High-Power Mn-Zn Ferrite PEL95 Material

With the increasing adoption of renewable energy and EV fast-charging stations, the demand for high-power power supplies is growing. Transformers used in power supplies are expected to be smaller, more efficient, and generate less heat. Ferrite materials are used in transformer products, but the core loss (iron loss) can vary significantly depending on the size of the ferrite core, the operating frequency, and the load. Therefore, selecting the optimal ferrite material is a key point in transformer design. This article introduces the features of the PEL95 material, developed specifically for high-power applications, and key considerations for its use.

Lineup of the PC95 Series and Features of PEL95 Material

Basic Material Properties

Advantages Over Conventional Ferrite Materials

Temperature Rise Experiment with Extra-Large 30 kW Transformer

Summary

PC95 Series Lineup and Features of PEL95 Material

Until now, TDK's high-power Mn-Zn ferrites have been mass-produced using PE22 and PC40 materials, but to meet the growing demand for lower power loss and higher efficiency, we have now added the PC95 series to our lineup of high-power Mn-Zn ferrites. Among these, the PEL95 material is particularly well-suited for achieving higher efficiency.
It is characterized by low losses at relatively low temperatures (below 100°C) and is expected to reduce core loss compared to conventional materials, especially in large cores, thereby achieving higher transformer efficiency.
For example, EV rapid charging systems require low heat generation and high-power operation. The transformers used in DC-DC converters for such systems tend to be large, and so to achieve even slight size reductions, cores with minimal losses are essential. PEL95 material is ideal for transformers operating in large-scale, high-power applications.

Figure 1: Operating Conditions and Suitable Core Weight Range for the PC95 Series

Basic Material Characteristics

Unless otherwise specified, representative values are used.

Material			PE22	PC40	PC95	PEL95	PEM95
Initial Permeability	μi		1800±25%	2300±25%	3300±25%	4100±25%	2900±25%
Core Loss	Pcv	25℃	890	670	350	290	440
	[kW/m³]	60℃	620	500	300	290	360
	100kHz, 200mT	100℃	520	420	290	360	320
		120℃	600	490	350	420	340
Saturation Flux Density	Bs [mT]	25℃	510	500	530	500	520
Saturation Flux Density	H=1194A/m	100℃	410	380	410	370	410
Curie Temperature	Tc [℃]		>200	>200	>215	>180	>210

Table 1: Comparative Material Characteristics

Figure 2: Temperature Dependence of Core Loss (Pcv)

Figure 3: Temperature Dependence of Permeability

Advantages Over Conventional Ferrite Materials

*PEL95 exhibits low core loss characteristics across a broad temperature range, particularly below 100°C, in large core configurations.
*Since the optimal material varies depending on operating frequency, Bm, and core shape, it is recommended to conduct comparative evaluations among the 3 materials, PC95, PEL95, and PEM95, when considering your choice.

Figure 4: Comparison of Core Loss (Pcv) Temperature Dependence in Product Shapes

Temperature Rise Test on Ultra-Large 30kW Transformer

Here is an example of temperature rise evaluation in a large transformer using PEL95 material.
The graph below shows the changes in core temperature over time when driving a large transformer. While competing cores exhibit continuous temperature increases leading to thermal runaway, cores made with PEL95 material stabilize at a consistent temperature after an initial rise.
Ferrite cores made of PEL95 material effectively suppress heat generation in large-scale applications.

Figure 5: Comparison of Core Loss (Pcv) Temperature Rise in an Extra-Large 30kW Transformer Using Multiple EE80 cores

Summary

TDK's PEL95 material achieves high efficiency and low heat generation in high-power transformers through its low core loss characteristics across a wide temperature range in large cores.
We provide samples in various large-scale shapes. If you are interested, please feel free to contact us.
*The application examples are case studies and can be applied to other applications. We can also accommodate custom shapes not listed in the catalog.

Representative Products	PQ60/42-Z	PQ65/54-Z	PQ107X87X70-Z	EE80X76X20	SP100X100X5	UU79X129X31	EC90X90X30	ETD59-Z
Application Example*	xEV DC-DC	xEV DC-DC	Rapid Charging Station	Rapid Charging Station	Industrial Equipment Power Supply	Industrial Equipment Power Supply	Industrial Equipment Power Supply	Industrial Equipment Power Supply
Application Example*	Industrial Equipment Power Supply	Industrial Equipment Power Supply	Rapid Charging Station	Rapid Charging Station	Industrial Equipment Power Supply	Industrial Equipment Power Supply	Industrial Equipment Power Supply	Industrial Equipment Power Supply
Image
Size(mm)	59 X 51 X 39	65 X 53 X 45	107 X 87 X 70	80 X 76 X 20	100 X 100 X 5	79 X 129 X 31	90 X 90 X 30	60 X 62 X 22
Size(mm)	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS	SHAPES AND DIMENSIONS