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high current DIY inductors

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jonpaul:
NiHaoMike, great problem and discussion.

1/ Laminated 60 Hz inductors and cores cannot be used on 20 kHz SMPS as the core losses are too high regardless of type of steel or lam thickness.

2/ Amorphous cores  have low losses but are super costly, you would need a custom cut core.

3/ The best source of IN STOCK low cost powdered iron cores in all shapes, EE, EI, toroids is MicroMetals in Anaheim Calif. These are specified to work in SMPS.

founder Jim Cox is a Ham and super engineer.

https://www.micrometals.com/

The website includes many selection and design app notes and guides and includes free design software.

I have used their parts and info back to 1980s. They have samples available as well!

4/ Ferrite like the CoolMu   are also fine but need a gap, the powdered iron have a distributed gap.

Gap  is needed for any DC  inductor.

All oldline ferrite mfg (Philips, FerroxCube, Siemens, Stacore) have disappeared or moved prod to China.

Hope this can assist your interesting design!

Good Luck,

Jon in Paris.

Just the ramblings of an old retired EE

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