An Introduction to Tape Wound Cores

Tape wound cores are magnetic components created by winding a continuous strip of electrical steel, typically nanocrystalline-amorphous or nickel alloy, into a rectangular or circular shape. The process involves precision winding to a uniform and consistent core to stabilize the core’s magnetic properties. Due to their superior magnetic characteristics and efficiency, these cores are widely used in transformers, inductors, and various other magnetic devices.

We are proud at MK Magnetics to offer a wide variety of custom configurations. Common uses of MK Magnetics cores include:

• Converters
• Inverters
• Transformers
• Chokes
• Electric motors
• Sensors
• Induction devices

Applications of Tape Wound Cores

Tape wound cores find applications across multiple industries due to their versatility and cost-effectiveness:

• Power Transformers: Minimize energy losses and improve overall efficiency.
• Inductors: Low core losses and high efficiency.
• Magnetic Shielding: Used to prevent electromagnetic interference (EMI).
• Current Transformers: Provide accurate measurement and protection in electrical systems.
• Pulsed Power Devices: Used for their ability to handle high-frequency radio signals with minimal losses.

Choosing the Right Tape Wound Core for Your Application

Your selection will affect material, size, frequency, temperature and other factors. We at MK Magnetics are proud to offer multiple options for tape wound cores.

• Material: Consider the magnetic properties desired in your application.
• Core Size: The most immediate factors, magnetic performance and space requirements, are essential here in relation to your core’s application.
• Frequency: Consider the operating frequency of your application, as these factors will influence the core’s efficiency and losses. Frequency is also a major factor in the choice of material type.
• Temperature: Cores heat themselves and resist heat based on multiple variables; be sure your operating temperature range matches the desired application without degradation.
• Application Requirements: Specific use cases call for unique requirements, such as high current handling, high temperature resistance, or precise magnetic properties.

Advantages of Tape Wound Toroidal Cores

Tape wound toroidal cores offer several key benefits over other common cores that make them ideal for varied applications:

• High Efficiency: The continuous strip design minimizes air gaps, reducing core losses and improving overall efficiency.
• Compact Design: The toroidal shape of core centers allows for a more compact, space-saving design essential in modern electronic use situations.
• Magnetic Properties: High permeability and low coercivity enhance performance in magnetic applications.
• Versatility: Suitable for applications from power electronics to magnetic shielding.
• Mechanical Stability: Gapped toroids offer greater mechanical stability than powdered metal cores.

Tape Wound Core Manufacturers

When it comes to selecting a reliable tape wound core manufacturer, our expertise in producing high-quality tape wound toroidal cores ensures customer satisfaction and exceeds industry standards.

Ordering Customized Tape Wound Cores

At MK Magnetics, we recognize that every application is unique. A significant element of the design and process is determining the base materials to be used based on project requirements.

Material Selection

• Nanocrystalline: Composed of polycrystalline materials with crystallite sizes just a few nanometers across, these materials bridge the gap between traditional coarse-grained materials and amorphous materials. Nanocrystalline materials offer the lowest losses, highest permeability, and high saturation flux density.
• Amorphous: While amorphous material comes with a disordered atomic structure, amorphous materials resemble glass but consist of non-crystalline alloys. Their disordered structure creates exceptional magnetic properties, including high saturation, low core loss, and high flux density.
• Grain-Oriented Silicon Steel: Optimized in the direction that its rolled, grain-oriented silicon steel offers high saturation and magnetic flux density. Grain-oriented silicon steel is often a more cost-effective option compared to other materials, making it a popular choice for across applications.
• Non-Oriented Materials: Non-oriented materials are versatile for many applications, exhibiting uniform magnetic properties in all directions.
• Nickel Alloys (50% to 80%): Nickel alloys permit better thermal stability compared to amorphous and nanocrystalline materials, ensuring reliable performance in demanding applications.
• Cobalt Alloys: Known for its low core loss and high flux density, Supermendur® is a cobalt-iron material choice for industries where minimizing mass and size is crucial.

Highlight: A Next-Generation Material At Your Disposal

Our nanocrystalline core is widely utilized for its superior permeability and minimal core losses compared to other alloys. It delivers optimal magnetic performance across a broad frequency range, making it exceptionally versatile for various applications.

The Manufacturing Process of Tape Wound Cores

The manufacturing process of tape wound cores involves several precise steps.

1. Material Selection: Choosing the appropriate material for example, nanocrystalline, amorphous, silicon steel, or nickel alloy, based on application requirements.
2. Slitting: The metal strip, hence the name tape wound, is slit to the required width, achieving uniform thickness and consistency.
3. Winding: The slit strip is then wound tightly around a mandrel to form the shape, with precise control over the winding tension and alignment for the completion of the final product.
4. Annealing: The wound core is then annealed (heated and rapidly cooled) to relieve stress on the material and enhance its magnetic properties.
5. Cutting: The core is frequently cut to allow for copper windings to be applied, as well as adding an air gap in the magnetic circuit. Multiple cuts aid in reducing fringing losses. Cutting is frequently used in DC power applications but can be used in other applications.
6. Polishing: The cut core faces are surfaced to minimize the air gap in the magnetic circuit.
7. Insulation: The core is coated with an insulating material to prevent short circuits and improve performance. Aluminum and nylon housing are also available.
8. Testing: Rigorous testing is conducted to ensure the core meets all client requirements and company quality standards.

A Range of Configurations Available

We also offer tape wound core configurations essential for superior performance reliability across applications.

Our tape wound cores offer configurations as follows:

• C-cores
• E-cores
• Bars/block
• Toroidal-shaped cores, including cased and epoxy coating
• Gapped toroids
• Other custom configurations

Don’t see the configuration you’re looking for? Contact us to discuss the fabrication of custom cores.

Industry Standards For Our Tape Wound Cores

Our certifications and ratings ensure that our tape-wound core products and processes meet customer and industry standards.

Our industry standards include:

• ISO 9001
• RoHS
• REACH
• EIA Standard RS-217
• ASTM (compliant)
• ANSI (compliant)
• ITAR
• DFARS
• Mil-Spec (compliant)

MK Magnetics’ Commitment

At MK Magnetics we are dedicated to being one of the world’s top tape wound core manufacturers. Our research and development departments work closely to explore new materials, manufacturing methods, and performance adjustments to make our tape wound cores some of the best options on the market.

• Expertise: Our team comes with combined decades of experience – we have the knowledge and expertise to produce top-quality tape-wound cores.
• Advanced Manufacturing Facilities: Our manufacturing facilities enable us to produce cores with precision and consistency.
• Customization: Each customer is offered customized solutions, ensuring optimal performance in all applications.
• Quality Assurance: Each produced core must pass rigorous quality control processes to ensure they meet the highest standards of quality and reliability.
• Customer Support: Our dedicated customer support team is available to assist with orders, technical inquiries, or provide general assistance.

Our dedicated engineering team is here to support you throughout your product design process. We provide expert guidance in selecting the most suitable materials for your application, understanding that each project has unique requirements. We also offer customized solutions and modifications to our core models to precisely meet your needs – if you require a modification, request it.