High Flux Density Cores
MK Magnetics, Inc. develops advanced high flux density cores engineered from low-loss soft magnetic materials such as grain-oriented silicon steel, cobalt iron, amorphous and nanocrystalline alloys. These alloys are at the forefront of modern power conversion, providing the high efficiency, compact size, and thermal stability required in today’s demanding energy systems. Our cores serve engineers designing power electronic transformers, high-frequency inductors, EV chargers, and pulse power devices, where consistent performance under elevated magnetic fields is essential.
Why High Flux Density Matters
A high flux density core supports stronger magnetic fields without early saturation. This capability allows power devices to deliver higher throughput with smaller, lighter components. For engineers, the result is reduced system footprint, higher frequency operation, and improved energy efficiency. With nanocrystalline and amorphous cores, designs achieve:
- Lower core losses across a wide frequency range
- High saturation flux density (Bs) for greater energy handling
- Excellent permeability for stable magnetic response
- Compact, lightweight designs that run cooler and more reliably
Material Options for High-Performance Applications
MK Magnetics offers a portfolio of advanced soft magnetic alloys selected to optimize power conversion:
- Nanocrystalline alloys: exceptional permeability, low coercivity, and excellent frequency performance.
- Grain-Oriented Silicon Steel: proven to be reliable in high electrical performance
- Amorphous alloys: high resistivity and low eddy current losses, ideal for transformers and compact inductors.
- Cobalt (up to 2.35T): valued for their high saturation flux density and specialized frequency response.
Produced as thin ribbons using rapid rolling solidification techniques such as melt spinning and planar flow casting, these materials are manufactured into tape-wound toroids, bars, and rectangular cores. Carefully controlled heat treatments (including magnetic field annealing) fine-tune permeability, anisotropy, and loss characteristics.
Applications of High Flux Density Cores
Our cores power critical systems where efficiency and stability cannot be compromised:
- Power Electronic Transformers (PETs): Compact, high-density transformers for smart grids, renewable integration, and solid-state power distribution.
- High-Frequency Inductors: Stable inductance and reduced loss at switching frequencies in the 10 kHz – 1 MHz range.
- EV Chargers: A magnetic core in an EV charger enables fast, stable energy transfer without overheating or EMI issues, supporting next-generation charging stations.
- Pulse Power and Energy Storage Systems: In devices built to charge electronic magnetic pulse energy, our cores provide a rapid response to sharp, repeating pulses with minimal energy loss.
- High-Power Motors: Enhanced torque density and reduced size enabled by nanocrystalline alloys
Engineering Support and Customization
MK Magnetics partners with engineers to match materials, geometry, and processing to target applications. Through BH loop testing, permeability measurements, and DC bias analysis, we validate performance under real-world conditions. Options include:
- Toroids, rectangular cores, and magnetic bars
- Gapped and ungapped configurations
- Custom multi-cut geometries and processed for specific frequency and thermal environments
Our design expertise modeling allows us to predict magnetic behavior for electrical, thermal , and mechanical applications.
Performance Advantages
By leveraging soft magnetic tape wound alloys, MK Magnetics cores deliver:
- Reduced energy losses at high switching speeds
- High stability under temperature and load variation
- Smaller, lighter designs that increase system packing density
- Extended lifetime of power electronics through reduced heating and vibration effects
These advantages translate directly into higher efficiency, lower operating costs, and improved system reliability.
Request a Quote
If you need a high flux density core tailored to your dimensions, frequency range, and application requirements, contact MK Magnetics for a detailed consultation. We support low- to high-volume orders, offering technical input to ensure your design achieves optimal magnetic performance. Whether the need is a V charger magnetic core or a solution for charge electronic magnetic pulse systems, MK Magnetics delivers performance you can count on.
