Reliable Flat Copper Wire Coil for High-Current Power Conversion

In modern power electronics, inductors play an important role in power conversion, energy transfer, filtering and current control. For applications requiring high current capacity and efficient heat dissipation, a properly designed air core inductor can provide a practical solution.

In this case, our high current air core inductor uses flat copper wire winding and an air-core structure, making it suitable for power electronic equipment where high current handling and low-loss performance are important.

Customer Application Requirements

The customer required a compact inductor for a high-current power conversion system. The application required:

• High current carrying capability
• Efficient heat dissipation
• Stable inductive performance
• Compact and reliable mounting
• Easy integration into the customer's PCB or power assembly

Traditional magnetic-core inductors were not ideal for this application because of space, thermal and design considerations. The customer therefore selected an air core inductor with flat copper wire winding.

Our Solution

We designed the coil using pure copper flat wire with a carefully controlled winding structure. The air-core construction eliminates the need for a traditional magnetic core while providing an open structure that can support effective heat dissipation.

The inductor is also designed with a DIP mounting structure, allowing it to be installed directly into the customer's electronic assembly and simplifying the production process.

Key Product Features

Pure Copper Winding
High-quality copper winding provides good electrical conductivity and supports high-current applications.

Air-Core Structure
The coreless design offers design flexibility and avoids magnetic-core saturation concerns in suitable applications.

High Current Capability
The flat copper wire structure provides a large conductive cross-section for demanding current applications.

DIP Mounting Design
The lead structure allows convenient installation and integration into power electronic assemblies.

Typical Applications

This type of high-current air core inductor can be used in:

• Power conversion systems
• DC/DC converters
• High-current power supplies
• Energy transfer circuits
• Power filtering systems
• Industrial power electronics
• Custom transformer and inductive assemblies

Why Choose Our Air Core Inductor?

For power electronics manufacturers, the inductor is more than a passive component—it must match the electrical, thermal and mechanical requirements of the complete system.

Our flat copper wire air core inductors can be customized according to application requirements, including winding dimensions, inductance, current requirements, terminal design and mounting structure.

From prototype development to volume production, we provide customized coil solutions for power electronics manufacturers.