wound nanocrystalline core

• How to Achieve High Inductance and Low Current in Power Supply Designs

  

  Jul 25, 2025

  In power supply designs, one of the biggest challenges is achieving high inductance without increasing the current too much, which can cause saturation. When this balance is not optimized, systems may emit unwanted noise or experience poor performance due to high current. This issue is particularly common in industries where efficiency, reliability, and noise reduction are critical. Finding a way to maintain high inductance and prevent excessive current from causing saturation is key to optimizing a power supply system.     A real-world case study demonstrates an effective solution to this problem.   One of our client had a power supply that emitted noticeable noise and had high current levels. Despite attempts to reduce the inductance to avoid saturation, the power supply still faced issues. The solution came when we combined nanocrystalline and amorphous magnetic materials in the core of the power supply. This hybrid core design successfully achieved high inductance, prevented saturation, and reduced noise.   Solving the Problem with a Hybrid Core Design The client approached us with a specific issue: when their power supply was powered on, it produced a loud noise and had an unacceptably high current. The issue arose from their earlier attempt to lower the inductance in the magnetic core to prevent saturation. However, this didn’t solve the problem, as it compromised the system’s overall performance. Their main challenge was to maintain high inductance while preventing the core from saturating, which would increase the current. To solve this issue, we proposed a hybrid approach by using a combination of nanocrystalline and amorphous materials for the magnetic core. The core was designed with the inner two-thirds made from nanocrystalline material and the outer third from amorphous material. This unique material combination solved the problem by offering several key advantages.   Nanocrystalline and Amorphous Materials: A Perfect Combination Both nanocrystalline and amorphous materials have specific magnetic properties that make them ideal for different parts of a power supply’s magnetic core: Nanocrystalline Material:Nanocrystalline materials are known for their high magnetic permeability and excellent performance at high inductance. They provide low core losses, which means more efficient energy storage in the magnetic field. The nanocrystalline material in the inner part of the core helped achieve the desired high inductance without overloading the system. Amorphous Material:Amorphous materials have a low saturation point and are highly stable at high frequencies. By placing amorphous material in the outer part of the core, we prevented the core from reaching saturation. This allowed the power supply to handle higher current levels without causing the core to saturate, keeping the system stable and free from excessive noise. By combining these two materials in the core design, we were able to achieve high inductance without sacrificing efficiency or stability.   Advantages of the Hybrid Core Solution This hybrid approach brought several significant benefits to the power supply system: Higher Efficiency: By combining the high inductance of nanocrystalline material with the low saturation point of amorphous material, we achieved a highly efficient system. The power supply could store more energy while preventing the core from becoming saturated. Reduced Noise: One of the key issues the client faced was the noise emitted by the power supply. The hybrid core design minimized this noise by preventing saturation and reducing vibrations. Improved Stability: With this solution, the power supply could operate under varying load conditions without the risk of instability or saturation. This increased the overall reliability of the system. Cost-Effective: This solution provided a way to solve the problem effectively without resorting to expensive or complex materials. The hybrid core design was both affordable and highly effective.   How This Solution Benefits Power Supply Designers For designers facing similar challenges, the combination of nanocrystalline and amorphous materials offers a straightforward and effective way to balance high inductance and low current. It provides a way to optimize power supply systems for better efficiency, reduced noise, and reliable performance. Additionally, it offers a cost-effective solution to improve the overall design without compromising on quality or performance. This solution is especially beneficial for applications where reducing noise and improving efficiency are critical. It provides a stable and reliable way to manage the inductance and current, ensuring optimal performance in demanding environments.   Final Thoughts on Achieving High Inductance and Low Current By using a combination of nanocrystalline and amorphous materials, we were able to create a highly effective solution that addressed the challenges of achieving high inductance and preventing saturation in a power supply design. The hybrid core not only solved the current and saturation issues but also reduced noise, improved stability, and increased efficiency. This case study shows that with the right approach and material selection, it is possible to achieve optimal performance in power supply systems. If you are facing similar challenges, don’t hesitate to reach out to us for tailored solutions that can help optimize your designs.   Contact Information For more information or to discuss your specific project, feel free to contact us at: Website: www.amorphousoem.com WhatsApp: +86 13686646827 Email: julia@amorphousoem.com   We are ready to help you achieve better performance and reliability in your power supply designs with our advanced magnetic materials.

  Hot Tags : nanocrystalline and amorphous materials for magnetic cores power supply noise reduction and saturation prevention high inductance low saturation magnetic core design benefits of hybrid magnetic core design for power supply cost-effective solutions for power supply optimization wound nanocrystalline core

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