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In electronic component applications, the stability and compliance of power supply circuits directly impact product performance, and improper inductor selection often becomes a major stumbling block that affects the entire system. Recently, a customer faced difficulties due to issues with power supply inductors, but ultimately resolved the problem with Gujiing’s one-stop technical support. Let’s take a look at the entire process!

The customer had previously used the DLCP112 I-shaped shielded inductor in their power supply products but encountered two major challenges: First, despite multiple attempts, the product failed to pass safety compliance testing, hindering its market launch. Second, the inductor generated significant heat during operation, with temperatures reaching over 80 degrees Celsius, which not only affected the stability of the power supply but also posed potential safety hazards.

Upon receiving the client’s request, the Gujing team immediately began an analysis and developed a tailored solution based on the power supply circuit characteristics and the client’s pain points. Considering the limitations of I-core inductors in heat dissipation and safety compliance, we first proposed switching to a ferrite ring inductor—the ferrite ring structure offers superior advantages in magnetic field concentration and heat dissipation efficiency, capable of fundamentally addressing the overheating issue.

To further increase the current-carrying capacity and mitigate heat generation, the team optimized the inductor design by increasing the wire gauge to enhance current handling capability. Additionally, recognizing the critical importance of safety compliance testing and the fact that inductance is just one factor affecting compliance, we produced multiple samples of ferrite ring inductors with varying inductance values for the client to test and select, ensuring the most suitable parameters were identified.

After multiple rounds of testing and validation, the client ultimately selected the T1508 model with a 120uH inductance (tolerance ±20%). Not only does this model demonstrate excellent safety compliance and pass all tests flawlessly, but we have also equipped it with a UL-certified sleeve to further enhance its anti-interference performance, helping the power supply circuit meet EMC (Electromagnetic Compatibility) standards.

Currently, testing of this inductor sample has been completed, and Gujing has expedited the production of 65 ferrite ring inductors for the customer to build prototypes, paving the way for subsequent mass production. From problem diagnosis and solution design to sample customization, testing and validation, and small-batch production support, Gujing provides one-stop technical services, closely following up to resolve customer challenges throughout the process. We have not only overcome power supply safety compliance and overheating issues but also ensured the progress of product R&D.

Moving forward, Gujing will continue to leverage its professional technical expertise and flexible customization solutions to address pain points in electronic component applications for more customers. We provide end-to-end support from component selection to implementation, helping products reach the market efficiently and in compliance with regulations!