As power electronics technology continues to evolve rapidly, end applications—including new energy vehicles, photovoltaic energy storage systems, server power supplies, and industrial high-voltage drive equipment—are placing increasingly stringent performance requirements on magnetic components. Achieving higher power density, superior thermal performance, and enhanced voltage withstand capability within limited installation space has become a critical challenge for power engineers during system design and component selection.
Leveraging years of expertise in magnetic component technology, CODACA has introduced the CPEX-LV Series High Voltage Withstand Customizable High Current Power Inductor, delivering an efficient and reliable solution specifically designed for high-voltage, high-current applications.
Ⅰ. Product Overview
The CPEX-LV Series High Current Power Inductor features CODACA's proprietary low-loss magnetic powder core material combined with a flat-wire winding design, providing extremely low DC resistance and minimized core loss.
The series offers excellent soft saturation characteristics, enabling it to withstand significantly higher peak currents. The maximum saturation current reaches 126 A, while the temperature rise current is up to 120 A, allowing long-term stable operation under high-current conditions and perfectly supporting compact, high-power-density designs.
Featuring a high-voltage insulation structure, the CPEX-LV Series provides an insulation withstand voltage of up to 1500 V AC, making it ideal for a wide range of high-voltage applications, including:DC-DC converters ,High-current switching regulators ,Server power supplies ,Photovoltaic inverters ,High-voltage drive equipment ,800 V HVDC electric vehicle platforms.
CPEX-LV Series includes five package sizes with the following models:CPEX2622LV ,CPEX2626LV ,CPEX3222LV ,CPEX3231LV ,CPEX3635LV.Specific specifications and parameters are shown in Table 1.
Ⅱ. Product Features
Up to 1500 V AC Insulation Withstand Voltage for Enhanced High-Voltage Safety
Compared with other High Current Power Inductor products in the CPEX family, the most outstanding feature of the CPEX-LV Series is its insulation withstand voltage of up to 1500 V AC.
Applications such as 800V HVDC systems, photovoltaic inverters, and industrial high-voltage drive equipment continuously operate at elevated bus voltages, placing stringent demands on insulation performance.
Thanks to its optimized insulation design, the CPEX-LV Series not only maintains stable operation under continuous high-voltage conditions but also effectively withstands transient events such as surge voltages and lightning impulses, providing reliable protection and significantly improving overall system safety and reliability.
Outstanding Current Handling Capability for Dynamic Load Conditions
In applications such as DC-DC converters and high-current switching regulators, drastic fluctuations in load current are commonplace, placing rigorous demands on an inductor's current-handling capability. The CPEX-LV series features excellent DC bias characteristics and utilizes core materials with high Bm (saturation magnetic flux density); this allows the inductors to easily handle instantaneous peak currents and transient spikes without suffering from saturation-induced failure, thereby ensuring reliable operation.
Furthermore, the series employs a flat-wire winding structure. This design not only achieves extremely low DC resistance (Rdc)—effectively reducing conduction losses—but also delivers a higher winding fill factor compared to conventional round-wire designs within the same footprint. This enhances heat dissipation and current-carrying capacity, enabling stable handling of very high currents within a compact package, thus balancing high performance with a space-saving form factor.
Shown below are the saturation current and temperature rise current curves for the CPEX3635LV series.
CPEX3635LV Series Saturation Current Curve
CPEX3635LV Series Temperature Rise Current Curve
1. Excellent thermal stability for complex and harsh operating conditions
The CPEX-LV series utilizes low-loss, high-temperature-resistant core materials combined with an optimized flat-wire coil winding design, ensuring exceptional thermal stability. With an operating temperature range of -55°C to +155°C (inclusive of ambient temperature and self-heating), the series exhibits minimal variation in inductance and DC bias characteristics due to temperature. This enables stable, long-term operation in complex, harsh environments—including high-frequency and high-temperature conditions—thereby ensuring the reliability of the end system.
2. Optimized electromagnetic compatibility (EMC) design to meet stringent interference requirements
As the power density of power electronics increases, electromagnetic interference (EMI) has become a critical issue, often disrupting normal equipment operation and destabilizing surrounding circuits. The CPEX-LV series employs a magnetically shielded structure that significantly reduces self-generated electromagnetic radiation and external circuit interference. This effectively optimizes electromagnetic compatibility (EMC), ensuring compliance with rigorous EMC standards. These characteristics make the series highly suitable for applications demanding strict EMC performance, such as server power supplies and telecommunications equipment.
3. Rapid customization services to precisely match end-user requirements
CODACA possesses in-house capabilities for developing core magnetic materials, enabling a rapid response to customer customization needs. We offer flexible customization options for the CPEX-LV series—ranging from core material selection and specific inductance values to dimensional adjustments for installation constraints. Our R&D team responds quickly and develops precise solutions to ensure a perfect match between the inductor and the end application, helping customers shorten development cycles and enhance product competitiveness.
III. Application Scenarios
CPEX-LV series of high current power inductors is widely used in high-voltage, high-current sectors. Key applications include data center server power supplies, photovoltaic inverters, industrial automation high-voltage drive equipment, and 800V HVDC systems for electric vehicles. These inductors have become the preferred choice for power engineers working on high-voltage designs.
IV. Production and Delivery
The CPEX-LV series has entered mass production with a stable lead time of 4–6 weeks, capable of meeting customers' large-scale production requirements.Furthermore,the products strictly comply with international environmental standards—including RoHS, REACH, and halogen-free requirements—balancing performance with environmental responsibility to suit global market applications.
V. Conclusion
CODACA’s CPEX-LV series—featuring high voltage tolerance, customization capabilities, and high current handling—precisely meets the core demands of high-voltage, high current applications. By providing efficient and reliable inductor solutions, the series empowers customers to achieve product upgrades and drive innovative breakthroughs.