Process improves common mode chokes in EVs and renewable energy

May 13, 2020 //By Nick Flaherty
A new process for common mode chokes can be used for a 250A choke with a 12mm diameter in a high power charger
A new process for common mode chokes can deliver a 250A choke with a 12mm diameter in a high power charger

A new manufacturing process for common mode chokes from Vacuumschmelze provides high load currents for sustainable mobility and renewable energy designs

The VACOCOIL chokes uses shaped copper bars that are placed on the core instead of the conventional heavy wire winding. This allows a cost-effective production which also takes into account the highest demands on technical cleanliness and process capability.

VACOCOILs are used as common mode chokes and are characterized by a significantly improved attenuation at frequencies above 1 MHz, a minimized winding capacity and up to 10 times improved impedance at 10 MHz.

For a High Power Charger (HPC) for charging electric vehicles, VAC developed a 250A choke with a 12 mm bar diameter. The chokes are characterized by highest permeability and lowest losses in combination with excellent thermal properties. Depending on the individual design, these chokes are suitable for load currents up to several hundreds of amps. In addition to charging equipment for electric vehicles, these chokes are used directly inside of electric vehicles for low weight and compact design. The VACOCOIL common mode chokes can also be used in high-performance inverters for wind and solar power systems. 

"VACOCOIL is a cost-optimized solution for numerous industrial applications with superior technical characteristics. We are proud that we have developed this manufacturing process, which enables us to offer chokes with unique properties", said Susanne Ganz, Product Manager ECA at VAC.

More details are at

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