Farewell to Plastic Housing! Coated Insulated Magnetic Cores Enable New Power Supply Miniaturization Solutions

As new energy, computing power, automotive and industrial equipment keep advancing toward miniaturization and high power density, the industry imposes increasingly stringent requirements on four key metrics of power equipment: overall dimension, temperature rise control, copper wire consumption and long-term reliability. The conventional insulation packaging solution with plastic housing suffers from excessive space occupation, high material consumption, poor heat dissipation, and susceptibility to aging and loosening, making it difficult to meet current compact mass production demands.

Against this backdrop, the coated insulated magnetic core solution, which eliminates plastic housing, stands out for its streamlined structure, superior heat dissipation and stable performance. It has become a preferred mainstream option for compact equipment design and draws wide attention from design engineers.

01 Remove External Housing to Greatly Reduce Overall Device Size

Traditional magnetic core packaging relies on plastic housing for electrical insulation. The housing itself occupies extra assembly space, which severely limits the miniaturization of inductors and fails to satisfy compact installation requirements of AI server power supplies, automotive high-voltage power supplies and miniaturized energy storage converters.

Coated insulated magnetic cores adopt integrated surface insulation coating for electrical isolation. No additional plastic housing is required, which simplifies the external structure of components and effectively cuts down the overall inductor package size. At the same power rating, it enables more compact structural design of equipment, aligns perfectly with the miniaturization and lightweight trend of new-generation power devices, and leaves more room for engineers to optimize structural selection.

02 Optimized Winding Structure to Cut Copper Wire Consumption

The plastic housing restricts the winding window of magnetic cores, resulting in longer winding lengths and redundant wiring. This directly increases copper wire consumption and raises mass production costs. Moreover, extra copper windings bring higher circuit impedance and impair equipment efficiency.

With integrated surface insulation, coated insulated magnetic cores need no clearance reserved for housing assembly, delivering higher utilization rate of winding windows and neater, more compact wiring. While meeting electrical performance and insulation safety standards, the solution effectively shortens copper winding length and reduces copper consumption in mass production. It helps manufacturers achieve refined cost reduction in bulk production and balances equipment performance with production economy.

03 Improved Heat Dissipation for Precise Overall Temperature Rise Control

For high power-density equipment operating continuously at high frequency, temperature rise control is critical to overall efficiency and service life. The enclosed structure of traditional plastic housing features poor thermal dissipation. Heat generated during operation cannot dissipate quickly, leading to heat accumulation, high overall temperature rise, accelerated component aging and compromised long-term operational stability.

The housing-free coated magnetic core has no closed thermal barrier, offering smoother heat dissipation paths to rapidly conduct heat away and mitigate overall heat accumulation. Adopting a refined low-stress coating process, the thin and uniform coating will not impair the inherent thermal performance of magnetic cores. It optimizes the thermal management system from the structural perspective and significantly improves temperature rise performance under high-frequency and heavy-load operating conditions.

04 Integrated Insulation Protection for Enhanced Long-Term Reliability

Plastic housing is assembled via snap-fit and joint structures. Under automotive vibration, heavy industrial vibration and cyclic temperature variation in outdoor environments, loosening, displacement, aging and cracking tend to occur. In long-term operation, these defects may trigger hidden risks such as insulation failure, component noise and performance drift.

Coated insulated magnetic cores feature integrated insulation coating with strong adhesion and good conformity, providing both electrical insulation and physical protection. It effectively resists cyclic temperature changes, mechanical vibration, moisture and dust, eliminating assembly risks and aging issues of conventional housing structures. It maintains stable insulation performance of magnetic cores over time, greatly extends equipment service life and operational reliability, and is suitable for various demanding long-term working conditions.

05 Premium Coating Process: The Core of Housing-Free Mass Production

Conventional coating processes often result in uneven coating thickness, residual stress, easy peeling and magnetic property shift. Although plastic housing is removed, new risks may arise during mass production. Amorphous and nanocrystalline magnetic cores are sensitive to stress, requiring higher compatibility for coating processes, coating materials and curing environments. Only refined process control can balance insulation effect and the intrinsic magnetic properties of cores.

In terms of process implementation, SUNBOW coated magnetic cores are specially adapted and upgraded for amorphous and nanocrystalline soft magnetic materials, which are stress-sensitive and demand high precision in magnetic performance. Different from the simple coating processing commonly used in the industry, SUNBOW is equipped with dedicated automatic coating production lines, paired with segmented gradient high-temperature curing processes. This fundamentally reduces common defects including residual coating stress, uneven coating thickness and insufficient adhesion. The entire production workflow is strictly standardized. Products undergo multi-dimensional performance sampling inspection before delivery. While meeting high-voltage insulation and lightweight housing-free structural design, the excellent electromagnetic properties of magnetic cores are fully preserved. It balances consistent product appearance, electrical stability and mass production adaptability, fully complying with the mass production standards of high-end power supplies for miniaturization, high reliability and low loss.

Compared with traditional housing packaging solutions, qualified coated insulated magnetic cores deliver four major upgrades: smaller size, less material consumption, lower temperature rise and higher reliability. It perfectly meets the miniaturized mass production requirements of high-end equipment in new energy, computing power, automotive, industrial control and other sectors.

Conclusion

Miniaturization, low loss and high reliability represent an irreversible trend in the power electronics industry. Streamlining structures, optimizing processes and cutting costs while improving efficiency have become core ideas for component design. Built on mature process accumulation and stringent quality control standards, SUNBOW coated magnetic cores accurately cater to the current industry demand for miniaturized mass production, effectively resolving various pain points of traditional packaging schemes. Going forward, we will continuously refine processes and polish product quality, providing stable and reliable domestic magnetic core supporting solutions for high-end power equipment across industries.

✨ SUNBOW, YOUR BEST PARTNER OF MAGNETIC MATERIALS