Custom power Inductors & Chokes

Custom Power Inductor Manufacturing

Power inductors are passive electronic components that play a crucial role in voltage conversion and power management circuits. They consist of insulated copper wires wound in a coil around a core material, typically ferrite, and are designed to store and release energy in the form of a magnetic field.

Leightner’s custom power inductors and chokes are essential components in various electrical and electronic applications, designed to meet specific requirements for energy storage, filtering, and voltage stabilization. These components are tailored to suit your unique project needs, offering optimal performance in diverse industries.

Types of Custom Power Inductors and Chokes

Laminated Inductors

Laminated core inductors are the most common and cost-effective option, suitable for a wide range of power and current levels. They consist of a series of sheets forming a core, which helps block eddy currents and minimize energy loss.

Toroidal Inductors

Compact, quiet, and efficient, toroidal inductors are ideal for low to moderate power and current ratings. Their closed-loop shape creates strong magnetic fields while minimizing stray magnetic fields, making them suitable for sensitive equipment.

C Core (Cut Core) Inductors

C core inductors offer advantages similar to toroids, including low losses and high efficiency, but are better suited for higher power and current requirements. They use a laminated steel toroidal core, allowing for large power shifts without overheating.

Choke Inductors

Chokes feature a donut-shaped core with an insulated wire wrapped around it. They are designed to filter out line noise by restricting high-frequency alternating currents while allowing DC current to pass through.

Benefits of Custom Power Inductors and Chokes

1. Tailored Performance: Custom designs ensure optimal performance for specific applications, addressing unique challenges such as EMI issues and spatial constraints.
2. Versatility: Leightner can produce inductors with various core types, winding configurations, and materials to meet your exact specifications.
3. Quality Assurance: Leightner can adhere to industry standards such as ISO 9001:2015, ensuring high-quality products.
4. Efficiency: Custom inductors can be designed to minimize signal losses and improve overall circuit efficiency.

Applications & Industries for Power Inductors & Chokes

Custom power inductors and chokes find applications in various fields, including:

• Power supplies
• Test equipment
• Medical electronics
• Manufacturing equipment
• HVAC inverters
• Server power supplies
• Solar inverters
• Bi-directional inverters
• PV inverters

Design Considerations for Power Inductors

When designing custom power inductors and chokes, several factors are taken into account:

1. Core Material: Leightner use various materials such as powdered iron, silicon steel, and ferrites to produce cores with excellent aging characteristics.
2. Shielding: Large magnetic fields produced by high currents may induce noise in other circuit parts. Magnetic shielding is often incorporated to protect against EMI problems.
3. Current and Voltage Ratings: Custom inductors can be designed for specific current ranges, typically from 5A to 400A, and power capacities from 1.5kW to 450kW.
4. Switching Frequency: Depending on the application, switching frequencies can range from 10kHz to 200kHz.
5. Temperature Ratings: Operating temperatures can vary, with options including 130°C, 155°C, 180°C, and 200°C.

By working closely with Leightner as an experienced inductor & choke manufacturer, our engineers can obtain custom power inductors and chokes that precisely meet their project requirements, ensuring optimal performance and reliability in your electrical and electronic systems for your application.

Let Leightner Design Your Toroidal Transformers Today

With over 50 years of manufacturing and 100s of 1,000s transformers built to specifications, Leightner can handle any applications of your custom toroidal transformer needs. Request a quote to start the manufacturing process today!