Comparison and design of DC chokes based on different magnetic materials

Different magnetic materials for cores of DC chokes are considered and compared in this paper. Four components are designed using both manufacturer software and an improved Fast design approach. The compared materials are: ferrites (3F3), powder materials (sendust MS and Hi-Flux™ HF) and amorphous materials (Microlite 245). Recommendations are derived regarding the use of available design software and discussed optimal design procedure aimed at minimizing losses and volume of the component. The competitive results are summarized and final recommendations are formulated regarding the application of compared materials and main core forms (ETD and toroids) in the realization of DC chokes.