Nanocrystalline Toroidal Ring Cores
Specialized manufacturer of nanocrystalline toroidal (ring-shaped) cores for EV chargers,EMI suppression, and high-frequency applications. Custom toroidal geometries with superior magnetic properties and design support.
Product Overview
Nanocrystalline toroidal cores feature a ring-shaped geometry that provides optimal magnetic flux containment and minimal electromagnetic interference. These donut-shaped transformer cores offer superior performance in space-constrained applications where efficient magnetic coupling and EMI suppression are critical.
Ideal for nanocrystalline common mode choke cores, EMI suppression toroidal cores, and power conversion applications, our cores enable compact designs with 99%+ efficiency in demanding environments from -40°C to +130°C.
The unique nanocrystalline structure, with grain sizes of 10-20 nanometers, provides exceptional magnetic properties that bridge the gap between traditional ferrite and amorphous materials. This revolutionary technology enables transformer designers to achieve unprecedented power density while maintaining excellent thermal stability and long-term reliability in critical applications.
Manufacturing Process
Our nanocrystalline toroidal cores are manufactured using state-of-the-art rapid quenching technology followed by precise controlled crystallization annealing. This process creates the optimal nanocrystalline structure with uniform grain size distribution for consistent magnetic properties.
- • Rapid solidification from molten state (10⁶ K/s cooling rate)
- • Controlled crystallization at 540-560°C
- • Precision winding with automated tension control
- • Stress relief annealing for optimal permeability
- • 100% magnetic testing and quality verification
Every nanocrystalline core undergoes rigorous testing to ensure compliance with international standards and customer specifications. Our quality management system ensures consistent performance across all production batches.
- • Initial permeability measurement (1kHz, 0.25mT)
- • Core loss testing (20kHz-100kHz range)
- • Saturation flux density verification
- • Temperature coefficient characterization
- • Dimensional accuracy inspection (±0.1mm)
- • Surface finish quality assessment
Key Benefits
High-frequency operation up to 100kHz for compact, efficient fast chargers
Reduced core losses and superior thermal stability for reliable operation
- • EMI filter cores
- • EV chargers
- • Industrial motor drives
- • UPS systems
- • Welding equipment
- • High-frequency transformers
- • Common mode chokes
- • Power factor correction
Specifications
- 10x higher permeability than ferrite (up to 100,000 μ)
- Ultra-low core losses at high frequency
- Excellent temperature stability (-40°C to +130°C)
- Compact design enables 50% space savings
- Permeability Range: 50,000 - 100,000 μ
- Saturation Flux Density: 1.2 - 1.25 T
- Operating Frequency: 20kHz - 100kHz
- Curie Temperature: 570°C
- Core Loss: <20 W/kg at 50kHz, 0.2T
- Temperature Coefficient: <0.5%/°C
Available Products
| Core Code | Dimensions (OD×ID×H mm) | AL Value | Applications |
|---|---|---|---|
| CC-NC-CMC-001-20 | 20mm×12mm×8mm | AL≥60 | Solar Inverters, Switch-Mode PSU, EMI Filters |
| CC-NC-CMC-002-25 | 25mm×16mm×10mm | AL≥65 | Solar Inverters, Switch-Mode PSU, EMI Filters |
| CC-NC-CMC-003-30A | 30mm×18mm×10mm | AL≥59 | Solar Inverters, Switch-Mode PSU, EMI Filters |
| CC-NC-CMC-004-30B | 30mm×20mm×15mm | AL≥88 | Solar Inverters, Switch-Mode PSU, EMI Filters |
| CC-NC-CMC-005-40 | 40mm×25mm×15mm | AL≥100 | Solar Inverters, High Volume, EMI Filters |
| CC-NC-CMC-006-40L | 40mm×32mm×15mm | AL≥47 | Large ID, Switch-Mode PSU, EMI Filters |
| CC-NC-CT-001-26 | 26mm×16mm×10mm | Low-loss CT | Current Measurement, Energy Metering, Protection Systems |
| CC-NC-CT-002-40 | 40mm×30mm×15mm | Standard CT | Current Measurement, Energy Metering, Protection Systems |
| CC-NC-CT-003-50 | 50mm×30mm×15mm | High-current CT | High Current Measurement, Industrial Power, Protection Systems |
| CC-NC-CT-004-40G | 40mm×30mm×15mm | Gap 0.20 | DC-tolerant Measurement, Power Electronics, Protection Systems |
| CC-NC-MINI-001-14 | 14mm×7mm×7mm | AL=75 | 5G Applications, PCB-Mount Systems, Portable Electronics |
| CC-NC-PWR-001-40G | 40mm×25mm×15mm | Gap 0.20 | EV On-Board Charger, PFC Choke, Power Electronics |
| CC-NC-PWR-002-65G | 65mm×38mm×25mm | Gap 0.25 | Power Transformers, Power Electronics, Industrial Systems |
| CC-NC-PWR-003-80G | 80mm×50mm×30mm | Gap 0.30 | EV Charging, Power Electronics, Industrial Systems |
CC-NC-CMC-001-20
20mm×12mm×8mm
AL≥60
Solar Inverters, Switch-Mode PSU, EMI Filters
CC-NC-CMC-002-25
25mm×16mm×10mm
AL≥65
Solar Inverters, Switch-Mode PSU, EMI Filters
CC-NC-CMC-003-30A
30mm×18mm×10mm
AL≥59
Solar Inverters, Switch-Mode PSU, EMI Filters
CC-NC-CMC-004-30B
30mm×20mm×15mm
AL≥88
Solar Inverters, Switch-Mode PSU, EMI Filters
CC-NC-CMC-005-40
40mm×25mm×15mm
AL≥100
Solar Inverters, High Volume, EMI Filters
CC-NC-CMC-006-40L
40mm×32mm×15mm
AL≥47
Large ID, Switch-Mode PSU, EMI Filters
CC-NC-CT-001-26
26mm×16mm×10mm
Low-loss CT
Current Measurement, Energy Metering, Protection Systems
CC-NC-CT-002-40
40mm×30mm×15mm
Standard CT
Current Measurement, Energy Metering, Protection Systems
CC-NC-CT-003-50
50mm×30mm×15mm
High-current CT
High Current Measurement, Industrial Power, Protection Systems
CC-NC-CT-004-40G
40mm×30mm×15mm
Gap 0.20
DC-tolerant Measurement, Power Electronics, Protection Systems
CC-NC-MINI-001-14
14mm×7mm×7mm
AL=75
5G Applications, PCB-Mount Systems, Portable Electronics
CC-NC-PWR-001-40G
40mm×25mm×15mm
Gap 0.20
EV On-Board Charger, PFC Choke, Power Electronics
CC-NC-PWR-002-65G
65mm×38mm×25mm
Gap 0.25
Power Transformers, Power Electronics, Industrial Systems
CC-NC-PWR-003-80G
80mm×50mm×30mm
Gap 0.30
EV Charging, Power Electronics, Industrial Systems
Design Guide
Selecting the optimal nanocrystalline toroidal core requires careful consideration of operating frequency, power level, and thermal constraints. Our engineering team provides comprehensive design support to ensure optimal performance.
- • Frequency Range: Optimal for 20kHz-100kHz operation
- • Power Density: Up to 10kW/kg achievable
- • Thermal Design: Consider ΔT rise and ambient conditions
- • Saturation Margin: Maintain 20% margin for reliability
- • Size Optimization: Balance between efficiency and cost
| Property | Nanocrystalline | Ferrite | Amorphous |
|---|---|---|---|
| Permeability | 100,000 | 10,000 | 50,000 |
| Saturation (T) | 1.25 | 0.4 | 1.56 |
| Frequency (kHz) | 100 | 500 | 20 |
| Core Loss | Very Low | Low | Ultra Low |
| Cost | Medium | Low | High |
Our experienced engineering team provides comprehensive design support from initial concept to production. We offer magnetic circuit analysis, thermal modeling, and prototype development services.
- • Magnetic circuit design and optimization
- • Thermal analysis and cooling solutions
- • EMI/EMC compliance consulting
- • Prototype development and testing
- • Production scaling and cost optimization
We manufacture custom nanocrystalline toroidal cores to meet specific application requirements. Our flexible manufacturing process accommodates various sizes and specifications.
- • Outer diameter: 10mm - 200mm
- • Inner diameter: Custom ratio optimization
- • Height: 5mm - 50mm
- • AL values: 50-500 nH/N²
- • Special coatings and insulation
- • Mounting and assembly options
FAQ
What makes nanocrystalline cores superior for EV charging applications?
Nanocrystalline cores offer 10x higher permeability than ferrite, enabling smaller, lighter designs with 99%+ efficiency at high frequencies up to 100kHz.
What temperature range can nanocrystalline toroidal cores handle?
Our nanocrystalline cores operate reliably from -40°C to +130°C with minimal permeability variation, ideal for automotive and industrial applications.
Ready to Optimize Your Design?
Get expert guidance on selecting the right nanocrystalline toroidal core for your application. Our engineering team provides comprehensive design support and custom solutions.