High-Temperature Low-Loss Mn-Zn Ferrite PEM95 Material

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

PC95 Series Lineup and PEM95 Material Features

Basic Material Properties

Advantages Over Conventional Ferrite Materials

Core Heat Evaluation

Summary

PC95 Series Lineup and PEM95 Features

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.
Within this series, PEM95 is a material suitable for high-load operation.
It exhibits low losses at high temperatures (above 100°C) and is expected to reduce core losses compared to conventional materials, especially in large cores under high-load conditions, thereby enabling transformers to generate less heat and be more compact.
For example, onboard chargers in electric vehicles require higher output to accommodate increased battery capacity. Furthermore, with the growing demand for faster charging times and smaller devices, transformers must now be capable of handling high currents while ensuring low power loss, minimal heat generation, and a compact design.
PEM95, with its low-loss characteristics under high-load conditions, is an optimal material for such transformers.

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 in Large Core Shapes

PEM95 exhibits low core loss characteristics in large core configurations at high temperatures exceeding 100°C.

*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

Core Heat Evaluation

Here is an example of temperature rise evaluation in a core using PEL95 material.
The graph below shows the change in core temperature over time when operating an EE52-shaped core under high-load conditions.
With PC95 material, the temperature continues to rise, leading to thermal runaway, whereas cores made with PEL95 material stabilize at a constant temperature after an initial rise.
This demonstrates that ferrite cores made of PEM95 material can effectively suppress heat generation under large, high-load conditions.

Figure 5: Evaluation of Temperature Rise in EE52-Shaped Cores

Summary

TDK's PEM95 material reduces core loss at high temperatures (above 100°C) in large, high-load conditions, enabling the development of more compact transformer products with lower heat generation.
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
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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