High-voltage DC-DC converters place demanding requirements on custom inductors because current ripple, insulation stress, thermal rise, and EMI behavior must be balanced in limited space. BaoHui Tech reviews these designs for saturation margin, core loss, winding structure, creepage, clearance, and production repeatability.
High Voltage Adds Insulation Constraints
A custom inductor may not provide isolation like a transformer, but high working voltage can still create spacing, insulation, and terminal safety requirements. Creepage, clearance, sleeving, winding layout, and hipot test points should be defined early.
Higher voltage converters can also produce fast switching transitions and strong electric fields, making lead routing, shielding, and proximity to other components important.
Design Inputs to Confirm
BaoHui Tech uses electrical and mechanical requirements to select a manufacturable design with appropriate safety margin.
- DC voltage, rated current, ripple current, peak current, and duty cycle
- Inductance target, allowed drop, saturation margin, and test current
- Core material, gap method, core loss, DCR, AC loss, and thermal path
- Creepage, clearance, insulation material, hipot requirement, and terminal style
- Mounting, vibration, lead routing, EMI concern, and production inspection
Testing in the Converter
Validation should include inductance under current, DCR, temperature rise, hipot where required, visual inspection, and operation in the actual converter. EMI testing may also be needed for fast-switching designs.
Production documents should define core material, gap process, winding method, insulation placement, terminal structure, and test limits.
BaoHui Tech Engineering Support
BaoHui Tech manufactures custom inductors, high frequency transformers, power transformers, common mode chokes, and EMI filters for high-voltage converters, inverters, energy systems, and industrial electronics.
FAQ
Useful inputs include topology, voltage, current, power level, operating frequency, waveform, insulation and safety requirements, thermal environment, dimensions, mounting method, target tests, and expected production volume.
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