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Power Inductors for PV Inverters: 14°C Lower Temperature Rise

High-current power inductors for string PV inverters reduced full-load temperature rise by 14°C and passed 1,000-hour damp-heat validation.

Power Inductors for PV Inverters: 14°C Lower Temperature Rise

Background

A string PV inverter derated in summer because the power inductor overheated at full load, reducing energy yield. The previous supplier's varnish aged after long-term operation at 85°C.

Challenges

  • 60A continuous current with both DCR and temperature rise reduced.
  • Outdoor damp-heat and thermal shock validation.
  • Height limited to 40mm.
  • 15-year design life.

Our Solution

Large-section ferrite rod with flat copper wire and improved mounting and potting.

  • Flat wire increased fill factor and cut DCR by about 12%.
  • High Curie temperature core limits inductance drop to 8% at 85°C.
  • Class H varnish and high-temperature potting improve thermal ageing resistance.

Results

  • Temperature rise reduced from 62°C to 48°C at full load.
  • Inductance change below 5% after 1,000h at 85°C/85%RH.
  • Passed 15-year equivalent accelerated life test; over 300,000 pcs per year.

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