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Kool Mu® material’s low loss and relatively high saturation level (10,500 gauss) make it
excellent for use in power factor correction circuits (PFC). Here is an example of using Kool
Mu in the PFC Boost Design.
D= Duty Cycle
Inductor Current
LI2=(0.598)(8.48)2=43
From the core selector chart below, Kool Mu part number: 0077439A7
µ = 60 Ve = 21.3 cm3
AL = 135 Aw = 4.27 cm2
le = 10.74 cm MLT = 8.66 cm (full)
Kool Mu Selector Chart
Turns could be added to achieve the 598 µH target, but 548 is not an unreasonable result.
8. Choose wire.
NOTE: AC Ripple at 65 kHz will result in skin effect losses. Multi-strand wire equivalent to
the #16 gauge would actually be used.
Cooper Losses:
For #16 Wire
Rcoil = MLT(N)(R/length)
Rcoil = (8.66 cm/turn)(94T)(0.1319 mΩ/cm)
Rcoil = 107 mΩ
Power Loss copper = (I)2(R)
Pcu = (6.14)2(0.017) = 4030 mW
NOTE: This neglects AC losses. Litz or multistrand wire should be used.
Design Summary:
Using 0077439A7 Magnetics Kool Mu Toroid
N=94 turns of multistrand equivalent to AWG#16, giving a fill factor of 33%
L=1190µH at no load
L=536µH at peak (8.58A)
Inductor Max Ripple = 26%
Core losses = 1.4-1.6 W
Copper losses = 4.0 W
ΔT estimate ≈ 22°C