How do the low losses of FeSi inductors help improve the energy efficiency of power supply systems?
Publish Time: 2025-08-27
In modern power electronics systems, energy efficiency has become a core performance metric for power supply products. Whether in data centers, renewable energy generation, electric vehicles, or industrial power supplies, high energy efficiency not only means lower operating costs but also directly impacts equipment thermal design, size optimization, and environmental compliance. With their extremely low iron and copper losses, FeSi inductors are becoming a key component for improving the overall energy efficiency of power supply systems.1. The Low Loss Characteristics of FeSi Materials: The Physical Basis for Improved Energy EfficiencyThe core of FeSi inductors lies in the FeSi soft magnetic alloy they use. This material undergoes a special compression and insulation process to create a core structure with a "distributed air gap." Compared to traditional ferrite cores, FeSi maintains low hysteresis and eddy current losses even at high magnetic flux densities. Hysteresis loss stems from the energy consumed by the core's repeated magnetization in an alternating magnetic field, while eddy current loss results from the heating caused by induced currents within the material. The insulating layer between the FeSi particles effectively blocks eddy current paths, significantly reducing the eddy current effect at high frequencies. Experimental data shows that within the operating frequency range of 50kHz to 200kHz, the core loss of FeSi inductors is over 30% lower than that of ferrite. This advantage is particularly pronounced in high-power density applications.2. Reduced Total System Losses Directly Improve Conversion EfficiencyThe overall efficiency (η) of a power system is typically determined by the ratio of input power to output power. As a key energy storage component in topologies such as DC-DC converters, PFC circuits, and inverters, the losses of inductors directly impact overall system efficiency.According to actual measurements, under the same power conditions, power modules using FeSi inductors can achieve a 0.5% to 1.5% improvement in conversion efficiency. While seemingly small, in megawatt-class photovoltaic inverters or server power systems, this improvement can save thousands of kilowatt-hours of electricity annually, significantly reducing carbon emissions and operating costs.3. Supporting High-Frequency Design, Boosting Power Supply Miniaturization and EfficiencyWith the increasing popularity of semiconductor devices (such as GaN and SiC), switching power supplies are moving toward higher frequencies. However, the losses of traditional ferrite cores increase dramatically at high frequencies, limiting further improvements in system efficiency. FeSi inductors, with their excellent high-frequency, low-loss characteristics, are an ideal choice for high-frequency power supply designs. Even at frequencies above 100kHz, FeSi maintains stable permeability and low losses, enabling power supply operation at higher frequencies without sacrificing efficiency. High frequencies allow for the use of smaller inductance values and smaller cores, resulting in smaller and lighter power supply systems while reducing winding copper losses and further improving overall energy efficiency.4. Excellent thermal stability reduces heat dissipation and indirectly improves system reliability.Low losses not only result in higher efficiency but also lower temperature rise. FeSi inductors typically exhibit a surface temperature rise 15-25°C lower than comparable ferrite inductors at full load. This means: additional cooling devices such as heat sinks and fans can be reduced or eliminated; thermal stress on peripheral components (such as MOSFETs and capacitors) can be reduced; and the long-term operational reliability of the entire power module can be improved. This is particularly important in enclosed or high-temperature environments (such as in-vehicle OBCs and outdoor inverters). Simplifying the system's heat dissipation design also indirectly reduces material costs and failure rates.The fundamental reason why FeSi inductors excel in modern power systems is their low-loss design, which is inherently based on the material's nature. They not only directly improve energy conversion efficiency but also provide comprehensive performance optimization for power systems by supporting higher frequencies, reducing temperature rise, and enhancing reliability. With the "dual carbon" goals and the increasing emphasis on energy efficiency, FeSi inductors are becoming an indispensable core component in efficient, intelligent, and sustainable power solutions.
