Step-up Chopper Inductors

Name: Step-up Chopper Inductors | Boost Regulator Inductors | Boost Converters - Frigate
Price: 249.00 USD
Availability: InStock

Modern chopper circuits operate at high switching frequencies often beyond 20 kHz—which can introduce core saturation, EMI noise, and voltage ripple. Step-up chopper inductors use high-permeability ferrite or powder cores with optimized AL values, ensuring magnetic stability under high dI/dt conditions. The design minimizes flux leakage and supports tight coupling for ripple-free performance.

Rated DC Voltage

Up to 1000 VDC

Operating Switching Frequency

20 kHz to 150 kHz

Inductance Range

10 µH to 1 mH

Inductance Tolerance

±10% at 25°C, measured at 10 kHz or rated ripple current

Core Material

High-frequency ferrite / iron powder / custom gapped core

Product Description

High peak currents in boost converters can saturate inferior cores, leading to inductor failure or thermal runaway. We design with deep saturation margin using gapped cores and custom B-H loop characterization, supporting continuous-mode conduction (CCM) without magnetic breakdown. This allows safe operation even during load transients or startup surges.

Maximum Saturation Current

Up to 200 A peak

Rated Continuous Current

Up to 100 A RMS

Winding Type

Copper with Litz wire or foil for skin effect mitigation and reduced high-frequency resistance

Thermal Class

Class H (180°C rated insulation system with verified thermal rise performance)

Core Loss Density

≤ 250 mW/cm³ at rated flux and frequency

Dielectric Strength

2.5 kVDC between winding and core

Temperature Rise

≤ 60°C over ambient at rated load and natural convection

Mounting Configuration

Through-hole or base-mount with vibration isolation

EMI Considerations

Shielded construction available; optimized leakage inductance for differential mode noise control

Standards Compliance

Designed to meet IEC 61558 / IEC 60076-6 / MIL-STD-202

Technical Advantages

Thermal management is a major concern in tightly packed SMPS and automotive ECUs. Step-up chopper inductors are built using low-loss core materials and copper windings with high fill factor, reducing I²R losses. Optional vacuum impregnation and thermally conductive encapsulants ensure minimal thermal resistance and excellent heat dissipation across the core and winding body.

Fast switching converters generate radiated and conducted noise. We incorporate shielded core designs, controlled leakage inductance, and interleaved winding strategies to limit differential and common-mode noise. These inductors contribute significantly toward helping your system pass EN 55032 / CISPR 32 and MIL-STD-461G EMI standards.

Let's Get Started

Need reliable Heat Sinks for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Solar MPPT Boost Converters

Maintains constant output voltage by stepping up variable solar panel voltage to match inverter input for efficient energy harvesting.

Battery-Powered Industrial Drives

Supports regulated voltage amplification from low-voltage battery sources to drive high-power motor controllers in portable or off-grid equipment.

Telecom Power Supply Modules

Used in 48V to 72V DC-DC converters to stabilize output for telecom base stations under varying load and line conditions.

Aerospace Avionics Systems

Provides regulated high-voltage DC in power conditioning units for avionics where weight, thermal stability, and electromagnetic compliance are critical.

Defense Radar and Communication Units

Boosts low-voltage DC supply to higher levels in pulsed power systems requiring rapid switching and precise energy transfer.

Uninterruptible Power Supplies (UPS)

Enables voltage stepping for battery backup systems during inverter mode, ensuring consistent DC link voltage under transient load conditions.

Inconsistent Inductance Under Load Variations

Most inductors exhibit inductance drift at higher loads. Our products are designed with stable L vs. I characteristics and use distributed air gaps or non-linear magnetic materials that flatten the saturation curve. This ensures consistent energy transfer and better duty cycle control across full load conditions.

Our chopper inductors are built to meet custom electrical and mechanical specs. Whether you need vertical/horizontal mount, specific creepage/clearance distances, potting, or tap configurations, we support full design customization to integrate seamlessly into your converter architecture.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate design step-up chopper inductors to avoid core saturation at high load currents?

Frigate uses custom gapped cores and selects materials with high saturation flux density. Each inductor is designed based on peak current and duty cycle to prevent magnetic overload. Saturation testing is done under worst-case load conditions. This ensures the inductance stays stable even during transient surges.

What makes Frigate’s step-up chopper inductors suitable for high-frequency switching applications?

Frigate selects low-loss ferrite materials that support switching frequencies above 50 kHz. The winding layout is optimized to reduce eddy current and skin effect losses. Each inductor is tested for high Q-factor and minimal core heating. This supports efficient operation in modern high-frequency boost converters.

How does Frigate handle thermal performance in compact inductor designs?

Frigate uses thermally conductive encapsulation and high-copper fill windings to manage heat. Core geometry is selected to minimize thermal hot spots. Inductors undergo thermal cycling tests to verify reliability over operating temperature ranges. This allows safe operation in confined enclosures without active cooling.

Can Frigate customize step-up chopper inductors for specific ripple current limits?

Yes, Frigate designs inductors based on your ripple current and switching frequency requirements. Core and winding parameters are adjusted to achieve target ΔI. FEM simulations are used to verify magnetic performance. This ensures the ripple stays within control limits under full load.

How does Frigate ensure EMI compliance in chopper inductor designs?

Frigate uses shielded cores, optimized winding symmetry, and controlled leakage inductance to suppress EMI. Layout is designed to minimize loop area and radiated emissions. All inductors are tested under conducted and radiated EMI standards. This helps customers pass EMI certification like CISPR or MIL-STD.

Get Clarity with Our Manufacturing Insights

Standardization Opportunities in Sheet Metal Components for Multi-Product D2C Platforms

D2C brands operate on aggressive timelines, high SKU diversity, and demand volatility. sheet...

Design Considerations for High-Efficiency Solar Inverter Transformers

Global solar capacity continues to expand at a rapid pace, projected to exceed 1,500 GW by 2030 according...

Incoterms Selection Guide When Importing Custom Check Valves for Offshore Oil and Gas Projects

Procurement teams do not treat Incoterms as a formality when they import custom check valves for...

How Toroidal Transformers in Electronics Help Reduce EMI

Electromagnetic interference (EMI) presents a serious challenge in the design of modern electronic systems....

A Comprehensive Guide to Sizing HVAC Ball Valves for Energy Efficiency

Energy costs from HVAC systems account for nearly 40% of total energy use in commercial buildings. Every...

Can JIT Supply Chains Survive in an Era of Global Disruptions and Growing Challenges?

Manufacturers depend on precision and efficiency. A missing part can halt production, cause financial...

Hot Roll forging vs. Cold Roll forging - Choosing the Right Process for Your Needs

Forging is a key process of modern manufacturing, shaping raw materials into components that power industries...

Key Factors to Consider When Sourcing Aluminum Heat Sink Extrusions for Electronics

Thermal control has become one of the most critical parameters in electronic design today. Modern devices...

Affordable CNC Machining for High-Quality Results at Competitive Prices

How can high-quality parts be created while keeping costs down? This challenge is especially pressing...

The Benefits of End-to-End Product Lifecycle Management for Manufacturers

Are manufacturers struggling with tracking products’ journey from design to end-of-life? Managing...

We'd love to Manufacture for you!

Submit the form below and our representative will be in touch shortly.

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

Step-up Chopper Inductors

Rated DC Voltage

Operating Switching Frequency

Inductance Range

Inductance Tolerance

Core Material

Product Description

Maximum Saturation Current

Rated Continuous Current

Winding Type

Thermal Class

Core Loss Density

Dielectric Strength

Temperature Rise

Mounting Configuration

EMI Considerations

Standards Compliance

Technical Advantages

Let's Get Started

Industry Applications

Inconsistent Inductance Under Load Variations

Related products

3-Phase Output Chokes

Battery Converter Chokes

Output Chokes

Smoothing Chokes

Having Doubts? Our FAQ

Get Clarity with Our Manufacturing Insights

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Step-up Chopper Inductors

Get Latest Price

Step-up Chopper Inductors

Get Latest Price