PFC Inductor Solutions to Reduce Power Loss and Enhance Performance
Why PFC Inductors Are Essential
A PFC Inductor is the core energy storage and filtering component in AC-DC power circuits. It ensures that input current follows the voltage waveform, helping to achieve a power factor of 0.95 or higher while suppressing high-frequency ripple and minimizing EMI.
High-performance PFC Inductors must balance four essential features:
- Operation mode compatibility
- Strong saturation resistance
- Low high-frequency loss
- Wide voltage range and high-current adaptability
These characteristics guarantee stable and efficient operation across applications—from low-power fast chargers to large industrial power supplies.
Understanding CCM, DCM, and CRM PFC Inductors
Different PFC topologies demand different inductor designs. Choosing the right mode ensures optimal power factor and minimal ripple:
- CCM (Continuous Conduction Mode): Standard for high-power applications (≥65W). Requires high inductance (30μH–300μH) and air-gap design for low ripple current (ΔI ≤ 20% Ir).
- DCM (Discontinuous Conduction Mode): Suitable for low-power applications (≤45W), such as fast chargers and LED lighting. Inductance usually ranges from 10μH–50μH.
- CRM (Critical Conduction Mode): Operates near core saturation, providing fast transient response for medium-power applications.
We specialize in custom CCM / DCM / CRM PFC Inductors, optimizing core materials, air-gaps, and winding layouts to meet power levels from 10W to 200kW.
Saturation Resistance: The Key to Reliability
High-current applications cannot compromise on saturation resistance. We use high-saturation magnetic materials:
- Sendust (Fe-Si-Al): Bs = 1.0T
- Fe-based amorphous cores: Bs = 1.5T
For CCM mode, air-gap designs (0.05–1.0mm) minimize saturation risks under DC bias. Safety margins are built-in: the saturation current (Isat, with 10% inductance drop) is ≥1.5× rated current, ensuring stable operation under extreme conditions.
Low-Loss Design: Boost Efficiency and Lifespan
A high-efficiency PFC Inductor combines saturation resistance with low-loss design:
- Core loss: PC95 ferrite or nanocrystalline materials, optimized for 65–200kHz switching.
- Copper loss: Litz wire reduces skin and proximity effects, maintaining low DCR (≤0.1Ω for medium-to-high power).
This design improves efficiency while extending product lifetime, supporting sustainable and reliable operation.
Applications Across Industries
Our PFC Chokes serve a wide range of industrial needs:
Industrial & Server Power (500W–20kW)
- PLCs, servo drives, UPS systems
- Handles 20A–50A high current
- Materials: Sendust, Fe-based amorphous cores
- Packaging: Through-hole or molded
Electric Vehicles & EV Chargers (3.3kW–200kW)
- Onboard chargers (OBC)
- DC fast-charging power modules
- Materials: Nanocrystalline cores + water-cooled sealed packaging
- Designed for harsh temperatures and humidity
Medical Equipment (100W–10kW)
- Ventilators, CT/MRI systems
- Materials: MPP (Fe-Ni-Mo) cores with low hysteresis loss and EMI
- Supports high-precision power factor control
Other applications include LED drivers, home appliances, and high-frequency induction heating. We offer fully customized PFC Inductor solutions for any scenario.
Key Considerations for Custom PFC Inductor Design
To choose the right PFC Inductor, define these parameters:
- Inductance value
- Winding (wire gauge & turns) or current rating if unspecified
- Core specifications, including operation mode (CCM / DCM / CRM), switching frequency (65–150kHz), input/output voltage, and power
- Insulation and environmental reliability
We match core materials and packaging designs precisely to power and operational requirements, ensuring stable, high-efficiency performance.
Magnetic Core Material Selection
| Material | Application | Key Features |
| Sendust (Fe-Si-Al) | High-current CCM | High saturation, excellent linearity |
| MnZn Ferrite | Medium-power / high-frequency | Low core loss, cost-effective |
| Carbonyl Iron | Low-cost DCM / CRM | Distributed air-gap, simplified control |
| MPP (Fe-Ni-Mo) | Precision / low-noise | Low hysteresis, minimal EMI |
Partner with PFC Experts for Success
Designing high-performance PFC Inductors isn’t just about selecting components—it requires material science, magnetic design, and practical application experience. Whether for industrial, automotive, or medical applications, we deliver custom PFC Choke solutions to maximize efficiency, reliability, and compliance.
"Main Power Electric — powering your ideas in your way."