0
109.2
104.0
102.4
102.6
87.8
85.0

ER_Rating
3.2
3.6
6.0
618.7
841.1
1488.0
2141.6
2378.4
2238.7
2911.9
2258.8

1.9
2.0
4.3
92.7
122.6
186.2
216.1
191.1
204.2
255.8
218.4

nd core volume Vc) given on core specification sheets.

+2AB-4DF

5G) - 2B(2F+G)

[#]

[nH]

[watts]

Npri
170.54
134.07
121.09
25.78
25.48
20.41
15.40
12.01
13.67
10.66
11.23

Lleakage
15055.51
12650.59
19184.72
441.63
332.83
269.37
182.26
105.33
142.55
146.30
256.23

Pwr Loss
0.04
0.04
0.04
0.87
1.12
1.64
2.02
2.18
2.09
2.09
1.72

Calculated

Calculated

Ferroxcube

Ferroxcube

Calculated

w/bobbin

w/bobbin

w/bobbin

w/bobbin

No bobbin

Lw

Aw

Lw

Aw

Lw

19.8
22.9
28.6
52.3
52.3
61.4
69.9
74.1
73.8
90.4
94.5

1.9
2.0
4.3
92.7
122.6
186.2
216.1
191.1
204.2
255.8
218.4

18.4
21.6
27.0

2.8
2.8
5.1

17.3
20.4
26.1
49.8
49.8
58.9
67.4
71.6
71.3
87.9
92.0

Calculated
No bobbin
Aw
6.4
6.6
11.2
116.6
151.1
220.5
252.7
226.3
240.2
294.0
253.1

Transfer

Data
Phillips

Core Rating

Core #

designation

Err:504
Criteria
TestETD

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Core #
ETD29
ETD34
ETD39
ETD44
ETD49
ETD54
ETD59

Acore
Err:504

Vc + Vw
Err:504

[mm]
Dim. A
30.6
35
40
45
49.8
54.5
59.8

[mm]
Dim. B
15.8
17.3
19.8
22.3
24.7
27.6
31

[mm]
Dim. C
9.8
11.1
12.8
15.2
16.7
18.9
21.65

ETD Core Formulas

Mean turn length lw =2 (E+F)/4 = 0.5(E+F) ; no bobbin
lw = 0.5(E+F+1.6) ; bobbin with 0.8 mm thick walls
Winding window area Aw = 2D = D(E-F) ; no bobbin
Aw = (D-0.8)(E-F-1.6) ; bobbin with 0.8 mm thick walls
Winding volume Vw = {0.25 E2 - 0.25F2]2D = 0.5D(E2 - F2)
Surface Area As
Exposed core surface:
left and right = C4B : top and bottom 2CA : front and back 2(2AB-2DE)
Summing 4BC + 2AC+4AB-4DE
Exposed winding surface:
Vertical cylindrical surface = 2D*2E/2 - 2(2DC) = 2DE - 4CD
Horizontal circuilar surfaces = 2(0.25E2) - 2CE = 0.5(E2) - 2CE
Summing exposed core and winding area:
As = 4BC+2AC+4AB-4DE+2DE-4CD+0.5(E2)-2CE

Ferroxcube
w/bobbin
[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

Dim. D

Dim. E

Dim. F

Lm
72
78.6
92.2
103
114
127
139

Ac
76
97.1
125
173
211
280
368

Vc
5470
7640
11500
17800
24000
35500
51500

Lw

11
11.8
14.2
16.1
17.7
20.2
22.5

22
25.6
29.3
32.5
36.1
41.2
44.7

Dimensions

9.8
11.1
12.8
15.2
16.7
18.9
21.65

52.0
60.0
69.0
77.0
85.0
96.0
106.0

Ferroxcube
w/bobbin

Ferroxcube
w/bobbin

[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

Aw

Vw
4940.0
7380.0
12213.0
16478.0
23205.0
30336.0
38796.0

As
3343
4281
5623
7171
8783
10941
13419

R
39.9
31.1
23.7
18.6
15.2
12.2
9.9

Psp
166.2
147.5
122.7
108.3
96.3
86.0
76.9

Jrms
3.4
3.2
2.9
2.7
2.6
2.4
2.3

Bpeak
144.8
138.5
129.4
123.5
118.3
113.4
108.8

95.0
123.0
177.0
214.0
273.0
316.0
366.0

[watts]

[#]

[nH]

[watts]

ETD_Rating
1045.0
1558.1
2459.3
3690.0
5184.6
7217.7
9968.7

Npri
21.68
17.74
14.75
11.16
9.56
7.51
5.96

Lleakage
283.75
242.76
182.55
107.92
89.09
62.58
40.32

Pwr Loss
1.73
2.22
2.91
3.71
4.55
5.66
6.94

Calculated
w/bobbin
Lw
52.4
60.1
68.6
77.4
85.4
96.9
106.7

Calculated
w/bobbin
Aw
108.1
141.9
199.7
240.2
300.8
401.6
465.5

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

Lw

Aw

52.0
60.0
69.0
77.0
85.0
96.0
106.0

95.0
123.0
177.0
214.0
273.0
316.0
366.0

Calculated
No bobbin
Lw
49.9
57.6
66.1
74.9
82.9
94.4
104.2

Calculated
No bobbin
Aw
134.2
171.1
234.3
278.5
343.4
450.5
518.6

Transfer

Data
Seimens

Core Rating

Core #

Designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestPM

Core #
PM 50/39
PM 62/49
PM 74/59
PM 87/70
PM 114/93

Dim. A
49.2
62.0
74.0
87.0
114

Dim. B
38.8
49.0
59.0
70.0
93

Dim. C
23.4
-

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

PM Core Forumlas

Effective magnetic length lm, core area Ac, and core volume

Mean winding length lw = 2(g +h)/2 = (g + h) ; no bobbin

lw = = (g + h + 1.6) ; bobbin with 0.8 thick walls

Winding window area Aw = d(h - g)/2 ; no bobbin

Aw = (d - 1.6)(h - g -1.6)/2 ; bobbin with 0.8 mm thick walls
Winding volume = Vw = lwAw = (h^2 - g^2)/2
Surface area As 2 (a/2)^2 + 2(a/2)h = a^2/2 + ah

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

Dim. D
26.8
33.4
40.7
48.0
63

Dim. E
4.8
-

Dim. F
1.4
-

Dim. G
19.7
25.5
29.5
31.7
43

Dim. H
39.7
48.8
57.5
67.1
88

Dim. I
5.4
5.4
5.4
8.5
5.4

Dim. J
37.6
-

e area Ac, and core volume Vm given in core specification sheet.

h)/2 = (g + h) ; no bobbin
th 0.8 thick walls

g)/2 ; no bobbin
in with 0.8 mm thick walls

(h^2 - g^2)/2

(a/2)h = a^2/2 + ah

Calculated
w/bobbin
[mm]

[mm2]

[mm3]

Lm
84
109
128
146
200

Ac
370
570
790
910
1720

Vc
31000
62000
101000
133000
344000

[mm]
Lw
191.5
238.3
278.2
315.3
416.4

Calculated
w/bobbin
[mm2]
Aw
231.8
345.0
516.1
784.2
1332.4

Calculated
w/bobbin
[mm3]

[mm2]

Vw
44406.6
82229.6
143586.6
247211.1
554755.1

As
13734.0
21570.5
30555.3
42097.0
72307.9

[C/W]

[mW/cm3]

[A/cm2]

[mT]

[watts]

[#]

[nH]

R
9.7
6.2
4.4
3.2
1.8

Psp
94.3
77.4
64.6
57.3
41.6

Jrms
2.5
2.3
2.1
2.0
1.7

Bpeak
117.3
109.1
102.0
97.6
86.7

PM_Rating
7578.3
14636.1
25944.8
40877.7
99424.2

Npri
5.49
3.84
2.96
2.69
1.60

Lleakage
90.33
51.23
35.08
35.12
15.93

[watts]
Power Loss
7.11
11.16
15.81
21.79
37.42

Calculated
w/bobbin
Lw
191.5
238.3
278.2
315.3
416.4

Calculated
w/bobbin
Aw
231.8
345.0
516.1
784.2
1332.4

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

Lw

Aw

Calculated
No bobbin
Lw
186.5
233.3
273.2
310.2
411.3

Calculated
No bobbin
Aw
268.0
389.1
569.8
849.6
1417.5

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestP

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

Core #
P7/4
P9/5
P11/7
P14/8
P18/11
P22/13
P26/16
P30/19
P36/22
P42/29
P66/56

Dim. A
5.5
6.5
6.8
9.5
13.4
15.0
18.0
20.5
26.2
32.0

Dim. B
1.6
2.0
2.2
2.7
3.8
3.8
3.8
4.3
4.9
5.1
7.0

Dim. D1
7.4
9.3
11.3
14.3
18.4
22.0
25.5
30.0
36.2
42.2
66.3

d
1
d

d3

h1
2
h2
2

d
4

A'
b

A'
b

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

Dim. D2
5.8
7.5
9.0
11.6
14.9
17.9
21.2
25.0
29.9
35.6
53.5

Dim. D3
3.0
3.9
4.7
6.0
7.6
9.4
11.5
13.5
16.2
17.7
28.8

Dim. D4
1.4
2.1
2.2
3.1
3.1
4.4
5.4
5.4
5.4
5.4
6.4

Dim. H1
4.2
5.4
6.5
8.4
10.6
13.4
16.0
18.8
21.7
29.4
55.8

Dim. H2
2.8
3.6
4.4
5.6
7.2
9.2
11.0
13.0
14.6
20.3
42.0

Lm
10.0
12.5
15.5
19.8
25.8
31.5
37.6
45.2
53.2
68.6
123.0

Ac
7.0
10.1
16.2
25.1
43.3
63.4
93.9
137.0
202.0
265.0
717.0

Potcore Formulas
Effective lm, Ac, Vc given on core spec sheet.
Mean winding length lw =

0.5(d2 + d3) ; without coil former

lw = 0.5(d2 + d3 + 1.6) ; with coil former having walls 0.8 mm thick

Winding window area Aw = 0.5 h2 (d2 - d3); without coil former
Aw =

0.5 (h2 - 1.6)(d2 - d3 - 1.6); with coil former having walls 0.8 mm thick

Winding volume = Awlw

d
4

Surface area = 2 (d1/2)2 + h1d1 = 0.5(d1)2 + h1d1

Ferroxcube
w/bobbin

Ferroxcube
w/bobbin

[mm3]

[mm]

[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

Vc
70.0
126.0
251.0
495.0
1120.0
2000.0
3530.0
6190.0
10700.0
18200.0
88300.0

Lw

Aw

Vw

As
125.0
200.9
294.5
479.4
781.7
1167.7
1606.2
2221.0
3121.8
4786.2
13814.4

R
1066.9
663.6
452.8
278.1
170.6
114.2
83.0
60.0
42.7
27.9
9.7

Psp
637.9
547.0
424.2
332.6
226.7
188.2
148.4
114.7
100.5
81.9
51.0

ls 0.8 mm thick

ving walls 0.8 mm thick

14.6
18.8
22.7
29.0
36.7
44.7
52.7
66.0
74.3
86.0
130.0

2.2
3.4
4.8
8.7
18.1
27.1
39.3
58.1
72.4
140.0
400.0

31.4
64.1
108.3
250.9
664.3
1211.4
2071.1
3834.6
5379.3
12040.0
52000.0

[A/cm2]

[mT]

[watts]

[#]

[nH]

[watts]

Jrms
6.6
6.1
5.4
4.8
3.9
3.6
3.2
2.8
2.6
2.4
1.9

Bpeak
238.2
225.0
204.8
187.2
162.4
151.6
138.8
126.2
120.1
111.4
93.4

P_rating
7.0
14.1
25.3
57.5
148.6
277.1
484.0
833.9
1365.9
2900.5
14834.5

Npri
143.04
104.94
71.89
50.77
33.92
24.82
18.30
13.80
9.83
8.08
3.56

Lleakage
6253.24
4334.25
2400.02
1564.74
896.18
532.64
325.76
232.76
140.99
103.66
20.29

Power Loss
0.06
0.10
0.15
0.25
0.40
0.60
0.83
1.15
1.62
2.48
7.15

Calculated

Calculated

w/bobbin

w/bobbin

Lw

Aw

16.3
20.4
24.0
30.1
37.8
45.4
53.9
63.0
74.9
86.2
131.7

0.7
2.0
3.8
8.0
16.0
26.2
38.1
56.4
78.7
152.4
466.6

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

No bobbin

No bobbin

Lw

Aw

Lw

Aw

14.6
18.8
22.7
29.0
36.7
44.7
52.7
66.0
74.3
86.0
130.0

2.2
3.4
4.8
8.7
18.1
27.1
39.3
58.1
72.4
140.0
400.0

Calculated

13.8
17.9
21.5
27.6
35.3
42.9
51.3
60.4
72.4
83.7
129.2

Calculated

3.9
6.5
9.5
15.7
26.3
39.1
53.4
74.8
100.0
181.7
518.7

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestPQ

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Core #
PQ20/16
PQ20/20
PQ26/20
PQ26/25
PQ32/20
PQ32/30
PQ35/35

Dim. A
21.3
21.3
27.3
27.3
33.0
33.0
36.1

Dim. B
16.2
20.2
20.2
24.7
20.6
30.3
34.7

Dim. C
10.3
14.3
11.5
16.1
11.5
21.3
25.0

Acore
Err:504

Vc + Vw
Err:504

Core Dimensions:

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

[mm3]

Dim. D
18.0
18.0
22.5
22.5
27.5
27.5
32.0

Dim. E
8.8
8.8
12.0
12.0
13.5
13.5
14.4

Dim. F
14.0
14.0
19.0
19.0
22.0
22.0
26.0

Dim. G
4.0
4.0
6.0
6.0
5.5
5.5
6.0

Dim. H
12.0
12.0
15.5
15.5
19.0
19.0
23.5

Lm
37.6
45.7
45.0
54.3
55.9
74.7
86.1

Ac
61.9
62.6
121.0
120.0
169.0
167.0
190.0

Vc
2330.0
2850.0
5820.0
6530.0
9440.0
12500.0
16300.0

PQ Core Formulas

Magnetic parameters (lm, Ac,Vc) given on core specificaitons sheets.

Winding dimensions:
Mean turn length lw = 0.5(D+E) ; no coil former
lw = 0.5(D+E +1.6) ; with coil former with walls 0.8 mm thick
Winding window area Aw = 0.5C(D-E) ; no coil former
area Aw = 0.5[C - 1.6](D-E-1.6) ) ; with coil former with walls 0.8 mm thick
Windng volume Vw = lwAw
Surface Area As:
Exposed core area:
Top and bottom = 2AF ; cutouts ignored.
Left and right vertical = 2BF
Front and back vertical = 2AB-2CD
Total exposed core surface = 2AF+2BF +2AB-2CD
Exposed winding area:
Vertical surface = 2CD/2 -2CF = CD - 2CF = C(D - 2F)
Top and bottom = 2(D/2)2 - 2FD
Total winding surface = CD - 2CF + 0.5D2 -2FD

Total surface area As = 2AF + 2BF + 2AB -2CD + + CD - 2CF + 0.5D2 - 2DF

Ferroxcube
w/bobbin

Ferroxcube
w/bobbin

[mm]

[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

Lw

Aw

Vw
1034.0
1584.0
1748.4
2679.0
2988.2
3535.1
14107.4

As
1667.8
1920.2
2705.7
3065.6
3549.8
4492.9
5742.6

R
79.9
69.4
49.3
43.5
37.6
29.7
23.2

Psp
256.6
224.1
185.0
172.3
147.8
145.0
97.7

Jrms
4.2
3.9
3.5
3.4
3.2
3.1
2.6

Bpeak
170.0
161.7
150.6
146.7
138.6
137.6
118.9

0.8 mm thick

44
44
56.4
56.4
66.7
66.7
75.4

23.5
36
31
47.5
44.8
53
187.2

+ 0.5D2 - 2DF

[watts]

[#]

[nH]

[watts]

PQ_rating
307.2
423.1
596.0
851.2
989.5
1137.6
3243.0

Npri
22.67
23.56
13.09
13.55
10.18
10.38
10.56

Lleakage
422.63
329.00
184.64
141.37
176.24
98.85
123.77

Power Loss
0.86
0.99
1.40
1.59
1.84
2.33
2.97

Calculated

Calculated

Ferroxcube

Ferroxcube

w/bobbin

w/bobbin

w/bobbin

w/bobbin

Lw

Aw

Lw

Aw

44.6
44.6
56.7
56.7
66.9
66.9
75.4

33.1
48.3
44.1
64.5
61.4
122.1
187.2

44
44
56.4
56.4
66.7
66.7

23.5
36
31
47.5
44.8
53

Calculated

Calculated

No bobbin

No bobbin

Lw

Aw
47.4
65.8
60.4
84.5
80.5
149.1
220.0

42.1
42.1
54.2
54.2
64.4
64.4
72.8

Transfer

Data
Phillips

Core Rating

Core #

designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestRMI

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Core #
RM4/I
RM5/I
RM6S/I
RM7/I
RM8/I
RM10/I
RM12/I
RM14/I

Dim. A
9.8
12.3
14.7
17.2
19.7
24.7
29.8
34.7

Dim. B
11
14.9
17.9
20.3
23.2
28.5
37.4
42.2

Dim. C
4.4
6.8
8.2
7.25
11
13.5
16.1
19

Acore
Err:504

Vc + Vw
Err:504

Dimensions:

Vertical core surfaces:

top view

h2
2

a
2
1.414a - b
c

b e

0.707b-0.5a

c
2

a
1.414

d3

0.5[a-d2]

h1
2

b e

0.707b-0.5a

c
2

1.414

d3

0.5[a-d2]

h1
2

[mm]

[mm]

[mm]

[mm]

[mm]

[mm]

[mm2]

Dim. D2
7.95
10.2
12.4
14.75
17
21.2
25
29

Dim. D3
3.9
4.9
6.4
7.25
8.55
10.9
12.8
15

Dim. E
5.8
6
8.8
9.3
9.5
10.9
12.9
17

Dim. H1
10.4
10.4
12.4
13.4
16.4
18.6
25.5
30.1

Dim. H2
7
6.3
8
8.4
10.8
12.4
16.8
20.8

Lm
23.3
23.2
29.2
30
38.4
44.6
56.6
70

Ac
13.8
24.8
37
44.1
63
96.6
146
198

RM/I Core Formulas

Core parameters:
Mean magnetic path length lm given in core spec sheet.
Core area Ac given in core spec sheet.
Core volume Vm given in core spec sheet.
Winding parameters: Coil former assumed to have 0.8mm thick walls
Mean turn length lw = 2(d2+d3)/4 = 1.57(d2+d3) no coil former
lw = 2(d2+d3 +1.6)/4 = 1.57(d2+d3 + 1.6) with coil former
Winding window area Aw = 0.5(d2-d3)h2 no coil former
Aw = (0.5d2 - 0.5d3 -0.8)(h2 - 1.6) with coil former
Winding volume Vw = lwAw

Core area - top and bottom surfaces : 2{ a^2 - shaded areas}

shaded areas (top only) = 2{[a/2]^2- c^2/4} + 2{[a/2]^2 - {0.7a-0.5b}^2}

= a^2/2 - c^2/2 + a^2/2 -0.5[2a^2 - 2.83ab + b^2] = 1.414ab -0.5b^2 - 0.5c^2
=1.5a^2+0.5b^2-0.5c^2-ab/1.414
total top and bottom surfaces = total top and bottom surfaces = 2[1.414ab -0.5b^
= 2.83ab - b^2 - c^2

side view

vertical surface area = 4(.707b-.5a)h1+ 2(1.414a-b)h1 +4(0

= 0.83h1(a+b) + 2h2(a-d2) +4e(h1-h2)

h2
2

Exposed core surface area = 2.83ab - b2 - c2 + 0.83h1(a+b

Exposed winding surface area:
vertical exposed winding surface = 0.5d2h2

d3

top and bottom exposed surfaces =2[ 0.5[d2/2]^2 - 0.5c^2

Total exposed winding surface = 1.57d2h2 + 0.79[d2]^2 - c

As = 2.83ab - b^2 - c^2 + 0.83h1(a+b) + 2h2(a-d2) +4e(h1

As = 2.83ab - b^2 - 2c^2 + + 0.83h1(a+b) + 2h2(a-d2) +4

h1
2

d3

h1
2

Ferroxcube
bobbin
[mm3]

[mm]

[mm2]

[mm3]

[mm2]

[C/W]

[mW/cm3]

Vc
322
574
1090
1325
2440
4310
8340
13900

Lw

Aw

Vw
166.3
244.0
462.0
735.0
1302.0
2233.2
4575.0
7881.0

As
552.9
735.2
1074.0
1460.3
1848.8
2702.4
4295.3
5845.6

R
241.2
181.3
124.1
91.3
72.1
49.3
31.0
22.8

Psp
585.9
465.1
358.1
366.8
255.7
213.7
172.1
138.9

mm thick walls

coil former

Ferroxcube
bobbin

19.8
24.9
30.8
35
42
52.3
61
71

8.4
9.8
15
21
31
42.7
75
111

^2 - {0.7a-0.5b}^2}
1.414ab -0.5b^2 - 0.5c^2

urfaces = 2[1.414ab -0.5b^2 - 0.5c^2]

a)h1+ 2(1.414a-b)h1 +4(0.5(a-d2)h2 +4e (h1 - h2)

ab - b2 - c2 + 0.83h1(a+b) + 2h2(a-d2) +4e(h1-h2)

= 0.5d2h2

=2[ 0.5[d2/2]^2 - 0.5c^2] = 0.25[d2]^2 - c^2

1.57d2h2 + 0.79[d2]^2 - c^2

1(a+b) + 2h2(a-d2) +4e(h1-h2) + 1.57d2h2 + 0.79[d2]^2 - c^2

3h1(a+b) + 2h2(a-d2) +4e(h1-h2) + 1.57d2h2 + 0.79[d2]^2

side view

[A/mm2]

[mT]

[watts]

[#]

[nH]

[watts]

Jrms
6.3
5.6
4.9
5.0
4.2
3.8
3.4
3.1

Bpeak
230.9
211.9
192.4
194.1
169.8
158.9
146.7
135.5

RMI_rating
50.2
86.2
156.7
267.0
411.2
743.1
1633.8
2720.9

Npri
74.88
45.38
33.51
27.87
22.30
15.54
11.14
8.89

Lleakage
1344.43
903.18
543.09
508.02
342.01
219.61
115.09
79.13

Power Loss
0.29
0.38
0.56
0.76
0.96
1.40
2.22
3.03

Calculated

Calculated

[nH]

[#]

Bobbin

Bobbin

Lleakage
1344.4
903.2
543.1
508.0
342.0
219.6
115.1
79.1

Npri
74.88
45.38
33.51
27.87
22.30
15.54
11.14
8.89

Lw

Aw
21.1
26.2
32.0
37.1
42.6
52.9
61.9
71.6

6.6
8.7
14.1
20.1
31.5
47.0
80.6
119.0

Ferroxcube

Ferroxcube

Calculated

Calculated

bobbin

bobbin

no Bobbin

No bobbin

Lw

Aw

Lw

Aw

19.8
24.9
30.8
35
42
52.3
61
71

8.4
9.8
15
21
31
42.7
75
111

18.6
23.7
29.5
34.5
40.1
50.4
59.3
69.1

14.2
16.7
24.0
31.5
45.6
63.9
102.5
145.6

Transfer

Data

Core Rating

Core #

Phillips designation

[mm]

[mm]

[mm]

Err:504
Criteria
TestU

Jrms
Err:504

Err:504
Err:504
Lleakage
Err:504
Pwr Loss
Err:504
Bpeak
Err:504

Acore
Err:504

Vc + Vw
Err:504

Core #
U/10/8/3
U/15/11/6
U20/16/7
U25/16/6
U25/20/13
U/30/25/16
U/33/22/9
U/67/27/14
U/93/76/16
U/93/52/30
U/93/76/30
U/100/48/25
U/100/57/25

Dim. A
10
15.4
20.8
25.4
24.8
31.3
33.3
67.3
93
93
93
101.6
101.6

Dim. B
8.2
11.45
15.6
15.9
19.6
25.3
22.2
27
76
52
76
47.5
57.1

Dim. C
2.9
6.25
7.5
6.4
12.7
16
9.4
14.3
16
30
30
25.4
25.4

U core dimensions

Mean core length

E

A
C

A-E
4
radius

A-E

B-D
2

A-E
4
radius

2D

A-E

B-D
2

B-D
2

Two section winding

Coil former
wall thickness
1 mm

E
1 mm
(A-E)
2

radius =

(E-3mm)
4

lw = 2(C+2mm) + 2{0.5(A-E) +2mm} + 2{0.25(E-3mm)} = 2C +(A-E) + 8mm +

Surface area As - single section windin

Exposed surface area

Exposed core surface bottom and top
Exposed core surface left and right = 2
Exposed co= 4AB 4DE-2D(A-E)/2*2
= 4AB 4DE 2AD + 2DE = 4AB 2DE
Summing three terms together
As,c = 4BC 2DC+2AC+4AB-2DE-2AD

Exposed surface area of winding

Top and bottom = (2)(4)(0.25)(E)^2
= 2.3E^2 + 2AE +2CE

Vertical surface = 2E(2D) +2(2D)(0.5

As,w = 2.3E^2 +2AE+2CE+ 10.6DE +

As = As,c + As,w = 4AB+2AC-2AD-2D

As = 4AB + 2AC + 8.6DE + 4BC +2.3

calculated
w/bobbin

calculated
w/bobbin

[mm]

[mm]

[mm]

[mm2]

[mm3]

[mm]

[mm2]

Dim. D
5
6.4
8.3
9.5
11.4
14.9
12.7
12.7
48
24
48
22.1
31.7

Dim. E
4.35
5.4
6.4
12.7
8.4
10.5
14.3
38.8
36.2
36.2
36.2
50.8
50.8

Lm
38.4
52
68
83.6
88.2
111
110
173
354
258
354
270
308

Ac
8.4
32.3
56.0
40.3
104.0
161.0
86.5
204.0
448.0
840.0
840.0
645.0
645.0

Vc
323.0
1680.0
3800.0
3380.0
9180.0
17900.0
9490.0
35200.0
159000.0
217000.0
297000.0
174000.0
199000.0

Lw

Aw

30.0
44.3
54.4
70.2
73.0
90.6
87.6
183.8
207.3
235.3
235.3
266.0
266.0

26.8
47.5
78.8
198.9
153.9
264.1
311.2
884.5
3308.8
1619.2
3308.8
2101.6
3057.7

Mean core length lc = 4D + 2E + 2{(A-E)/8 + (B-D)/4} = 4D + 2E + 0.25[(A-E) +2(B-D)]

A-E

B-D
2

A-E

B-D
2

Core Area Ac = 0.5C(A-E)

Core Volume Vc = 2BAC- 2DEC lc Ac

Mean turn length lw

Single section winding

Coil former
wall thickness

2B
2D

mm

Coil fo
wall t

1 mm

1 mm
E

1 mm

(A-E)
2

1 mm

E-3mm)
4

m)} = 2C +(A-E) + 8mm + 0.5(E-3mm)

radius =
(E-1mm)

radius
0.5(E-1

With coil former:

lw = 2 [(E-1mm)/2] + 2 {0.5(A-E) + 2mm} + 2(C+2mm) = (E-1mm)
Without coil former: lw = E +A-E+2C
Winding Area Aw

With coil former:

Single section Aw = (E-1mm)(2D-2mm)
Two section Aw =(2D-2mm)(E-3mm)

Without coil former:

Aw = 2DE

Winding volume Vw lwAw

a As - single section winding

face area of core As,c

e surface bottom and top = 2BC + 2(B-D)C = 4BC - 2DC
e surface left and right = 2AC
= 4AB 4DE-2D(A-E)/2*2
E 2AD + 2DE = 4AB 2DE 2AD

ree terms together

2DC+2AC+4AB-2DE-2AD = 4AB+2AC-2AD-2DE+4BC-2CD

face area of winding As,w

tom = (2)(4)(0.25)(E)^2 + (4)(0.5)(A-E)E + 2CE = E^2(6.3-2) + 2AE + 2CE
+ 2AE +2CE

ace = 2E(2D) +2(2D)(0.5)(A-E) + C(2D) = 4DE + 2AD-2DE+2CD

= 10.6DE + 2AD +2CD

^2 +2AE+2CE+ 10.6DE +2AD +2CD

As,w = 4AB+2AC-2AD-2DE+4BC-2CD+ 2.3E2 +2AE+2CE+ 10.6DE +2AD +2CD

2AC + 8.6DE + 4BC +2.3E2 + 2AE + 2CE

[mm3]

[mm2]

[C/W]

[mW/cm3]

[A/mm2]

[mT]

[watts]

Vw
803.2
2105.9
4285.4
13970.3
11241.7
23935.4
27251.0
162567.7
686006.9
381043.1
778653.3
558956.1
813267.9

As
824
1782
2991
4564
5186
8381
7671
24770
61961
50555
69835
57785
66856

R
161.8
74.8
44.6
29.2
25.7
15.9
17.4
5.4
2.2
2.6
1.9
2.3
2.0

Psp
379
244
191
136
131
104
108
65
38
44
34
41
34

Jrms
5.1
4.1
3.6
3.0
3.0
2.7
2.7
2.1
1.6
1.7
1.5
1.7
1.5

Bpeak
196.4
166.8
152.6
134.4
132.7
121.5
123.4
102.1
83.8
88.3
80.1
86.0
80.6

U_rating
66.7
309.9
722.7
975.1
1888.6
4081.0
2678.5
11507.5
59322.6
61605.1
100049.2
57779.2
72061.3

(A-E) +2(B-D)]

=
)

Coil former
wall thickness

1 mm

1 mm
radius =
0.5(E-1mm)

+ 2(C+2mm) = (E-1mm) + (A-E) +2C + 8mm

Without coil former:

[#]

[nH]

[watts]

Npri
144.60
44.28
27.92
44.02
17.28
12.19
22.34
11.45
6.36
3.22
3.55
4.30
4.59

Lleakage
11412.57
1534.52
684.05
3809.53
336.52
198.64
1030.27
1540.39
132.23
76.85
46.72
236.40
187.90

Power Loss
0.43
0.92
1.55
2.36
2.68
4.34
3.97
12.82
32.06
26.16
36.14
29.90
34.60

coil former

coil former

Ferroxcube

Ferrooxcube

calculated

calculated

bobbin

bobbin

No bobbin

lw

Aw

Lw

Aw

Lw
25.1
39.5
49.5
65.4
68.2
85.8
82.7
178.9
202.5
230.5
230.5
261.1
261.1

30.0
44.3
54.4
70.2
73.0
90.6
87.6
183.8
207.3
235.3
235.3
266.0
266.0

26.8
47.5
78.8
198.9
153.9
264.1
311.2
884.5
3308.8
1619.2
3308.8
2101.6
3057.7

29
48.7

27.4
37.3

No bobbin
Aw
43.5
69.1
106.2
241.3
191.5
312.9
363.2
985.5
3475.2
1737.6
3475.2
2245.4
3220.7