KEMET METCOM Automotive Grade SMD Power Inductor MPXV Series

KEMET METCOM Automotive Grade SMD Power Inductor MPXV Series

Overview

• Automotive Applications

• Requirements and Technology Trends

• Metal Composite Inductor Technology Advantages and Limitations

• MPXV Performance Comparison

• Product Lineup

• Roadmap

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 2

Automotive Applications
… and not limited to …

• LED headlights
• Electronic control units (ECU)
• Audio and multimedia systems
• Autonomous drive systems
• Advanced driver assistant systems (ADAS)
• Meter cluster panels
• Head-up displays (HUD)
• Electric water and oil pumps (EWP & EOP)
• Electric power steering (EPS)
• Battery management systems (BMS)

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Automotive Inductor Application Areas
… where performance matters
 π Filter
• π Filter Application
 o Most common for automotive
 applications in input filtering for ECUs
 and connected to the battery voltage
 rail (12/24/48V)

• DC/DC Converter Output Filter
 Application DC/DC Converter Output Filter
 o Buck or Boost DC/DC switching
 converters or LLC soft switching
 converters
 o Used to smooth the current

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Application Requirements & Technology Trends

• Decrease in package size The mission

• Enhanced EMI behavior

• Reliability of components

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Decrease in Package Size

 • As frequency is increased, needed inductance
 and capacitance will decrease proportionally
 o Leads to smaller components
 Frequency

 • Individual power density for smaller
 components increases
 Size

 • Efficiency becomes more important to simplify
 heat management

 • Soft switching becomes more attractive due to
 WBG technologies and high speed silicon
 o Lower losses (up to 50% reduction)
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Enhanced EMI Behavior
Switching speed influences high frequency harmonics and increases filtering demand

 80dB noise
 Lower Spectral
 Power at Higher
 frequency

 90dB noise
 Higher Spectral
 Power at Higher
 frequency

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Reliable Components Required
 Electronic components in cars as a percentage
 of total car cost
60%
 • More electronics per vehicle
50% necessitates higher reliability
 components
40%
 o Zero defects and low FIT rates in
30%
 higher ambient temperatures

20%
 • Shielding, insulation resistance,
10%
 washing & mechanical aspects
 are also important and need to
0% be considered
 1970 1980 1990 2000 2010 2030*
 Percentage of total cost
 * Projected

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Magnetics, Sensors & Actuators Business Group
History of power inductors and magnetic products

 • More than 40 years experience in automotive market
 • AEC-Q200 compliant components
 • IATF 16949 qualified plants

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Performance Limitation and Losses
 0 500 1000
 8
 40
DC Copper Loss 4

 0
Commonly referred to as DCR, it is the loss in -10 B-H Hysteresis
 -4
the form of heat due to the resistance of the I nominal V
 -60 -8
windings of the inductor.

AC Copper Loss
Is the loss of the copper with AC currents which
results from the skin effect of a conductor. This
 Eddy Current
effectively reduces the cross section of the wire
with increasing frequency.
 Skin Effect

Core Loss
 2 
 =
 0
Is the loss of a magnetic material due to
alternating flux conditions and includes the
effects of both hysteresis and eddy currents.
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Performance Limitation and Losses (Heat)

• Thermal heat rise depends on “significant” Example of heat rise on FR-4 PCB
 losses produced by thermal resistance • Vin : 9VDC
 (depends on layer thickness of PCB & • Vout : 2.5VDC
 airgap of coil vs. core) • Imax : 3A
 • Fswitching : 500 kHz
 • Exp. Vripple : 70mV @ 2A
• Airflow around the inductor is usually not • PN: MPXV1D0630L1R0
 possible within automotive ECU´s (1µH / 6x6mm / 9A rated / 7.1mΩ)

• Total power loss is a sum of the power Δ9.2℃
 losses caused by:
 o DC current (Loss increases exponentially
 with DC current)
 o Relation of voltage change i.e. 12V input
 3.3V output = 8.7V (Larger voltage change
 creates higher losses)
 o Frequency (Higher frequency causes larger
 losses)
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Inductor Structure

 Metal Composite Inductor Structure Ferrite Inductor Structure
 Mn-Zn/NI-Zn Core
 Molded Core

 Conductor

 Conductor GAP

 Terminal
 Connective point
 Terminal

GAP : Including the GAP into the core Advantage of molded metal
 Binder • Smaller package Advantage of assembled ferrite
 Insulating coating • Stable Inductance with • Lower DCR
 Around the metal power temperature • Lower core loss
 • Low acoustic noise
 Metal Powder
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 • Higher saturation current

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EMI Performance Comparison
 Magnetic Flux Leakage Comparison
 Detail of model TOP View Side View

 Molded Inductor
 Core type : Metal
 Molded
 Inductance : 33 uH
 DCR : 154 mΩ
 Isat : 4.0 A
 Idc : 2.6 A

 Assembled Inductor
 Core type : Ferrite
 Assembled
 Inductance : 33 uH
 DCR : 175 mΩ
 Isat : 2.6 A By Maxwell 3D
 Idc : 2.0 A Load 1.8A
 1div = 1mm

 Molded type is better for magnetic flux leaking than assembled type.
 Magnetic Flux leaks from gap in assembled structure of ferrite inductor.
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Ferrite and Metal Composite Comparison
 Saturation Comparison
 Advantage of Ferrite
 1. Higher inductance with high permeability
 2. Stable inductance in the right range
 High L and Low DCR capability

 Advantage of Metal Composite
 1. Very slow saturation
 2. Very stable saturation over thermal range
 Core Loss Comparison
 Good for Auto app especially

 Advantage of Ferrite
 Very low core loss in dynamic frequency range
 Mn-Zn Ferrite Metal Core
 Low power consumption capability

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METCOM Power Inductors

METCOM MPXV Power Inductors are metal composite
inductors ideal for use in DC to DC switching power
supplies, as power inductors as well as EMI filter inductors.

METCOM’s metal composite core has high saturation
characteristics ideal for designs requiring stable inductance
across temperature and current

Part MPXV 1 D0630 L 3R3
Number Inductance in μH (3R3 = 3.3 μH)
System Power Inductor
 Size: D 30 | = 6x6 mm | 30 = 3.0 mm height
 Product Version 1
 METCOM Automotive Product Series

For more detailed information: www.kemet.com/METCOM

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AUTOMOTIVE SMD POWER INDUCTOR

METCOM Power Inductor MPXV Series
AEC-Q200 qualified, IATF 16949 production & up to 155°C
  Click and select
 METCOM MPXV Series range
 100
Applications: 5x5 mm | (Height)
 D0520 | 2.0 mm
✓ Input filtering (π or LC) 90 D0530 | 3.0 mm

✓ Buck- or boost SMPS 6x6 mm | (Height)
 80
 DC/DC output filtering D0618 | 1.8 mm
✓ LED front lighting 70
 D0624 | 2.4 mm
 D0630 | 3.0 mm
✓ Small drives for water- D0650 | 5.0 mm
 pumps and power steering 60 8x8 mm | (Height)
✓ Autonomous drive & ADAS D0830 | 3.0 mm
✓ Displays & multimedia 50 D0840 | 4.0 mm

✓ Battery management 10x10 mm | (Height)
 Rated Current (A)

 40 D1040 | 4.0 mm
 D1054 | 5.4 mm
Benefits: 12x12 mm | (Height)
 30
 D1235 | 3.5 mm
✓ Low DC resistance D1250 | 5.0 mm
✓ Large range (>200 parts) 20 D1264 | 6.4 mm
 17x17 mm | (Height)
✓ Known PCB footprint D1740 | 4.0 mm
✓ High temperature (≤155°C) 10
 D1770 | 7.0 mm
✓ High stability & quality 22x22 mm | (Height)
 0
✓ AEC-Q200, IATF & PPAP 0.10 1.00 Inductance (μH) 10.00 100.00
 D2240 | 13 mm
 16

KEMET MPX and MPXV Series

• The MPXV series of inductors is the automotive version of our MPX
 series, which launched in 2019

• Both series will cross to the IHLP, providing customers with the option of a
 second source

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Main Parameters to Consider for an Inductor in a
 π Filter Application

• RDC
 o A low RDC will keep the efficiency high Example of 6x6mm size METCOM Inductor

• Resonance Frequency
 o Drops with higher inductance values
 o Increases with smaller case sizes
 47µH

 33µH
• AC losses can be almost ignored 10µH
 o The ripple current in this application is
 relatively low since it is purely the EMI 4.7µH
 energy that needs to be attenuated
 o Losses are related to DC resistance of 18
 the coil only

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Main Parameters to Consider for an Inductor in
 DC/DC Output Filtering Applications

• Q factor
 o A good measure of efficiency as it relates the
 inductance to the resistance (DC & AC 0630
 resistance) –> Q = 2π*f*L/ R or Z/R ferrite
 o The sweet spot for METCOM is roughly from
 700kHz up to 3MHz where the Q is high and
 losses are low (in this case ≥80 for the 0630 / 0530
 1µH)
• Saturation behavior
 o METCOM has a soft, steady saturation
 o Bigger current transients will still be
 filtered, but with a lower inductance 19

• The AC and switching DC losses need to be
 considered with thermal heat rise
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Competitive Performance Comparison
 … one example

 Saturation
 Rated current
Part number Inductance Size DC resistance current
 (40K heatrise)
 (-20% L)

 6.5x6.5x3.0mm

 102mΩ typ
 IHLP2525 10µH 3A 7A
 105mΩ max

 7.0x6.5x3.0mm

 67mΩ typ
MPXV1D0630 10µH 4.2A 3.5A
 78mΩ max

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Comparing Datasheets: Same Item?

 KEMET:
 Max. 4.5A @ 115°C
 =
 > 4.5A @ 85°C

 Max. 3.3A @ 85°C Max. 2.2A @ 85°C

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When It Almost Suits …

• Customized designs are possible if the MPXV is not suitable for your
 application

• METCOM designs are always a compromise between RDC and saturation

• In a given mechanical space:
 o The more volume the coil represents (→ lower RDC) the less space is remaining for
 the core material (→ lower saturation capability)
 o Parameters that are important to the electronic designer can vary depending on the
 application (i.e. type of heat sink used)
 o Standard designs focus on “what makes sense” on a standard FR-4 board where
 saturation (L -20%) shall be in the range of the rated current

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Design Tools https://engineeringcenter.com/tools/

• KEMET’s K-SIM tool version 3.0 is launching April 27th and Inductor
 simulations will be available.
 o Inductance vs. Current
 o Temperature rise with current
 o Power loss curves
 o http://ksim.kemet.com/

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Roadmap / What Comes Next ?
 CURRENT 2020 2021 2022

 Metal Composite
 MPC ★ MPX
 Industrial
 Power Inductor MPLC Series
 Series Jun (102parts)
 Grade for PC/GPU,GFX ◇5◇6◇8
 Industry
 Oct (99parts)
 ◇10◇12◇17◇22 Under Development

 Automotive MPLCV & MPCV
 Metal Composite
 Grade Power Inductor
 Series MPHV
 for Automotive ◇17 ◇22
 (custom Large Type
Automotiv e &
Transportation
 & special) Up to 80A
 ◇6 ◇10 ◇10 ◇12 Op temp ≤ 155 ˚C

 Automotive Metal Composite
 Power Inductor
 ★ MPXV
 Series
 MPEV
 Series
 Grade
 Vishay – Bourns Mar (213 parts) Oct (tbd)
 (series) cross
Automotiv e &
 ◇5,◇6, ◇8, ◇10 ◇6,◇10
Transportation
 ◇12, ◇17, ◇22 Op temp ≤ 180 ˚C
 Op temp ≤ 155 ˚C
 *i.e. ◇5 → 5x5mm PCB footprint
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Conclusion

• METCOM technology is key for automotive applications

• KEMET offers more than 200 PN´s in AEC-Q200 grade

• MPXV series is matching and exceeding industry performance

• KEMET MSA BG is ready to receive orders now

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Thank you!
 Please submit additional questions at:
 https://go.kemet.com/contact-us

 LeAnna Weakley
 Field Application Engineer
 KEMET Electronics Corporation
 leannaweakley@kemet.com
 39555 Orchard Hill Place Suite 505
 Novi, MI 48375
 26
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