High Bs Nanocrystalline Core 1.25T

• 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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