The Toroidal Choke-Leaded Toroidal Inductor is a high-performance Power Inductor designed to excel in demanding electronic systems. As a key component in power management and signal processing, this toroidal choke combines advanced engineering with precision manufacturing to deliver superior performance across various applications. Unlike traditional inductor designs, its toroidal construction ensures efficient magnetic field containment, minimizing energy loss and enhancing overall system efficiency. Whether integrated into EMI Filter systems or high-frequency RF circuits, this inductor stands out for its ability to handle high currents while maintaining excellent EMI suppression—making it a reliable choice for engineers and procurement professionals seeking both performance and durability.
Explore the design and details of our Toroidal Choke-Leaded Toroidal Inductor:
Product Features & Advantages
Our Toroidal Choke-Leaded Toroidal Inductor is engineered with distinct features that set it apart from conventional inductors:
Core Design Advantages
- Toroidal Construction: The toroidal shape ensures 95%+ magnetic field containment, reducing interference with adjacent components compared to E-core or bobbin inductors. This design also minimizes stray magnetic flux, making it ideal for compact circuit layouts.
- High Saturation Material: Utilizes advanced magnetic materials with high saturation flux density, allowing the inductor to handle peak currents without significant inductance drop—critical for power supply stability.
- Low EMI Radiation: By containing magnetic fields and reducing flux leakage, the inductor actively suppresses EMI, simplifying compliance with international EMC standards for your end products.
Performance Highlights
- High Current Capacity: Designed to support continuous currents ranging from 0.5A to 38.7A (depending on the series), making it suitable for high-power Transformer and power supply applications.
- Low DC Resistance (DCR): With DCR as low as 0.001Ω, the inductor minimizes power loss, improving overall system efficiency—especially important in battery-powered or energy-sensitive devices.
- Wide Operating Frequency: Performs reliably across a broad frequency spectrum, from low-frequency power circuits to high-frequency RF Inductor applications up to 100MHz.
- Thermal Stability: Operates consistently in temperatures ranging from -40℃ to +125℃, ensuring reliability in harsh environments such as industrial machinery or automotive systems.
- Leaded Configuration: Pre-formed leads with standard spacing (customizable) simplify through-hole mounting, reducing assembly time and ensuring secure connections in vibration-prone environments.
Our Competitive Edge
Compared to generic toroidal chokes, our product offers:
- Tighter inductance tolerance (±5% as standard, ±2% available on request) for precise circuit tuning.
- Enhanced mechanical durability with robust encapsulation, resisting shock (up to 50G) and vibration (10-2000Hz) per IEC 60068 standards.
- RoHS-compliant materials and lead-free finishes, meeting global environmental regulations.
Technical Specifications
Our Toroidal Choke-Leaded Toroidal Inductor is available in four main series, each optimized for specific applications. Below are the key technical parameters:
ATC-TC Series
- Inductance Range: 40µH to 470µH
- DC Current Rating (IDC): 0.5A to 3A
- Maximum DC Resistance (DCR): 0.045Ω to 0.1Ω
- Typical Application: Low-power EMI filters and signal processing circuits
TM Series
- Inductance Range: 1.0µH to 1000µH
- DC Current Rating (IDC): 1.6A to 38.7A
- Maximum DC Resistance (DCR): 0.002Ω to 0.49Ω
- Typical Application: High-power Transformers, industrial power supplies
TR Series
- Inductance Range: 10µH to 1000µH
- DC Current Rating (IDC): 1.3A to 20.2A
- Maximum DC Resistance (DCR): 0.0022Ω to 0.4Ω
- Typical Application: RF circuits, motor drive systems
TS Series
- Inductance Range: 1.0µH to 1000µH
- DC Current Rating (IDC): 1.5A to 34A
- Maximum DC Resistance (DCR): 0.001Ω to 0.284Ω
- Typical Application: High-efficiency power converters, automotive electronics
General Specifications (All Series)
- Operating Temperature: -40℃ to +125℃
- Storage Temperature: -40℃ to +125℃
- Insulation Resistance: ≥1000MΩ at 500V DC
- Dielectric Withstand Voltage: 1500V AC for 1 minute (between winding and core)
How to Use the Toroidal Choke
Proper installation and integration are critical to maximizing the performance of your Toroidal Choke-Leaded Toroidal Inductor. Follow these steps for optimal results:
- Select the Right Series:
- Assess your application’s current requirements (peak and continuous) and match them to the IDC rating of the series (e.g., TM Series for high-power needs).
- Verify inductance values against your circuit’s filtering or tuning requirements.
- Circuit Layout Planning:
- Position the inductor away from sensitive components (e.g., sensors, RF receivers) to leverage its low EMI radiation—maintain a 2cm+ gap where possible.
- Ensure the PCB footprint matches the lead spacing (standard: 10mm, customizable on request) to avoid mechanical stress on leads.
- Mounting & Soldering:
- Use through-hole soldering with a temperature of 260℃ ±5℃ for 5-10 seconds to prevent damage to the winding insulation.
- For high-vibration environments (e.g., automotive), add epoxy adhesive at the base of the leads to reinforce mechanical stability.
- Thermal Management:
- In high-current applications (IDC >10A), ensure adequate PCB copper pour (≥35μm) around the inductor to dissipate heat.
- Avoid enclosing the inductor in sealed compartments without ventilation, as excessive heat can reduce lifespan.
- System Testing:
- Measure inductance under operating current using an LCR meter to confirm stability.
- Conduct EMI testing to validate noise suppression performance in your specific system.
Application Scenarios
The versatility of our Toroidal Choke-Leaded Toroidal Inductor makes it suitable for a wide range of industries and applications:
Power Electronics
- Switch-Mode Power Supplies (SMPS): Used as input/output filters to reduce ripple current and suppress EMI, improving efficiency in consumer electronics (e.g., laptops, TVs) and industrial power supplies.
- Transformers & Inverters: Integrated into high-frequency transformers for solar inverters and UPS systems, where high current handling and low loss are critical.
RF & Communication Systems
- RF Circuits: Acts as a RF Inductor in radio transmitters and receivers, providing stable tuning and reducing signal interference.
- Base Stations: Used in EMI filters to ensure compliance with 5G network equipment standards, minimizing interference between components.
Industrial & Automotive
- Motor Drives: Filters noise in variable frequency drives (VFDs) for industrial motors, extending equipment lifespan by reducing voltage spikes.
- Automotive Electronics: Integrated into onboard chargers (OBCs) and DC-DC converters for electric vehicles (EVs), withstanding extreme temperature fluctuations.
Sensor & Measurement Systems
- Precision Sensors: Protects sensitive sensor networks (e.g., medical imaging, industrial IoT) from electromagnetic interference, ensuring accurate data collection.
- Test & Measurement Equipment: Used in oscilloscopes and signal analyzers to maintain signal integrity at high frequencies.
Benefits for Customers
Choosing our Toroidal Choke-Leaded Toroidal Inductor delivers tangible benefits for your business and end products:
- Reduced System Costs: Low DCR minimizes power loss, reducing energy consumption in end products—a key selling point for customers focused on sustainability.
- Faster Time-to-Market: Pre-tested and compliant with global standards (CE, RoHS), reducing the need for extensive in-house testing and accelerating product launch.
- Enhanced Product Reliability: Thermal stability and mechanical durability reduce field failures, lowering warranty claims and improving brand reputation.
- Design Flexibility: Multiple series and customization options allow engineers to optimize designs without compromising performance.
- Simplified Compliance: Low EMI radiation helps end products meet strict EMC regulations (e.g., CISPR, FCC), avoiding costly redesigns.
Certifications and Compliance
Our Toroidal Choke-Leaded Toroidal Inductor is manufactured to meet international standards, ensuring quality and compatibility worldwide:
- ISO 9001:2015: Certified production process, guaranteeing consistent quality control from material sourcing to final testing.
- RoHS 2.0 (EU 2011/65/EU): Free of lead, mercury, and other restricted substances, compliant with global environmental regulations.
- CE Marking: Meets essential requirements for health, safety, and environmental protection in the European Economic Area (EEA).
- IEC 60938: Compliant with international standards for fixed inductors, ensuring interoperability with global electronic systems.
- UL Recognition: Available upon request for applications requiring UL-listed components (e.g., medical devices, aerospace).
Customization Options
We understand that unique applications require tailored solutions. Our engineering team offers the following customization options:
- Inductance Values: Custom inductance ranges beyond standard series (e.g., 0.1µH to 10,000µH) to match specific circuit requirements.
- Current Ratings: Modified winding designs to support higher peak currents (up to 50A) for specialized industrial applications.
- Lead Configurations: Custom lead lengths, spacing, or termination types (e.g., solder pads, crimp terminals) for unique PCB layouts.
- Encapsulation: Epoxy or conformal coating options for enhanced moisture resistance (IP67 rating available) in harsh environments.
- Marking: Custom part numbers or logos on the inductor body for easy identification in large-scale production.
Minimum order quantity (MOQ) for custom designs starts at 500 units, with lead times of 4-6 weeks.
Production Process
Our Toroidal Choke-Leaded Toroidal Inductor is manufactured using a rigorous, multi-step process to ensure consistent quality:
- Material Selection: High-purity iron powder cores (or ferrite for high-frequency models) and enameled copper wire (AWG 18-36) are sourced from certified suppliers and inspected for purity and performance.
- Core Preparation: Cores are deburred and annealed to reduce internal stress, ensuring stable magnetic properties over time.
- Winding: Automated toroidal winding machines precisely wind copper wire around cores, with tension control to avoid wire damage and ensure uniform turns.
- Lead Attachment: Leads are soldered or crimped to the winding ends, with pull-strength testing (≥5N) to verify connection integrity.
- Encapsulation: Optional epoxy coating is applied and cured to protect windings from moisture and mechanical damage.
- Testing: Each unit undergoes 100% testing, including inductance (at 1kHz and 10kHz), DCR, insulation resistance, and dielectric withstand voltage.
- Quality Control: Random sampling from each batch undergoes thermal cycling (-40℃ to +125℃, 100 cycles) and vibration testing to validate long-term reliability.
Customer Testimonials
Hear from our satisfied customers across industries:
- Global Power Supply Manufacturer: "The TM Series toroidal chokes reduced our power supply EMI by 30% compared to our previous supplier, allowing us to meet FCC Part 15 standards without additional filtering components. Lead times are consistently on schedule, which is critical for our just-in-time production." — Engineering Manager, USA
- Automotive Electronics Supplier: "We’ve integrated the TS Series into our EV DC-DC converters. The high current handling and -40℃ to +125℃ rating ensure reliability in extreme conditions. Custom lead spacing was delivered exactly as specified, simplifying our PCB design." — Procurement Director, Germany
- RF Equipment Designer: "The low EMI radiation of these toroidal chokes was a game-changer for our 5G base station filters. We’ve reduced board space by 20% by eliminating shielding components. The TR Series’ frequency stability is unmatched." — R&D Lead, South Korea
FAQ
Here are answers to common questions from our customers:
Q: What is the difference between toroidal chokes and other inductor types?
A: Toroidal chokes offer superior magnetic field containment, lower EMI, and higher efficiency compared to E-core or rod inductors. Their compact, donut shape also saves space in PCB layouts—ideal for high-density designs.
Q: Can I use the same inductor for both power filtering and RF applications?
A: It depends on the frequency range. Our TR and TS Series are optimized for RF (up to 100MHz) and power circuits, but for frequencies above 100MHz, we recommend consulting our engineers to select the right core material (ferrite vs. iron powder).
Q: What is the maximum lead time for standard and custom orders?
A: Standard series (ATC-TC, TM, TR, TS) are in stock with 2-3 week delivery. Custom designs typically take 4-6 weeks, with expedited options (3 weeks) available for an additional fee.
Q: How do I calculate the right inductor for my application?
A: Key factors include operating frequency, maximum current (continuous and peak), required inductance, and temperature range. Our technical team can assist with selection—contact us with your specifications for a free recommendation.
Q: What warranty do you offer?
A: All inductors come with a 2-year warranty against defects in materials and workmanship. We also offer a 3-year extended warranty for customers who purchase 10,000+ units annually.
Q: Are samples available for testing?
A: Yes, we provide up to 5 free samples of standard series for qualified customers. Custom samples are available for a nominal fee, which is refundable on subsequent orders of 1000+ units.
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