High Power E Series

The CWS' ES, LCES, EK, LCEK and E73040 Series of High Power Inductor and High Current Inductor are designed using Helical Winding (Helix Coil) in semi quasi planar structure to achieve lower DC resistance (DCR), lower AC resistance (skin effect loss), and high inductance. The LCES and LCEK are newer versions of the ES and EK respectively using square center post and are lower in cost. The core materials used are Distributed Air Gaps Compacted Cores from Magnetics, CSC and Micrometal. Both Gapped and UnGapped cores are used to extend the DC bias capability.

Gapped Ferrite E-core inductors with quasi distributed air gaps (using multi-section air gap structure) are popular for electric car DC-DC charger application where core loss needs to be very low. The EF552825 Series multi-air gaps ferrite inductor is designed by dividing a single large air gap into 6 small parallel gaps along the entire length of the 3 legs of the Ferrite E-cores. Custom sizes and custom inductance versus DC bias are available by contacting CWS Sales.

LT SPICE model can be downloaded from the link LT Spice for E Series, LT SPICE for E Series,.

Thermal model can be downloaded from the link provided in the table below for each part # .

Power Loss Calculator can be used from the link provided in the table below for each part # .

Power Loss Calculator Help/Guide/Example file can be downloaded here, Power Loss Calc Help/Guide/Example file.

These are unpotted inductors. For potted/encupsulated versions, please see our EES- and EEK-Series. 

The E and LC Series High Power Inductor and High Current Inductors are capable of handling high DC bias current, high energy storage and high voltage swing due to higher mass and higher saturation flux densities of the cores used. Various Mounting configuration with pre-tinned leads for direct connection. Mounting Spacers ( PN: EKES-SP001) can be bonded or placed under the cores to rest the inductor flat into the PCB during manufacturing if needed.
 

The table below shows the types of cores used in each of the part numbers. The ES and LCES Series and the E70340 Series are using Sendust or KoolMu core type and is suitable for swinging chokes, energy storage filter inductor in SMPS with high ripple current, in-line noise filters with large AC voltage swing, unidirectional drive application such as pulse transformer and flyback transformer. The E70340-0013 and E70340-004 are using Gapped iron powder core and used in similar applications where lower cost is needed. Sendust or KoolMu has good frequency response up to 1 Mhz, lower core losses, and will operate at a lower temperature.

The EK and LCEK Series are for those applications requiring small inductance drop when a high DC current (DC bias) is flowing into the inductor. The EK and LCEK series are built using XFlux, FluxSan, Mega Flux cores with higher saturation flux density. The EK and LCEK Mega Flux,XFlux,FluxSan version is suitable for Output Ripple filtering, High Power Output Chokes and High Current Inductor where a good DC bias characteristic is desired. The core loss of the Sendust/Koolmu and Mega Flux are very similar at a frequency below 300 Khz. Mega Flux version cost a little more than the others. Mega Flux cores are not suitable for application over 750 Khz, and has a much higher core loss than the Koolmu/Sendust cores at frequencies higher than 500Khz. For new designs, the LCES and LCEK series are recommended as the cost is better with similar performance.

The part PDF drawing has the DC Bias Current versus Inductance table. It is not necessary that Inductors with higher Inductance versus DC Bias Current is better in all cases. This is because Energy Storage in a filter is defined as 1/2 x [L] x [Sq I], where [L] is the inductance and [Sq I] is the square of the current flowing into the Inductor. For energy storage filtering applications, having a good DC bias is not always a desired feature. When the current flow into the inductor increases, the amount of energy stored increased to the square of the current [Sq I], and if the inductance [L] does not drop when the current increase, the energy stored maybe too high and could potentially cause a circuit to blow up. For such energy storage filtering application such as Input Filter ( Phi or butterworth or chebyshev filters) or the Boost Inductor, the ES Series using Koolmu or Sendust is usually the desired choice. However, every application is different and the design engineer must balance the trade-offs.

LT SPICE model can be downloaded from the link LT Spice for E Series, LT SPICE for E Series,. 
Altium Library model can be downloaded from the link Altium Library for E Series, Altium Library for E Series,.

APPLICATION:  Industrial High Current Filter Inductors, Switching Regulator Inductor, In-Line Noise Filters, Pulse Transformer, Fly Back Transformer, Differential Mode Choke, Boost Power Factor Correction Choke and Welding Machine Output Inductor.  Inductance range from 10 uH to 200 uH, Current Rating from 10 Amps to 250 Amps.  Designed with High Flux, Kool Mu, Sendust or Iron Powder E-Cores. Custom design available. Please email or call us.
FEATURES:    Can achieve up to 60% more energy storage than wire wound Inductors Use of Flat Helical winding to reduce DCR, lower copper loss, reduce size, even out heat dissipation and achieve up to 80% of copper fill factor Helix coils are self supported with no bobbins or coil forms Designed using High Flux, MFlux, KoolMu Sendust cores for extreme high temperature operations of 200 deg C Designed using gapped and un-gapped Micrometal's 40, 52 and 8/90 mix Iron Powder Cores for high saturation flux and lower cost. Designed for commercial, industrial and military application Operating temperature range: -55 deg C to +200 deg C Inductance values : 1 uH to 80 uH Current rating : Up to 250 Amps 3D Models, Thermal Models and SPICE models are available for download from the table below Our product in this High Power E Series was designed here in Orange County, California, USA and design pattern was issued on September, 2022. The details of our pattern on this series is: Patent no: US D962,867 S. Issued Sep. 6, 2022 U.S. Patent Pending.
Notes: 1)The prices shown below are for sample or prototyping low quantity. Please call 800-377-3244 or  email sales@coilws.com for larger volume OEM pricing. 2) Our large OEM pricing is extremely competitive. We will meet or beat any competitors prices with better deliveries 3) Custom designs are available to meet any of your requirements. Please contact us 4) The data shown below can be sorted by clicking each column header.Click once again to sort in reverse order.  5) Rated Current is based on a 60 deg C temperature rise at an ambient temperature of 40 deg C. High Flux, KoolMu, Sendust versions can operate to over 200 deg C. Iron Powder cores may exhibit thermal aging which limits the operating temperature to 100 deg C.  6) Helical wire used on High Flux, KoolMu, Sendust and Iron Powder versions has Kapton insulation and can withstand a temperature of 220 deg C.