Application of Kodaka automotive-grade inductors in automotive DC/DC converters

In recent years, with the growth of production and sales of new energy vehicles, the market demand for DC/DC converters has continued to rise. DC/DC converters play a very important role in new energy vehicles, such as electric vehicles, fuel cell vehicles, and hybrid vehicles. According to different application requirements, the common topologies of DC/DC converters used in new energy vehicles include: BOOST, BUCK, and BUCK-BOOST.

As an energy transmission component, DC/DC converters need to meet the requirements of high conversion efficiency to improve energy utilization, achieve energy conservation and environmental protection, and help achieve the "dual carbon" goals. At present, the efficiency of DC/DC converters can be as high as 98%, which is directly related to the loss of many components such as inductors, capacitors, resistors, and switches.

As one of the core components of DC/DC converters, inductors are widely used in DC/DC converters. The selection of coil and core materials and production process have a great impact on the conversion efficiency and stability and reliability of DC/DC converters. Therefore, when designing a DC/DC converter for an on-board power supply, it is very important to select high-quality and high-reliability automotive-grade inductors.

Application of Inductors in Automotive DC/DC Converters

Design requirements for automotive DC/DC converter inductors

Low loss: The operating frequency of the on-board DC/DC converter is relatively high, up to 500KHz or even 1MHz. The inductor needs to be designed with low-loss core material to reduce the core loss in high-frequency applications, reduce heat, and improve output efficiency.

High voltage resistance: There are many high-voltage components in new energy vehicles, such as power batteries, drive motors, on-board controllers, etc. Among them, the motor drive system voltage is above 400V or 800V. As a key component of the DC/DC converter, the inductor needs to be able to withstand high voltage.

High current resistance: Most automotive electronic circuits use high-power design solutions. The inductor must maintain sufficient inductance under high transient peak current conditions to ensure the normal operation of the circuit. At the same time, it is also necessary to withstand continuous high current output for a long time to keep the inductor surface temperature rise within the specified value.

High reliability: The operating environment of the DC/DC converter is relatively complex, facing problems such as high temperature in the engine compartment, vehicle vibration, and drastic fluctuations in battery voltage. This places high demands on the reliability of inductor products, requiring them to have strong resistance to mechanical shock and vibration, resistance to cold and hot shock, and resistance to high temperature and high pressure.

Small size: With the integration trend of vehicle power systems, such as the emergence of DC/DC+OBC two-in-one and DC/DC+OBC+PDU three-in-one products, high power density and high efficiency have become the development direction of vehicle power. For inductors, small size and thinness will become design requirements to meet the needs of small volume and high-density installation of DC/DC converters.

Anti-interference: With the integrated development of automotive electronic parts and the high-density installation of components, electromagnetic interference problems have emerged. The inductor adopts a magnetic shielding structure design to enhance the shielding effect and effectively reduce electromagnetic interference.

Kodaka automotive DC/DC converter inductor solution

As a professional manufacturer of one-piece molded inductors and high-current inductors with 22 years of experience in inductor development, Kodaka Electronics has developed and designed multiple series of automotive-grade inductors VSRU, VSAB, VSEB, etc. with low loss, high reliability and high current resistance for automotive DC/DC converters. The products have been mass-produced and widely used in multiple automobile manufacturing projects.

To ensure long-term stable operation of inductor products in complex environments, Kodaka automotive-grade inductors have passed rigorous product testing and are in compliance with AEC-Q200 Grade 0 reliability test certification. The operating temperature range is -55°C to +155°C (up to 165°C).

01

Automotive Grade Super High Current Inductor VSRU Series

The automotive-grade high-current inductor VSRU27 series has an inductance range of 1.00 to 15.00 μH, a saturation current of up to 100 A, and a minimum DCR of 0.46 mΩ.

The VSRU27 series uses flat coil windings and low-loss core material design, with extremely low DC resistance and AC resistance. It can work in high current solutions for a long time to maintain low temperature rise. The symmetrical air gap structure design and uniform distribution of magnetic flux density in the core improve the anti-saturation ability of the inductor and can maintain good inductance linearity through transient high peak current. The VSRU27 series base adds a third welding terminal to effectively improve the vibration resistance and reliability of the inductor.

02

Automotive Grade One-Piece Molded Inductor VSAB Series

Magnetic shielding structure, strong resistance to electromagnetic interference

Special mixed magnetic powder core, outstanding voltage resistance

AEC-Q200 (-55°C~155°C)

The automotive-grade one-piece molded inductor VSAB series has an inductance range of 0.47 to 82.00 μH and a maximum saturation current of 24 A.

The VSAB series adopts an integrated structure, with high core utilization, better electrical performance, and high mechanical strength. The magnetic material is designed with a specific mixed powder material, which has outstanding voltage resistance. The coil is buried in the magnetic powder to form a magnetic shielding structure, which has strong anti-electromagnetic interference ability and ultra-low buzzing noise. In addition, the thin and light design of the integrated inductor can also save installation space and is suitable for high-density mounting.

03

Automotive Grade One-Piece Molded Inductor VSEB-H Series

.Low loss, high reliability, wide bandwidth and wide temperature

. T-Core core structure design

■AEC-Q200 (-55~ 155"C)

The automotive-grade one-piece molded inductor VSEB-H series has an inductance range of 0.47 to 22.00μH and a maximum saturation current of 18.2A.

The VSEB-H series adopts flat coil winding, low-loss alloy powder hot pressing integrated molding and T-Core core structure design. The inductor coil is not easy to deform and tilt, ensuring the consistency of the inductor electrical performance and the reliability of the product. The hot pressing process increases the density of the core and reduces various risks in the die-casting process of the product. The product has the characteristics of high saturation current, low loss, wide application frequency and high reliability.