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Block Core | Modular Assembly for SMPS, EV Chargers & Renewable Inverters

Block Core - Compact Laminated Structure Engineered for High-Frequency Power Conversion in SMPS, EV Systems, and Green Energy Applications

The Block Core represents a specialized category within silicon steel magnetic cores, engineered as a compact three-dimensional structure. Comprising precision-stacked insulated silicon steel segments, its cubic geometry enables symmetrical flux distribution—distinct from rectangular cores’ linear design. Optimized lamination thickness (0.1–0.35mm) and grain-oriented silicon steel (2.9–3.5% Si) ensure minimal hysteresis loss at elevated frequencies (400Hz–10kHz), serving critical roles in modern power electronics.

Space-Efficient Architecture

Cubic form factor maximizes core volume within minimal footprint, ideal for compact devices. Interlocking segment assembly minimizes joint reluctance, enhancing flux path continuity versus conventional layered stacks.

High-Frequency Performance

Core loss maintained at 1.2–4.5W/kg under 1kHz/1.0T conditions, supporting switched-mode power systems. Ultrathin laminations with ceramic insulation suppress eddy currents by >85% compared to solid cores.

Scalable Configuration

Modular design allows flexible scaling (e.g., 50mm³ to 500mm³) for applications ranging from micro-inverters to EV charging systems.

Thermal Stability

Segmented metallic contact enables multidirectional heat dissipation, permitting sustained operation at power densities up to 25kW/m³. Reduced hot-spot formation via uniform flux distribution.

Common Applications

Switch-Mode Power Supplies (SMPS)

High-frequency DC-DC converters: Achieves >94% efficiency in server PSUs through rapid flux response. UPS systems: Delivers stable voltage conversion under dynamic loads.

Electrified Transportation

Traction motor controllers: Withstands vibration (IEC 61373 compliant) while maintaining flux stability in EV drivetrains. On-board chargers: Compact core volume enables integration within battery management systems.

Advanced Electronics

Renewable energy inverters: Supports 10–100kHz switching in solar microinverters.

Wireless power transmitters: Cubic symmetry enables omni-directional flux coupling for Qi-standard devices.

MRI shimming coils: Delivers precision field uniformity for medical imaging systems.