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  Case Study: How a German Heavy-Duty EV Manufacturer Tamed 800V EMI with the JHNO71.5*29.6*30.0 Core

  Jan 13, 2026

  Germany's automotive engineering sector is world-renowned for its uncompromising standards, especially in the emerging sector of 800V Heavy-Duty Electrification. Recently, a Munich-based Tier-1 supplier for electric trucks faced a critical hurdle in their 350kW Fast Charging Unit design. This case study explores how our JHNO71.5 provided the high saturation and thermal resilience needed to handle extreme currents where standard Ferrite failed. The Challenge: "The 800V Heat Trap" The German engineering team was developing a high-power DC/DC converter for an electric semi-truck. The shift from 400V to an 800V architecture meant faster charging, but it also brought severe EMI challenges and massive heat generation. Saturation at Peak Load: The charging currents exceeded 400A. Traditional ferrite cores saturated instantly, losing inductance and allowing EMI noise to breach VDE standards. Limited Cooling: The busbar layout was tight. The core needed to handle high DC bias without requiring an active cooling loop directly on the choke. Vibration & Stress: Unlike passenger cars, heavy-duty trucks generate significant vibration. The magnetic core needed superior mechanical protection. They needed a "Heavyweight" magnetic solution—robust, large, and thermally stable. The Solution: The Heavy-Duty JHNO71.5*29.6*30 We introduced the 30, a high-performance Iron-based Nanocrystalline core specifically dimensioned for high-power units. Why this specific core solved the problem: Massive Effective Area (Ae) for High Power:With an Outer Diameter (OD) of 71.5mm and a Height of 30mm, this core offers a significantly larger magnetic cross-section than standard 55mm cores. This prevents saturation even under the massive current spikes typical of heavy-duty charging cycles. High Bs (1.25T) vs. Ferrite:While Ferrite saturates at ~0.4T, our Nanocrystalline material maintains linearity up to 1.25 Tesla. This allowed the German team to reduce the physical size of the filter by 50% compared to a ferrite stack, fitting perfectly into the IP67 aluminum housing. Broadband Attenuation (10kHz - 30MHz):The core provided exceptional insertion loss across the critical frequency spectrum, ensuring the 800V system passed the stringent CISPR 25 Class 5 and commercial vehicle EMC standards (ISO 7637). Thermal Endurance:Operating in a gearbox-adjacent environment, the core's stability from -40°C to +140°C (Curie temp 570°C) ensured zero performance degradation during long-haul climbs in summer heat. Robust "German-Grade" Packaging To meet the vibration requirements of the truck industry, the JHNO71.5*29.6*30.0 is encapsulated in a reinforced PBT (UL94-V0) Case. This square-profile casing protects the nanocrystalline ribbon from mechanical shock and mounting pressure, ensuring the permeability remains constant over the vehicle's 15-year lifecycle. The Outcome: Production Ready By integrating the JHNO71.5*29.6*30.0, the client achieved: 30% Volume Reduction in the EMC filter stage. Full Compliance with 800V EMC regulations without additional shielding. Thermal Safety: The core runs cooler due to lower hysteresis losses compared to alternative metal powder cores. ConclusionIn the era of 800V heavy-duty EVs, "standard" magnetic components are no longer enough. The 30 Nanocrystalline Core offers the brute strength (High Bs) and precision (High Permeability) required by German engineering standards. For more details, check: https://www.amorphousoem.com/product/jhno71529630-nanocrystalline-common-mode-choke-core-for-ev-power-units

  Hot Tags : High Power Nanocrystalline Core High Saturation Flux Density Core (1.25T) High Current EMI Filter Core Heavy-Duty EV Charger Core Iron-Based Nanocrystalline Tape Wound Core Thermal Stable Toroidal Core (-40°C to 140°C)

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  Case Study: How an Italian EV Charger Manufacturer Solved Thermal & EMI Challenges with Our 54mm Nanocrystalline Core

  Jan 11, 2026

  In the competitive landscape of European automotive electronics, thermal management and EMI compliance are the twin hurdles every engineer must clear. Recently, a prominent Tier-1 manufacturer of On-Board Chargers (OBC) based in Turin, Italy, approached us with a critical design bottleneck. This case study details how switching from Ferrite to our Iron-based Nanocrystalline Core (54.0x 50.5 x 18.0 mm) helped them downsize their 22kW charging module while surviving extreme engine compartment temperatures. The Challenge: Saturation at High Temperatures The Italian engineering team was designing a high-density DC/DC converter stage for a new electric hypercar. They faced two specific problems using traditional Mn-Zn Ferrite cores: Thermal Derating: At the target operating temperature of 120°C, the Ferrite cores were losing significant permeability, leading to EMI filter failure. Size Constraints: To prevent magnetic saturation under high current spikes, they had to stack multiple ferrite cores, which violated the strict height restriction of the OBC housing. They needed a solution that offered high saturation flux density (Bs) and stable inductance in a compact footprint. The Solution: High Bs Nanocrystalline Technology After reviewing their magnetic circuit requirements, we proposed our Nanocrystalline Toroidal Core (Model: 54.0）. Here is why this specific core was the perfect fit for their application: 1.25T Saturation Flux Density (Bs): Unlike Ferrite (Bs ~0.4T), our iron-based nanocrystalline material handles three times the flux density. This allowed the Italian team to replace two stacked ferrite cores with a single Nanocrystalline unit, reducing weight and volume immediately. Extreme Thermal Stability: With a Curie Temperature of 570°C and a crystallization temperature of 510°C, the core’s magnetic properties remain virtually unchanged from -40°C to +140°C. Superior Inductance per Turn: The core delivers an AL value of ≥ 100.0 µH (at 1kHz, 0.3V). This high impedance allowed the engineers to achieve the required Common Mode attenuation with fewer wire turns, further reducing copper loss (I²R). Robust Packaging for Automotive Standards Reliability is non-negotiable in the EU market. The Italian client was particularly impressed with the encapsulation. The core is housed in a Square-Top Seam Black PBT Case (Polybutylene Terephthalate). Material: UL94-V0 rated PBT. Temperature Rating: Certified for continuous operation up to 140°C. Mechanical Protection: The rigid case protects the delicate nanocrystalline ribbons from winding stress, ensuring the mechanical pressure does not degrade the magnetic permeability (magnetostriction effect). The Result: Successful EMC Certification By integrating the 54.0mm Nanocrystalline core, the client successfully: Reduced Component Height: Met the 20mm clearance requirement (Core height is 18.0mm). Passed CISPR 25 Class 5: The high permeability at 10kHz–150kHz solved their low-frequency noise issues. Enhanced Durability: The effective cross-sectional area (Ae = 168.48 mm²) provided robust performance without saturation during load dump transients. ConclusionFor power electronics engineers struggling with space constraints and high-temperature environments, traditional materials often fall short. As proven by our Italian partners, switching to High-Bs Nanocrystalline cores is not just an upgrade—it is a necessity for next-gen EV power electronics. Looking for high-performance magnetic cores? Check our full datasheet for the 54.0mm series or contact our engineering team for custom samples. For more details, check: https://www.amorphousoem.com/product/jhno-nanocrystalline-common-mode-choke-core-for-ev-power-units

  Hot Tags : Nanocrystalline Common Mode Choke Core High Bs Nanocrystalline Core 1.25T High Temperature Stable Magnetic Core (140°C) Compact EMI Core for High Current Broadband Noise Suppression Nanocrystalline PBT Encapsulated Toroidal Core

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  Amorphous vs. Nanocrystalline Cores: The Critical Selection for EVs and PV Inverters

  Dec 11, 2025

    The relentless push toward electrification—from high-performance Electric Vehicle (EV) power control units to grid-optimizing Photovoltaic (PV) inverters—is uniformly demanding components that can handle higher switching frequencies, increased power densities, and extreme efficiency. When system frequencies push past conventional limits, traditional ferrite materials often become the bottleneck, introducing significant losses. For R&D engineers, selecting the right soft magnetic material is not just a component swap; it's a critical decision that dictates the product's performance, size, and ultimate cost. Amorphous and Nanocrystalline materials are the key contenders in this high-stakes selection battle.   1. The Deep Dive: How Material Structure Defines High-Frequency Performance Both Amorphous and Nanocrystalline cores achieve their characteristic exceptionally high permeability  and ultra-low core loss  due to their unique microstructures:   Amorphous Cores: The atoms are in a disordered, non-crystalline state, which eliminates grain boundaries and effectively minimizes eddy current losses. Typically iron-based, amorphous materials boast a high Saturation Magnetic Flux Density (Bs) (up to 1.6T), making them highly suitable for high-current, high-power applications where minimizing volume is paramount.   Nanocrystalline Cores: These are created by subjecting amorphous alloys to a precisely controlled annealing process, resulting in ultra-fine grains (only 10 nanometers in size). This structure nearly eliminates effective magnetic anisotropy, leading to the lowest loss and highest permeability among soft magnetic materials, especially across the mid-to-high frequency spectrum.   Here is a quick reference table comparing key parameters for engineers:   Performance Parameter Traditional Ferrite Amorphous Core (Fe-based) Nanocrystalline Core (Fe-based) Design Significance Saturation Flux Density (Bs)  0.4-0.5T  1.5-1.6T 1.2-1.3T Determines transformer/inductor volume (Higher Bs allows smaller size). Operating Frequency Range Mid-to-High Freq. (>100kHz） Mid-to-Low Freq. (<50 kHz) Wideband (10 kHz to 10 MHz) Defines system efficiency and switching capability. Permeability （ui） approx 1000~5000 approx 10000~50000 Up to 190000 Critical for common mode choke effectiveness and turn count. Core Loss (Pv) High (at high frequencies) Low Extremely Low Directly impacts heat generation and system reliability.   2. Key Applications: Efficiency Breakthroughs in Automotive and Solar EV Power Control: The Key to Cooling and Filtering As On-Board Chargers (OBCs) and DC-DC converters push past 100kHz, the ultra-low loss of nanocrystalline materials makes them the preferred choice for main transformers and resonant inductors, significantly reducing thermal dissipation and boosting efficiency.   For Electromagnetic Compatibility EMC, EV control units generate substantial high-frequency noise. Nanocrystalline cores, with their exceptionally high permeability, are the ideal material for manufacturing high-performance Common Mode Chokes (CMCs), effectively suppressing noise across the 10 kHz to 10 MHz range.     PV Inverters: Balancing Power and Efficiency Amorphous alloys are frequently used in large-current filter inductors within high-power PV systems. Their high Bs and excellent low-frequency loss characteristics allow them to handle large current swings in a smaller form factor. In modular inverters targeting higher power density, Nanocrystalline is adopted in high-frequency transformers and CMCs to maximize conversion efficiency and overall system compactness.     3.  Grasping Future Design Trends   While Amorphous cores remain vital in large-power filtering and lower-frequency applications due to their high saturation flux density and cost advantages, Nanocrystalline cores are rapidly becoming the default solution for high-frequency power electronics driven by SiC/GaN platforms. This shift is driven by their ultra-low loss and superior permeability across a wide bandwidth. Engineers must precisely balance operating frequency, thermal limits, and power density targets when finalizing their material selection.   The future will demand even higher system frequencies, placing greater pressure on soft magnetic materials. Continuous optimization of nanocrystalline core performance will be central to ensuring the long-term reliability of high-performance power electronics systems.   Is your next high-frequency, high-power project bottlenecked by magnetic core selection?   As a specialized manufacturer of high-performance Amorphous and Nanocrystalline soft magnetic materials, Dongguan JH Amorphous controls the core technology from ribbon to precise thermal processing. We provide customized core solutions tailored specifically to your OBC, DC-DC, or PV inverter design needs, guaranteeing efficiency improvements and size optimization.   We invite you to visit our website  today or send your detailed design specifications to our engineering team. Let our professional soft magnetics experts provide you with the selection advice and sample support you need to unlock the next level of performance for your product!

  Hot Tags : how to Balance Power and Efficiency in PV inverter Amorphous vs. Nanocrystalline How Material Structure Defines High-Frequency Performance high-performance Common Mode Chokes is nanocrystalline core worthy on EV The Key to Cooling and Filtering in EV Power Control

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  How Magnetic Materials Shape the Future of Liquid-Cooled 8.5 kW Server Power Supplies

  Dec 09, 2025

  Engineering Insights into EMI Filters, PFC Chokes, and the Role of 1K107B Nanocrystalline vs. 1K101 Amorphous Cores As power supplies for data centers and AI servers enter the 8.5 kW to 12 kW range, engineers face a significant architectural shift. Liquid cooling is becoming mainstream, switching frequencies are rising, and power density is pushing beyond 100 W/in³. These trends have brought a new bottleneck to the front of PSU design: Magnetic materials — especially those used in EMI filters and PFC chokes — increasingly determine the feasibility of next-generation liquid-cooled power architectures. A commonly referenced teardown image of an 8.5 kW server PSU illustrates this point clearly: EMI Filter positioned at the thermal entrance PFC Choke (TTPFC) running at high frequency Bulk Capacitors in the center LLC stage and main transformer toward the cold plate regions Compact mechanical layout optimized for liquid cooling This configuration highlights a fundamental truth: when switching frequency increases and heat-spreading paths become constrained, magnetic core loss becomes the dominant thermal source in these front-end components.   1. Why Liquid Cooling Makes Magnetic Materials More Critical Liquid cooling greatly improves heat extraction from power semiconductors (GaN, MOSFETs, SR devices). However, many magnetics — especially EMI filters and PFC inductors — are not mounted directly on cold plates. In an 8.5 kW PSU: The cold plate is reserved for semiconductors and key transformers EMI and PFC inductors sit in restricted airflow zones Their thermal paths are poorly coupled to the liquid cooling loop This leads to an important engineering observation: Magnetic components now rely far more on intrinsic core loss performance, rather than on mechanical cooling solutions. As a result, differences between materials such as 1K107B nanocrystalline and 1K101 amorphous become significantly amplified.   2. The Rise of High-Frequency PFC: A Stress Test for Magnetic Materials Typical PFC switching frequencies have increased from: 20–30 kHz → 40–70 kHz → approaching 100 kHz in TTPFC designs. This shift improves power density but also raises: AC flux density Switching ripple High-frequency harmonics Core temperature Because of this, the high-frequency loss curve becomes the dominant factor in magnetic selection.   Key Findings: 1K107B Nanocrystalline Core Lower high-frequency core loss More stable permeability Better temperature behavior Enables smaller inductors Reduces hotspot temperature by 10–20°C in many PSU designs   1K101 Amorphous Core Core loss increases steeply above 20–40 kHz Larger physical size required Higher hotspot temperatures Less suitable for compact, liquid-cooled PSUs In practice, many 6–8 kW PSU designs using 1K101 encounter either:✔ Excessive temperature rise✔ Oversized inductorsBoth of which limit system scalability.   3. Material Selection for EMI Filters in Liquid-Cooled PSUs EMI filters are especially sensitive to high-frequency noise and temperature constraints. They require: High permeability Low HF loss Surge robustness Stable inductance under thermal stress Nanocrystalline material (1K107B) offers advantages in: Broadband EMI suppression Maintaining inductance at elevated temperatures Reducing size for compact front-end layouts Lower incremental loss across switching harmonics Therefore: In modern 8.5 kW PSU designs, EMI filters increasingly favor 1K107B over 1K101.   4. Where Amorphous Material Still Excels Despite the advantages of nanocrystalline cores in high-frequency stages, 1K101 amorphous remains the preferred material for: Current transformers (CTs) Low-frequency PFC input inductors Large magnetic flux swing operations HVDC filtering stages High saturation flux requirements This means: The shift is not about replacing amorphous materials,but about using each material where it performs best.   5. Industry Trends: Migration Toward High-Frequency-Optimized Materials Across major server OEMs and hyperscale power suppliers, engineering teams are converging on a clear material strategy for liquid-cooled PSUs: ✔ EMI Filter → 1K107B Nanocrystalline ✔ PFC Choke (TTPFC) → 1K107B Nanocrystalline ✔ Current Transformers → 1K101 Amorphous ✔ Input Inductors → Mixed (depending on ripple and frequency) A shared viewpoint is emerging: As PSU power density surpasses 100 W/in³,magnetic material selection becomes just as critical as topology selection.   🗣️ Discussion: What Will Be the Next Bottleneck? As server PSUs evolve from 8.5 kW → 10 kW → 12 kW, liquid cooling and GaN technologies will continue to push the boundaries of power density. But magnetics remain key thermal contributors — especially in front-end EMI and PFC stages. A question for engineers designing next-generation AI server PSUs: Which magnetic component do you expect to become the next limiting factor in ultra-dense liquid-cooled designs? EMI choke? TTPFC inductor? LLC transformer? Or the magnetic materials themselves?   Your insights and field experiences are welcome.

  Hot Tags : nanocrystalline core for high-frequency PFC choke design nanocrystalline vs amorphous comparison for TTPFC inductors 1K107B Nanocrystalline Cores 1K101 Amorphous Cores Magnetic materials for EMI filters and PFC chokes Nanocrystalline material (1K107B)

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  Why Magnetic Core Material Plays a Crucial Role in Inductor Performance: A Deep Dive

  Nov 20, 2025

  Now fast-paced world of electronics, engineers are constantly faced with the challenge of optimizing circuit performance while maintaining compactness and energy efficiency. One crucial, yet often overlooked, component in these designs is the magnetic core used in inductors. The material of the magnetic core can dramatically influence the inductor’s performance, particularly in high-frequency applications. This blog will explore how different magnetic core materials impact inductor performance, why choosing the right material is critical, and how these materials affect the efficiency and longevity of your electronic devices.   The Importance of Magnetic Core Material Magnetic cores play a vital role in the function of inductors. They influence inductance, energy storage, efficiency, and power losses. The performance of an inductor is highly dependent on the magnetic material it’s made from, and the right choice of material can make a significant difference in how well the device operates across different frequencies and power levels. There are several materials commonly used for magnetic cores in inductors, such as ferrite, silicon steel, and nanocrystalline alloys. Each material comes with its own set of advantages and limitations, making it essential for engineers to understand the material properties in order to make the right choice for a given application.   How Different Magnetic Core Materials Affect Performance Mn-Zn Ferrite CoresFerrite cores are made from iron oxide combined with other metals, and they are widely used in high-frequency applications like switch-mode power supplies and transformers. They offer relatively low eddy current losses at high frequencies, making them suitable for circuits operating in the kilohertz (kHz) to megahertz (MHz) range. Additionally, ferrite cores have high magnetic permeability, which means they can store more magnetic energy with relatively low losses, improving circuit efficiency. However, Mn-Zn ferrite cores have limitations at very high frequencies, where losses can increase due to core material saturation. Ferrite cores are also less efficient at very low frequencies, which makes them less suitable for power transformers or circuits that require low-frequency performance.   Nanocrystalline CoresNanocrystalline cores, a newer material in magnetic technology, offer exceptional performance in high-frequency applications. These cores are made from iron and other elements arranged in a nanocrystalline structure, which allows them to exhibit significantly higher magnetic permeability compared to ferrite cores. Nanocrystalline cores provide lower losses and higher efficiency in high-frequency circuits, such as power inductors in high-frequency switching power supplies. Their higher saturation flux density makes them particularly useful for high-power applications, where maintaining performance at higher current levels is essential. The main advantage of nanocrystalline cores over ferrite is their ability to operate with up to 30% lower high-frequency losses. They also maintain low hysteresis losses even at very high frequencies (several hundred kHz), making them ideal for applications in the 5G telecommunications, electric vehicles (EVs), and data centers.   Silicon Steel CoresSilicon steel is another material that has been used for decades in power transformers and other low-frequency applications. Its relatively low magnetic losses make it suitable for power transformers operating at 50-60Hz in traditional power grids. However, silicon steel’s performance at higher frequencies is limited due to significant eddy current losses. This makes it less suitable for high-frequency applications, such as modern power electronics or devices that operate in the kHz-MHz range.   The Mechanism Behind Magnetic Core Performance The performance of magnetic cores in inductors is largely determined by the following factors: Magnetic Permeability: The ability of a material to support the formation of a magnetic field. Higher permeability means better energy storage capacity and lower losses. Hysteresis Losses: The energy lost when the magnetic material is magnetized and demagnetized. Materials with lower hysteresis losses are more efficient. Eddy Current Losses: Induced currents within the core material that cause heat loss. High-frequency applications require materials that minimize these losses. Saturation Flux Density: The maximum magnetic field strength the material can handle before its magnetic properties break down. A higher saturation flux density means the material can handle higher currents without losing performance.   Quantifying the Performance Gains Nanocrystalline materials reduce high-frequency losses by up to 30% compared to Mn-zn ferrite cores. They also provide 2-3 times higher permeability, which means more efficient energy storage and enhanced inductor performance in high-power, high-frequency applications. These materials are particularly useful in systems requiring low hysteresis loss and high-frequency operation (several hundred kHz), which are essential in modern electronics like switch-mode power supplies, 5G networks, and electric vehicles (EVs).   Choosing the Right Core Material for Different Applications When selecting a magnetic core for an inductor, engineers must consider the specific requirements of the application: Switch-Mode Power Supplies (SMPS): Ferrite and nanocrystalline cores are ideal for high-frequency operation and minimizing losses. Electric Vehicles (EV): Nanocrystalline cores, with their high saturation flux density and low losses, are essential for handling large currents in high-power applications. 5G Networks: High-performance cores, such as nanocrystalline, offer superior efficiency for handling high-frequency signals while minimizing power loss. Data Centers: For high-speed communication and efficient power conversion, nanocrystalline cores are increasingly being used to improve system efficiency.    The Critical Role of Magnetic Core Material in Inductor Design Magnetic core material plays a critical role in the performance of inductors and the overall efficiency of electronic circuits. By selecting the appropriate core material—whether it’s ferrite, nanocrystalline, or silicon steel—engineers can ensure that inductors function efficiently across different frequencies and power levels. Understanding the benefits and limitations of each material is essential for optimizing circuit designs in today’s high-performance, energy-efficient electronic systems. As technologies like 5G, electric vehicles, and AI data centers continue to evolve, the importance of choosing the right magnetic core material will only grow.   What’s Your Biggest Challenge in High-Frequency Inductor Design? In the fast-evolving world of electronics, engineers are continuously tasked with pushing the limits of technology. Whether you’re designing power supplies, communication systems, or next-gen EVs, understanding the relationship between magnetic core material and inductor performance is key to achieving optimal results.   Let us know your thoughts, DM us. 

  Hot Tags : magnetic core nanocrystalline cores over ferrite nanocrystalline core VS Mn-zn ferrite core nanocrystalline common mode choke high saturation nanocrystalline core

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  Why Do Nanocrystalline Cores Stay Rock Solid Under High Current? — The Truth Behind Magnetic Saturation

  Nov 13, 2025

  Discover why nanocrystalline cores outperform traditional magnetic materials under DC bias and high current. This article explains their anti-saturation behavior, supported by real customer cases and B-H curve analysis for transformers, inductors, and EMC filters. In magnetic component design, one of the biggest challenges engineers face isn’t cost — it’s magnetic saturation. Under high current or DC bias, once the core saturates, inductance drops, losses rise, and EMI performance collapses.   Recently, one of our EV charger clients faced this exact problem. Their common mode choke was overheating and failing EMI tests. Testing revealed that the high-permeability permalloy core was severely saturated under DC bias, leading to a sharp decline in effective permeability. We suggested switching to nanocrystalline cores.  But after reviewing the B-H curves, the difference was undeniable: High-μ alloys magnetize quickly but saturate under strong magnetic fields; Nanocrystalline materials maintain permeability stability even under heavy DC bias; Low-μ ferrites resist saturation but lack sufficient inductance for high-power systems. The results were remarkable:✅ EMI margin improved by 40%✅ Core temperature dropped by 15°C✅ No redesign required ✳️ Why Nanocrystalline Cores Perform Better Nanocrystalline alloys feature ultra-fine grains (10–20 nm), resulting in smooth domain wall motion, low hysteresis loss, and stable permeability.Key properties include: High saturation flux density (1.2 T) Medium to high permeability (μ ≈ 80K ~ 190K) Excellent DC bias tolerance Strong temperature stability ( -40 ~ 140 degree) That’s why nanocrystalline cores are ideal for: Common mode chokes (EMC filters) Power inductors High-frequency transformers EV chargers, inverters, and power modules In short, nanocrystalline materials achieve the perfect balance between permeability and saturation resistance — keeping magnetic cores rock solid under current.   🏭 About JH Amorphous JH Amorphous is a professional manufacturer specializing in nanocrystalline and amorphous magnetic cores, serving global customers in transformers, inductors, common mode chokes, and EMC filter applications.We focus on delivering high-performance, customizable core solutions to help engineers design magnetic components that remain stable and efficient even under high current, high frequency, and harsh conditions.   👉 Visit our website or contact our export team to learn more about JH Amorphous products and technical support.JH Amorphous — Your Trusted Partner in Advanced Magnetic Materials.

  Hot Tags : nanocrystalline cores common mode choke anti-saturation core EMC filter magnetic materials transformer core

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  How Nanocrystalline Cores Redefine Efficiency and Size in Power Electronics

  Nov 03, 2025

  In power electronics, the eternal challenge is achieving higher power density, lower losses, and greater efficiency — all in smaller, lighter systems. For decades, engineers have pushed the limits of magnetic materials to make this possible. Now, a new generation of material — the nanocrystalline alloy — is unlocking what once seemed impossible. It’s not just an upgrade to existing cores. It’s a paradigm shift in electromagnetic design — enabling solid-state transformers, EV fast chargers, and next-generation power converters to go further, faster, and cooler.   1. The Efficiency Equation: Where Every Watt Counts In modern energy systems, even a 1% gain in conversion efficiency can translate to megawatt-hours of saved energy and millions of dollars in reduced operating costs. Traditional materials — silicon steel or ferrite — struggle as switching frequencies increase. Their eddy current losses rise exponentially, creating excessive heat and forcing bulky cooling systems. Nanocrystalline alloys rewrite that equation: High resistivity (~120 μΩ·cm) drastically cuts eddy current losses. Fine grain size (<20 nm) reduces domain wall motion losses. Uniform microstructure ensures consistent magnetic performance even under thermal stress. As a result, core loss can be reduced by up to 70%, directly improving overall system efficiency — a critical advantage for solid-state transformers (SSTs), DC/DC converters, and high-frequency inverters. In power electronics, less heat = less waste = longer life.That’s why nanocrystalline cores aren’t just about performance — they’re about system reliability.   2. Shrinking the Core, Expanding the Possibilities Every watt saved also means less magnetic material needed. With permeability levels in the range of 10⁵–10⁶, nanocrystalline cores allow designers to achieve the same magnetic flux with 40–70% less volume compared to ferrite or amorphous cores. That translates to: Smaller transformers and inductors Lighter EV charger modules Compact high-density data center power supplies And because nanocrystalline maintains stable permeability across frequencies from 1 kHz to 100 kHz, engineers no longer need to trade size for efficiency. In the race to miniaturize power systems, nanocrystalline alloys have become the ultimate enabler.   3. Real-World Impact: From Fast Chargers to AI Power Grids Let’s look at some numbers: A 30 kW EV fast charger requires around 3–4 kg of nanocrystalline core, reducing system losses by up to 2%. A 100 kVA solid-state transformer using nanocrystalline can be 40% smaller and 15–25°C cooler than one with amorphous cores. In large data centers, even a 1% boost in efficiency at the power distribution level can save tens of millions of kWh annually. From the roadside charger to the AI supercomputer, energy efficiency is now a material challenge — and nanocrystalline alloys are the answer.   4. Engineering for the Future: Why This Matters Power electronics is entering a new era — high frequency, high density, and high intelligence. But that progress depends on what’s inside the magnetic core.Without materials that can handle high flux, high frequency, and high temperature simultaneously, innovation stalls. Nanocrystalline alloys break that bottleneck.They bring: High magnetic flux density (1.2–1.6 T) Low losses at high frequency Thermal and magnetic stability across wide temperature ranges This unique balance between structure and performance makes nanocrystalline the material foundation of the next generation of power systems.   5. The Big Picture: Material Innovation Drives Energy Innovation From EV charging to AI datacenters, microgrids to renewable integration, the most advanced systems share one truth — they all rely on efficient magnetic materials. Nanocrystalline alloys are no longer a lab experiment.They’re being mass-produced, cost-optimized, and integrated into commercial products worldwide. Just as silicon enabled the digital revolution, nanocrystalline alloys are becoming the core material of the energy revolution.     Nanocrystalline cores redefine the boundaries of power electronics.They make systems smaller, cooler, smarter, and more efficient. In the transition toward electrification and intelligent power, this is the material that makes the impossible possible.

  Hot Tags : SolidStateTransformer EV charging Data Center magnetic materials nanocrystalline cores nanocrystalline alloy

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  Why Nanocrystalline Alloys Are the Core of Next-Generation Power Electronics

  Oct 28, 2025

  Nanocrystalline alloys deliver unmatched magnetic permeability, low core loss, and superior high-frequency stability—making them the ideal core material for solid-state transformers, EV chargers, and compact high-efficiency power systems.   Why This Material? — The Science Behind Nanocrystalline Alloys Among all soft magnetic materials, very few can simultaneously achieve low loss, high permeability, and stable high-frequency performance.Nanocrystalline alloys are the rare exception — a breakthrough material that bridges the gap between traditional silicon steel and amorphous alloys. Structurally, a nanocrystalline alloy consists of ultrafine crystalline grains (10–20 nm) embedded within an amorphous matrix.This hybrid structure combines the “no grain boundary, low eddy current” benefits of amorphous materials with the improved magnetic alignment of crystalline ones. The result is a magnetic material that maintains high permeability, low loss, and excellent thermal and frequency stability — the perfect foundation for modern power electronics and solid-state transformers (SSTs).   1. High Magnetic Permeability — The Key to Compact Efficiency Magnetic permeability defines how easily magnetic flux can pass through a material.Nanocrystalline alloys offer permeability in the range of 10⁵–10⁶, far exceeding that of silicon steel (≈10³–10⁴) and amorphous alloys (≈10⁴–10⁵). This enables transformers and inductors to shrink by 30–70% in volume and cut core weight by more than half, without sacrificing performance. Even more critically, nanocrystalline alloys retain high permeability under kilohertz-level frequencies,while silicon steel and amorphous cores experience sharp declines.That makes them the material of choice for high-frequency, high-efficiency SSTs, EV power modules, and data center converters.   2. Moderate Saturation Flux Density, Optimized for High-Frequency Stability Unlike amorphous alloys with higher Bs (≈1.5T) but poor high-frequency stability,nanocrystalline alloys offer a moderate Bs of ≈1.2T, balanced by ultra-low loss and superior permeability at operating frequencies of several kHz to tens of kHz. In high-power-density systems such as EV fast chargers or on-board DC/DC converters,where fast response and minimal heat buildup are essential,this balance allows higher efficiency, smaller size, and better thermal control. Simply put — amorphous may saturate higher, but nanocrystalline runs cooler and smarter.   3. Low Core Loss and High-Frequency Efficiency — The Foundation of Power Electronics The defining advantage of nanocrystalline alloys lies in their low total core loss across wide frequency ranges. High resistivity (110–130 μΩ·cm) suppresses eddy current loss; Tiny grain size (<20 nm) minimizes magnetic hysteresis and domain wall motion loss; Uniform internal stress ensures stability even under high switching frequencies. As a result, nanocrystalline cores deliver minimal power loss even at 10–50 kHz,making them the cornerstone for solid-state transformers and compact power converters that must operate efficiently under continuous high-frequency switching.   4. Thermal Stability and Reliability — Designed for Real-World Conditions Nanocrystalline alloys maintain magnetic performance consistently across -40°C to 150°C,ensuring reliability in both freezing northern climates and tropical heat. Their low loss and higher thermal conductivity reduce temperature rise within the magnetic core,simplifying cooling design and improving long-term system stability. For next-generation SSTs and EV power modules that must operate continuously,this translates directly into greater reliability and longer service life.   5. From Innovation to Industrial Scale — The Maturity Advantage Recent advances in ribbon casting, heat treatment, and coating technology have transformed nanocrystalline alloys from a lab innovation into a mass-produced industrial material.With mature Fe-Si-B-Cu-Nb alloy systems and large-scale production lines,China now leads in global capacity and application development, bringing down costs and enhancing consistency. Today, nanocrystalline ribbons are already used in solid-state transformers, EV fast chargers, UPS systems, and renewable power converters — validating their industrial readiness.   6. A Material for Its Time — The Energy Transition Catalyst Every phase of the energy transition is defined by a breakthrough material: The grid era belonged to silicon steel. The energy-saving transformer era belonged to amorphous alloys. The high-frequency, power-electronics era belongs to nanocrystalline alloys. With global surges in EVs, AI data centers, renewable energy, and high-efficiency charging,nanocrystalline materials are no longer an upgrade — they’re a necessity.   Nanocrystalline alloys are not just “better materials.”They are the enabling foundation of tomorrow’s power electronics ecosystem. Refer to our blog

  Hot Tags : nanocrystalline alloy solid-state transformer Power Electronics magnetic core soft magnetic materials nanocrystalline cores manufacturer

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  A Tale of Two Coatings: Exploring Surface Technologies for Nanocrystalline Cores

  Oct 20, 2025

   Discover the difference between Electrostatic Powder Spraying and Powder Rolling coatings for nanocrystalline cores. Learn how Dongguan JH Amorphous Co., Ltd. enhances performance, reliability, and winding protection through advanced coating technologies.   In the world of magnetic materials, details matter — especially when it comes to protecting and enhancing high-performance nanocrystalline cores.At Dongguan JH Amorphous Co., Ltd., we continuously refine our processes to help customers achieve the perfect balance of performance, durability, and cost efficiency. Recently, our engineering team compared two coating methods widely used in our nanocrystalline core production. Both provide robust protection, but each brings unique advantages depending on your application.   Coating A: Electrostatic Powder Spraying Coating This traditional technique uses electrostatically charged powder sprayed onto the core surface, followed by high-temperature curing. Key Features: Surface: Slightly uneven with minor texture — functional but not perfectly smooth. Edges: Sharper draft angles. Cost: More economical, ideal for cost-sensitive projects. Wire Compatibility: Suitable for standard wire diameters. Best suited for: Projects that prioritize cost efficiency and standard magnetic performance.   Coating B: Powder Rolling Coating A more advanced process, powder rolling ensures a uniform, tightly bonded coating layer with superior surface quality. Key Features: Surface: Exceptionally smooth, providing both visual appeal and functional precision. Edges: Rounded R-angles that are gentle on copper wire during winding. Cost: Slightly higher, reflecting the enhanced precision. Wire Compatibility: Can handle thicker copper wire, allowing more design flexibility. Best suited for: Applications demanding premium finish, higher wire tolerance, and improved durability.   Why Coating Quality Matters The coating layer might look simple, but it plays a crucial role in: Improving electrical insulation Reducing mechanical wear Preventing EMI interference Extending core lifespan A well-applied coating ensures smoother winding, fewer production defects, and more reliable magnetic performance in power electronics, EV chargers, and renewable energy converters.   The JH Amorphous Commitment At JH Amorphous, we believe that perfection lives in the details.From raw material design to precision coating, every step reflects our dedication to efficiency, consistency, and customer success. Our R&D team works closely with global partners to deliver customized amorphous and nanocrystalline core solutions, optimized for next-generation energy and industrial applications. About Dongguan JH Amorphous Co., Ltd. Dongguan JH Amorphous Co., Ltd. is a professional manufacturer specializing in amorphous and nanocrystalline magnetic cores and parts.We serve industries including power electronics, renewable energy, automotive electrification, and industrial automation, offering both standard and custom magnet solutions. Contact Information:📧 julia@amorphousoem.com🌐 www.amorphousoem.com   Author:Julia YimInternational Marketing ManagerDongguan JH Amorphous Co., Ltd.

  Hot Tags : Nanocrystalline Manufacturing Magnetic Cores Engineering Innovation Electrostatic Powder Spraying Coating Powder Rolling Coating Magnet Core Coating Technology

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  Why is my PTC heater noisy?

  Sep 11, 2025

  In electric vehicles (EVs), passenger comfort and energy efficiency are key design considerations. High voltage PTC (Positive Temperature Coefficient) heaters are widely used for cabin heating and battery thermal management. However, many engineers face a persistent issue: excessive noise and EMI interference generated by PTC heater modules. Why Do PTC Heaters Generate Noise? High voltage PTC heaters operate at 400V–800V and involve fast switching electronics. These factors can lead to multiple noise sources:- EMI Noise: Switching spikes from MOSFETs/IGBTs cause common mode and differential mode interference.- Buzzing & Humming: Magnetostriction and vibration effects.- High-Frequency Whine: Audible tones caused by poor filtering or PCB layout resonances. Traditional Solutions and Their Limits Engineers have tried:- Ferrite cores (low cost but limited performance at high frequencies)- Shielding and PCB layout optimization- Oversized inductors (increase cost and weight) Why Nanocrystalline Cores Are the Answer Nanocrystalline magnetic cores offer:- High Permeability (μ up to 80,000) for EMI suppression- Low core loss at high frequencies- Compact size for space-saving- Proven use in EV chargers, DC/DC converters, and now PTC heaters Case Example: EV Heater Noise Suppression A Tier-1 automotive supplier struggled to pass EMC testing for their high voltage PTC heater. The noise spectrum showed severe issues at 150 kHz–300 kHz and 30 MHz–110 MHz, where ferrite materials are less effective. After replacing ferrite beads with nanocrystalline toroidal cores (OD 4 × ID 2.5 × H 2.5 mm):- EMI noise across these bands was successfully suppressed- Overall EMI reduced by 40%- Temperature rise decreased by 15 °C under full load- Compact design enabled 30% space savingMost importantly, the heater module passed EMC certification and entered mass production.   High voltage PTC heaters are critical in EVs for cabin comfort and battery thermal management. Engineers facing EMI or acoustic noise issues should consider nanocrystalline cores as a proven, scalable solution. Our team provides samples with IATF 16949 standard, technical support, and long-term supply to help your project succeed.     

  Hot Tags : PTC heater electromagnetic noise problem PTC heater core material for low noise reduce PTC heater noise PTC heater noise suppression nanocrystalline magnetic cores nanocrystalline toroidal cores

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  191125 Size Nanocrystalline Magnetic Core for Automotive Inductor: Reliable Speed-Limiting Solution for EV and Car Electronics

  Aug 26, 2025

  With the rapid growth of electric vehicles (EVs) and intelligent automotive systems, the demand for high-performance inductors has never been greater. Automotive electronics require components that deliver stable inductance, low power loss, and long-term reliability under harsh conditions. Among them, the 191125 size nanocrystalline magnetic core  inductor stands out as an excellent solution for speed-limiting inductor applications, onboard chargers, and automotive power management modules. This article provides a comprehensive overview of the product’s features, advantages, and application value in the evolving automotive industry. 1. What is the 191125 Size Nanocrystalline Core for Inductor? The 191125 nanocrystalline magnetic core is designed bear core outside dia. 19mm, inner dia. 11mm, height 25mm, Fe-based nanocrystalline 1K107B material. At a working frequency of 100KHz, it delivers a stable inductance value ranging between 52μH and 73μH. The product is optimized for automotive-grade environments, ensuring consistent performance even under extreme conditions such as high temperature, vibration, and electromagnetic interference. In automotive applications, speed-limiting inductors are critical to electromagnetic compatibility (EMC). They help suppress high-frequency noise and stabilize current flow, preventing malfunctions in sensitive electronic systems. By adopting nanocrystalline material, the 191125 inductor combines compact size with superior magnetic performance. 2. Advantages of Nanocrystalline Magnetic Core Compared with traditional ferrite cores, nanocrystalline cores offer significant benefits: High Permeability: Enables higher inductance values with fewer turns, saving space and reducing cost. Low Core Loss: Ensures excellent efficiency at high frequencies, making it suitable for EV power electronics. Temperature Stability: Maintains consistent inductance over wide operating ranges (-40°C to +150°C). Superior EMI Suppression: Effectively reduces noise, ensuring system-level stability in automotive circuits. These properties make nanocrystalline cores ideal for EV power conversion systems, DC/DC converters, onboard chargers, and noise suppression circuits. 3. Key Specifications of the 191125 Nanocrystalline core Size(mm): bear core: OD:19  ID:11  HT: 25 , Coated finished core:  OD:19.5  ID:10.5  HT: 25.5 Structure: wound nanocrystalline core Frequency Range: Optimized for 100KHz operation Single Inductance Value: 52μH – 73μH Application Focus: Automotive speed-limiting inductors, EV power management modules, onboard charging units Such specifications prove the product’s suitability for automotive-grade performance, ensuring reliability in demanding EV systems. 4. Automotive Application Scenarios a. Electric Vehicles (EVs) The 191125 nanocrystalline inductor plays a critical role in EV motor control systems and battery management modules, where stable inductance ensures smooth current handling and improved energy efficiency. b. Automotive Power Management Modules In DC/DC converters and inverters, stable inductance minimizes ripple current, reduces heat generation, and improves overall system reliability. c. Speed-Limiting Inductor Applications As part of EMC compliance, speed-limiting inductors filter noise spikes and protect circuits against interference, ensuring safe vehicle operation. d. Onboard Chargers & Charging Stations In OBCs and fast-charging systems, inductors with low loss and high stability improve charging efficiency and extend battery life. 5. Why Choose the 191125 Nanocrystalline core for Automotive Inductor? Automotive-Grade Reliability: Designed for high vibration, temperature, and humidity environments. Stable Inductance Range: 52–73μH at 100KHz ensures predictable and efficient performance. Long Lifespan: Nanocrystalline core materials reduce wear and degradation over time. Energy Efficiency: Lower losses help optimize EV range and reduce heat dissipation. Broad Applicability: Suitable for EVs, hybrid vehicles, onboard chargers, and smart automotive systems. 6. Market Trend and Industry Outlook The global automotive inductor market is expanding rapidly, driven by the adoption of EVs, hybrid cars, and intelligent vehicle platforms. According to industry forecasts, demand for automotive-grade inductors will grow at double-digit rates over the next five years. Nanocrystalline inductors are expected to dominate future applications due to their superior performance in high-frequency, high-power environments. The 191125 nanocrystalline core for inductor is well positioned as a reliable choice for next-generation EV power electronics. The 191125 size nanocrystalline magnetic core for automotive inductor core combines stable inductance (52–73μH), low core loss, EMI suppression, and automotive-grade durability, making it the ideal solution for speed-limiting applications and other car electronics. For more insights, contact JH Amorphous engineer team via sales@amorhpousoem.com.    As the world moves toward greener, smarter, and more energy-efficient transportation, choosing high-performance inductors is critical. The 191125 inductor not only enhances vehicle reliability but also contributes to safer driving and sustainable mobility.

  Hot Tags : 191125 inductor core EV inductor Nanocrystalline core Nanocrystalline Core Onboard charger Nanocrystalline core DC/DC converter Nanocrystalline core Automotive electronics Nanocrystalline core

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  Common Problems with Onboard Chargers (OBCs) in Electric Vehicles and How Nanocrystalline Cores Solve Them

  Aug 25, 2025

  Introduction to Onboard Chargers (OBCs) and Their Role in Electric Vehicles Onboard Chargers (OBCs) are a critical part of electric vehicles (EVs), converting AC electricity from the grid into the DC power needed to charge the vehicle's high-voltage battery. As EV demand grows, the need for faster and more efficient charging has increased, which brings new challenges to OBC designs. These challenges are primarily related to heat management and electromagnetic interference (EMI), both of which can severely impact the performance and lifespan of OBCs. This article discusses the common problems associated with OBCs and how nanocrystalline cores provide an effective solution. The Key Problems in OBCs: Heat and Electromagnetic Interference Overheating and Performance Degradation A major concern for OBCs is heat, which results from the energy losses that occur during power conversion. Excessive heat can cause components to degrade faster and force the system to throttle its performance to avoid damage. This can reduce the overall efficiency of the vehicle's charging system and lead to increased failure rates in the power electronics. For instance, when operating at maximum capacity, OBCs can experience failure rates that are 40% higher than at normal operating levels, primarily due to overheating. Electromagnetic Interference (EMI) High-speed switching, a characteristic feature of OBCs, generates EMI. This interference can disrupt the vehicle's other sensitive electronic systems, such as communication buses and infotainment units, leading to potential malfunctions. Modern power semiconductors, like GaN (Gallium Nitride) and SiC (Silicon Carbide), operate at high frequencies, generating electromagnetic noise in the 2.4 GHz and 5 GHz bands, which requires highly efficient filtering solutions.   How Nanocrystalline Cores Solve the Heat and EMI Issues Reducing Heat Generation: The Role of Nanocrystalline Cores Nanocrystalline cores have an exceptional ability to reduce core losses, which are responsible for generating heat. Their grain structure, which is much smaller than conventional magnetic materials, results in significantly lower core losses, reducing heat generation by up to 1000 times compared to traditional materials. This reduction in heat allows OBCs to operate at higher power levels without the need for bulky cooling systems, which leads to a more compact and efficient design. Suppressing Electromagnetic Interference (EMI) Nanocrystalline cores excel in EMI suppression due to their high permeability. This allows them to absorb high-frequency noise over a broad range of frequencies, making them ideal for use in common-mode chokes (CMCs) designed to filter out EMI. By improving noise suppression, nanocrystalline cores ensure that the OBC can meet stringent EMC standards and maintain the integrity of the vehicle's electronic systems.   Nanocrystalline Cores vs. Traditional Ferrite Cores: A Comparative Analysis Parameter Nanocrystalline Cores Ferrite Cores Saturation Flux (Bs) 1.2T 0.4T Max Operating Frequency ≥1 MHz <200 kHz Curie Temperature ∼570°C ∼120°C DC Bias Performance >80%@100 Oe 20%@100 Oe Size/Weight 50% weight, 75% size reduction No significant reduction Cost Lower system-level cost Higher due to additional cooling components     The Future of OBC Design with Nanocrystalline Cores Nanocrystalline cores are poised to revolutionize the design of onboard chargers for electric vehicles. By addressing the critical challenges of overheating and EMI, they enable the development of more efficient, compact, and reliable OBCs. This innovation is key to advancing EV technology and supporting the growing demand for faster, more efficient charging solutions.

  Hot Tags : nanocrystalline cores EV Technology Onboard Chargers Electric Vehicle Charging Electromagnetic Interference Overheating in OBCs

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