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Nanocrystalline Cores

Your Professional Nanocrystalline Cores Manufacturer in China

Sunbow Group specializes in the design, development and production of new-type amorphous, nanocrystalline, silicon steel sheets and other magnetic materials and related products. The company's main products include various types of amorphous, nanocrystalline ribbons and high and low voltage current transformer cores, precision current transformer cores, common mode inductor cores, PFC inductor cores, high frequency power transformer cores and related devices.

Customized Solutions

We are at the forefront of a design led approach to delivering challenging and custom solutions for magnetic cores or components for production. Whether your need is simple or complex, we can develop a solution to achieve your goals. With in- house experts we can design, develop and test prototypes that meet performance and environmental requirements of your application.

Advanced Equipment

The company has advanced equipment such as large-scale vacuum smelting furnaces, pressure spraying belts, various magnetic annealing furnaces and close cooperation with domestic scientific research institutions and universities, which ensures the company's R & D ability and product quality.

Complete Qualifications

At present, the company has two production bases, with a number of patented technologies, and has passed ISO9001, IATF16949 quality management system certification. All products have passed ROHS, SGS and other environmental protection certifications.

Wide Range of Applications

The company mainly serves the fields of new energy vehicles, photovoltaic power generation, wind power generation, smart home appliances, smart meters, wireless charging, and various power supplies, inverters, filter inductors, and shielding materials in the national strategic emerging industries.

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Introduction of Nanocrystalline Cores

Nanocrystalline cores are made from metallic-glass materials with a crystalline structure. These cores are distinguished by superior permeability coupled with low power loss and high saturation. These advantages have made them more popular than any other core material for novel applications.
Nanocrystalline cores are a choice solution for common mode choke (CMC) applications as they exhibit high permeability, low power loss, and high saturation. Common mode chokes made with nanocrystalline material are used in a wide range of applications including switched-mode power supplies (SMPS), uninterruptible power supplies (UPS), solar inverters, frequency converters, EMC filters, EV chargers, and multiple automotive and welding applications. When compared to ferrite cores, nanocrystalline cores provide a wider operational temperature range and significantly higher impedance at high frequencies.
Due to the high permeability of nanocrystalline cores, common mode chokes, current transformers, and magnetic amplifiers (magamps) can be smaller in size and handle higher current. Saturation induction of 1.25T and a wide temperature range mean that CMCs made with nanocrystalline cores are less vulnerable to current imbalance and loss of performance at high temperature. The material's low AC losses result in excellent efficiency, and the option of durable cases-available in polyester (<130°C) and rynite polyester (<155°C) - makes cores suitable for winding with thick wire.

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Temperature Stability
Nanocrystalline alloys exhibit excellent stability when exposed to temperature fluctuations, with a near-linear performance change. Compared to a ferrite core, a nanocrystalline core has a significantly higher Curie temperature and a slower, more predictable rate of change, making nanocrystalline a better choice for applications with significant thermal demands.
Magnetic Performance
The structure of nanocrystalline allows for the arrangement of the magnetic domains by annealing the cores under the influence of specialized fields. This process can affect the B-H curve of the material for specific applications.

High Magnetic Induction

Like amorphous materials, nanocrystalline alloys have higher permeability than any other magnetic material. Their impressive induction not only improves performance but also allows for reduced component size.

High Saturation

Nanocrystalline cores have the high saturation magnetic induction strength to handle high-current applications with strong interference.

Flexibility

The nanocrystalline production process is extremely flexible, allowing manufacturers to achieve varied frequency, impedance, and filtering characteristics.

Features of Nanocrystalline cores

Nanocrystalline cores are a revolutionary material redefining the landscape of electronics and beyond. Imagine a material with the magnetic prowess of a superhero, boasting superpowers like:

Super Strength

Incredibly high permeability, channelling magnetic fields with ease, leading to smaller, more efficient components.

Super Speed

Low core losses, minimising energy dissipation and heat generation, ideal for high-frequency applications.

Super Toughness

High saturation flux density, allowing them to handle powerful magnetic fields without losing their composure.

Nanocrystalline Cores: Benefits to Various Industries

These tiny crystals, measuring just a few nanometers, are meticulously arranged to form cores for transformers, inductors, and filters. Their unique properties unlock a treasure trove of benefits across various industries:

Power Electronics

●Smaller, lighter transformers: Nanocrystalline cores enable compact, high-efficiency transformers for power supplies, inverters, and chargers, reducing device size and weight.
●Reduced energy consumption: Lower core losses translate to less energy wasted as heat, improving overall system efficiency and contributing to a greener footprint.
●Enhanced noise filtering: Superior performance at high frequencies makes nanocrystalline cores ideal for filtering electromagnetic interference (EMI) in power electronics circuits.

Automotive Industry

●Efficient electric vehicle (EV) chargers: Nanocrystalline cores in EV chargers minimise energy losses, leading to faster charging times and extended battery range.
●Quieter electric motors: Their low noise generation contributes to the quieter operation of electric motors in EVs and hybrid vehicles.
●Improved fuel efficiency: By enabling smaller, lighter power electronics components, nanocrystalline cores indirectly contribute to better fuel economy in hybrid vehicles.

Telecommunications

●Enhanced signal quality: Their excellent high-frequency performance makes nanocrystalline cores ideal for filters and transformers in telecommunication equipment, ensuring cleaner signal transmission.
●Increased data transfer rates: Nanocrystalline cores contribute to faster data transfer speeds in communication networks by minimising signal distortion.
●Compact, reliable equipment: Their ability to handle high power densities allows for the creation of smaller, more efficient telecommunication equipment.

Why are Nanocrystalline Toroidal Cores Used in Transformers

Nanocrystalline toroidal cores are very suitable for transformers, especially current transformers. These are the reasons why most of the cores are nanocrystalline transformer cores.

Very Less Volume

One of the most significant advantages of the nanocrystalline toroidal cores is their significantly less volume despite their efficient toroidal cores consuming much less space in the body of transformers. Compared to other lined cores, it is worth noting that toroidal cores consume 64% less space.

Current Transformer for Current Monitoring

Less Weight

The nanocrystalline transformer cores are very light in weight. It is due to their less volume and compact ring-shaped body. The toroidal cores are mostly closely wounded, which is a notable factor in their low weight. They tend to have 50% less weight than other standard cores.

Possess High Magnetic Field

Due to their closed-looped body, nanocrystalline toroidal cores have a high magnetic field. The magnetic lines are extensively found around the toroidal cores, which is why they have high magnetic inductance.

An Easy Escape of Magnetic Flux

The nanocrystalline toroidal cores have a round-shaped body, so it is feasible for magnetic flux to escape from its body. It makes them perfect for any environment as they radiate less electromagnetic interference.

Application of Nanocrystalline Core

Application of Nanocrystalline Core Material in High Frequency Transformer
At present, high frequency transformers generally use ferrite cores. The magnetic permeability of the Nanocrystalline core changes much less with temperature than the ferrite core. It can improve the stability and reliability of the switching power supply. When the temperature changes, the loss of the Nanocrystalline core is much lower than that of the ferrite core. In addition, the ferrite core has a low Curie point temperature and is easily demagnetized at high temperatures. If a super microcrystalline core is used to make a transformer, the amount of change in magnetic induction during operation can be changed from O. 4T increased to 1. OT, the operating frequency of the power switch tube is reduced to below 100 kHz.

Application of Nanocrystalline Core in Common Mode Inductor
When a common mode inductor (also known as a common mode choke) is fabricated using an ultrafine crystal core, a large amount of inductance can be obtained by winding a small number of turns, thereby reducing copper loss and saving wire and reducing The volume of the common mode inductor is small. Common mode inductors made with Nanocrystalline cores have high common-mode insertion loss and suppress common-mode interference over a wide frequency range, eliminating the need for complex filter circuits. A common mode inductor is fabricated by using a ferrite core and an Nanocrystalline core, respectively.

Application of Nanocrystalline Core in EMI Filter
The Nanocrystalline core can be widely used in the EMI filter of switching power supply, which can effectively suppress the spike voltage generated by the rapid change of current. A spike suppressor can be fabricated by winding one or several turns of copper wire on the Nanocrystalline core. The structure is very simple and the suppression of noise interference is very good. The Nanocrystalline core has a very low core loss and a high squareness ratio. When the current suddenly changes to zero, it exhibits a large inductance, which can hinder the reverse current of the rectifier. When the current is turned off, the current continues in the negative direction due to the reverse recovery time of the rectifier. Reduced, but the Nanocrystalline core has a very high magnetic permeability, which will present a large amount of inductance, so it does not go through the theoretical operating point (should correspond to the moment when the reverse peak current IR occurs). It is directly to the working point (ie, the reverse remanent point), and then magnetized to start another cycle. This characteristic of suppressing the peak current of the rectifier is called “soft recovery.”

Nanocrystalline Cores Manufacturing Material

The manufacturing technique for NC samples differs significantly from that utilized for ceramic manufacture since the final core is generated by a continuous laminar structure that is wrapped.

Metals Used
Nickel iron and silicon iron are the most often employed metals in producing nanocrystalline toroidal core. Due to a new supplier, a master magnetic and thermal material distributor has introduced a comprehensive range of amorphous cores, bespoke Nanocrystalline cores, and 80% nickel-iron alloy cores to its inventory.

Amorphous Ribbon
The amorphous ribbon has the benefit of not having crystalline structures like other magnetic materials since amorphous metals do not. Because the atoms in an amorphous metal are randomly organized, its resistivity is approximately three times that of its crystalline equivalent. Amorphous alloys are created by cooling the melt at a rate of around 1 million degrees per second.

Fundamental Core Substances
Toroid, gapped toroid, cut cores, and specialized stampings are among the core configurations. With the inclusion of these items, it is now possible to offer competitive rates on low-frequency magnetics designs in addition to the high-frequency magnetics designs it previously supported.

Nanocrystalline Ribbon
The nanocrystalline ribbon comprises Fe, Si, and B with Nb and Cu additions. Just like an amorphous ribbon, it is created by a quick cooling procedure into a thin ribbon that is initially amorphous and then crystallized in a second heat treatment at 500-600 degrees Celsius. This produces a microstructure with tiny grain sizes of 10 nanometers, thus the term nanocrystalline.

Amorphous Cores with Air Gaps
Amorphous choke cores in standard, and bespoke sizes with plastic casings, epoxy coating, or varnish impregnated are among the configurations and applications supplied. The amorphous cut cores come in typical ACC sizes and bespoke designs. Choke coils are an everyday use. Amorphous choke cores with air gaps are also available in standard and bespoke sizes, with plastic casings, epoxy coating, or varnish coated. Decreased magnetic component volume, high relative permeability values, and stable operation at high temperatures are all advantages of iron-based nanocrystalline materials. These characteristics are defined mainly by the production procedure.

Our Certificates

All products have passed ROHS, SGS and other environmental protection certifications.

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Our Testing Equipment

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Common Problem of Nanocrystalline Cores

Q: What are the typical applications of Nanocrystalline Cores?

A: Common Mode Choke Cores (CMC Cores): Nanocrystalline common mode choke core has excellent frequency and impedance characteristics, which makes it the state-of-the-art material for a wide range of applications, e.g. power supply, electric drive and electric control systems for electric vehicles, photovoltaic power inverters, wind power converters, switching power supply for home appliances, as well as EMC solutions of industrial power supplies such as inverter welding machine.
High Frequency Power Transformer Cores (HFPT Cores): Nanocrystalline Power transformer cores are widely used in various high-frequency industrial power supplies. For example, nanocrystalline toroidal cores are mainly used in inverter welding machine power supply, induction heating equipment power supply, communication power supply, UPS power supply, X-ray machine power supply, laser power supply, variable-frequency power supply, etc. As for nanocrystalline rectangular and C-shape cores, they are mainly used in electric locomotive traction/auxiliary power supplies, DC converters, electrostatic precipitating power supplies, etc.
Current Transformer Cores (CT Cores): Nanocrystalline current transformer cores are mainly used in electric power transmission, electronic watt hour meters, and leakage protection switches, etc.

Q: What is the difference between ferrite core and nanocrystalline core?

A: When compared to ferrite cores, nanocrystalline cores provide a wider operational temperature range and significantly higher impedance at high frequencies.

Q: What is the difference between amorphous and nanocrystalline cores?

A: By the end of the production process, the amorphous cores remain with a metallic-glass structure, while the nanocrystalline cores obtain a refined structure of nanometric magnetic grains scattered in an amorphous metallic matrix.

Q: What is the temperature of a nanocrystalline core?

A: Nanocrystalline cores have very high curie temperature about 560℃, much higher than traditional ferrite core about 200℃. High curie temperature make nanocrystalline core excellent thermal stability, and can continuous working at up to 120℃ environment.

Q: What are the advantages of nanocrystalline?

A: What are the advantages of nanocrystals? Compared to ferrite cores, the impedance of nanocrystalline cores is extremely high and the effective frequency band is very wide. This allows components to be made smaller and saves engineering time that otherwise would be needed to design and test other EMI countermeasures.

Q: What are the disadvantages of nanocrystalline core?

A: Usually, the main disad- vantage of nanocrystalline cores for high power applications has been the significant increase in core losses after cutting.

Q: What are the uses of nanocrystalline core?

A: Nanocrystalline cores are mainly used in inverter welding machine power supply, X-ray/laser/communication power supply, UPS and high frequency induction heating power supply, charging power supply, electrolytic and electroplate power supply, as well as Frequency control of motor speed power supply.

Q: What is the material of nanocrystalline core?

A: Nano crystalline soft magnetic material is a new development. The material composition is 82% iron with the remaining balance silicon, boron, niobium, copper, carbon, molybdenum, and nickel. The raw material is manufactured and supplied in an amorphous state.

Q: What is a nanocrystalline material?

A: A nanocrystalline (NC) material is a polycrystalline material with a crystallite size of only a few nanometers. These materials fill the gap between amorphous materials without any long range order and conventional coarse-grained materials.

Q: Why are nanocrystalline materials stronger?

A: The increase in yield strength is a result of enhanced fraction of grain boundary, which impedes the motion of dislocations. Hence the strength of the nanocrystalline metals has been shown to increase by as much as an order of magnitude as the grain size decreases to lower limits of the nanoscale.

Q: What are the characteristics of nanocrystalline core?

A: Nanocrystalline ribbon is the standard core material for power components, mainly transformers for 1 - 80kHz and broad-band Common Mode Chokes (CMC). The core's key features include high saturation induction (1,2 – 1,7 T), low core losses, and the possibility to tailor core shapes and magnetic properties.

Q: What is a nanocrystalline structure?

Q: Why we use nanocrystalline core for electronic components?

A: Lower loss, smaller and lighter: The loss of nanocrystalline cores is only 30% of permalloy cores, which is 70%-80% lower than ferrite cores. Therefore, transformers and inductors consume less power and are smaller in size, so nanocrystalline cores can be applied to more sophisticated instruments and equipment, which is not possible with ferrite cores.
Easy to process and manufacture: Nanocrystalline material can be made into different shapes, powder and spray ribbon are common, so nanocrystalline is an excellent material to alternative other materials (silicon steel or ferrite). Nanocrystalline ribbons can be used to make toroidal core or c cores, and the size of the magnetic core can be controlled more accurately by increasing or reducing the number of winding turns of the ribbon.
Nanocrystalline vs Ferrite: In today's trend of high-frequency components, nanocrystalline materials are more suitable than ferrite or silicon steel in applications such as transformers, current sensors, inverter, inductors, cores and coils. Its advantages are mainly reflected in the following aspects:
●High permeability in a wide frequency range.
●High saturation magnetic flux density.
●Low loss.

Q: What exactly are metallic nanocrystals?

A: The term "soft" in magnetics refers to a magnetic material that exhibits a low coercivity, such as an alloy formed by crystallizing a Fe-based amorphous magnetic materials alloy. Nanocrystal grains are equally distributed throughout this material's amorphous (or non-crystalized) state. At ambient temperature, this material is ferromagnetic, and when combined with nanocrystals, it achieves low saturation magnetostriction constant, making it an incredibly soft magnetic material. Because of its superior properties compared to traditional magnetic materials, this material was primarily employed in choke coils and transformers for power electronics. Because of its remarkable properties, its components may be considerably smaller.

Q: What are the uses of nanocrystalline core?

Q: What are the applications of nanocrystalline materials?

A: Photovoltaic plants with energy storage systems. Solar-based hybrid energy systems with enriched overall efficiency. Hybrid energy systems and energy storage technologies. Phase change materials for thermal management.

Q: What is nanocrystalline technology?

A: Nanocrystals are carrier-free colloidal delivery systems that mean they are almost 100% drug. Drug delivered through nanocrystals have the potential of improving oral bioavailability of water insoluble drugs, reducing dose, increasing dissolution velocity and increasing particle stability.

Q: What is the structure of a nanocrystalline material?

A: Nanocrystalline materials are single- or multiphase polycrystals with crystallite sizes in the range of a few nm (typically 5–20 nm), so that about 30 vol% of the material consists of grain or interphase boundaries. Due to the huge amount of grain boundaries and/or the broad distribution of interatomic spacings in the grain boundaries the properties of nanocrystalline materials differ from that of crystalline and amorphous materials with the same chemical composition. Nanocrystalline materials seem to permit the alloying of conventionally insoluble components.

Q: Why are nanocrystalline materials stronger?

Q: What are the applications of nanocrystalline materials?

Q: What are the properties of a nanocrystalline core?

A: The crystalline atomic structure of a nanocrystalline core creates superior magnetic properties, including high saturation and very high permeability across a wide frequency range. Nanocrystalline alloys also exhibit low AC loss and high efficiency, even at high temperatures.

We're professional nanocrystalline cores manufacturers and suppliers in China, specialized in providing high quality customized service. We warmly welcome you to buy nanocrystalline cores made in China here from our factory.

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