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Electrical & Electronics

Magnetically Integrated Power Module

Type: Integrated magnetics (planar / wound)

Topology: LLC / CLLC / coupled

Core: Ferrite / nanocrystalline / powder

Power: 1 – 100 kW

Mount: PCB or chassis, conduction cooled

Product Detail | Technical Information | Packaging | More

Product Detail

Shanghai MAC is a leading Magnetically Integrated Power Module manufacturer and supplier.

A magnetically integrated power module is a combined magnetic assembly that merges two or more magnetic functions—such as a transformer, resonant inductor, and coupled choke—into one core structure for power converters and storage units. It is used in battery energy storage systems, solar and wind inverters, EV onboard chargers, UPS, and telecom and industrial power supplies where board space and loss are critical. Conventional discrete magnetics take large volume, add stray loss, and create EMI and thermal hotspots that lower converter efficiency, complicate layout, and raise system cost and weight. Our modules apply integrated planar or wound cores with the selected ferrite or nanocrystalline material to cut component count, shrink volume, reduce copper and core loss, and raise power density for compact, high-efficiency power stages, simpler thermal design, and energy-storage magnetic assemblies.

If you want to know more about our magnetic components products or Magnetically Integrated Power Module price please feel free to contact us, we will reply you within 24 hours.

1. Single core with ≥2 windings integrates transformer and coupled choke for power converters.

2. Planar, toroidal or PQ cores are selected based on converter topology and power rating.

3. Copper/litz windings use flux sharing to optimize coupling and cut high-frequency losses.

4. Magnetic materials match switching frequency; modules range 1–100 kW with proper thermal design.

5. Integrated magnetics reduce total loss, and cooling prevents saturation for stable continuous operation.

1. Higher Power Density: Single integrated core replaces discrete magnetics to shrink PCB space and overall height.

2. Lower Total Loss: Optimized flux & winding design cuts core/copper loss, boosting efficiency and shrinking heat sinks.

3. Reduced EMI & Noise: Tight coupling lowers stray fields and CM noise, easing filter and shielding requirements.

4. Simpler Thermal Path: Unified heat structure removes hotspots, supporting reliable conduction cooling under load.

5. Fewer Parts & Higher Reliability: Combined magnetic module reduces BOM, solder joints and assembly failures.

1. Solar & Wind Inverters: Ferrite planar magnetics deliver high efficiency to shrink grid-tied inverter designs.

2. EV Onboard Chargers & Drives: Low-profile low-EMI integrated magnetics suit 3–22 kW OBC and traction converters.

3. UPS & Telecom Power: Custom coupled inductors provide thermal margin for reliable interleaved industrial converters.

4. Energy Storage Converters: Low-loss integrated magnetics boost power density for BESS bidirectional charge-discharge.

5. DC Fast Charging Units: Compact magnetics cut equipment size and maintain stable high-current charging output.

Technical Information Of Magnetically Integrated Power Module:

Product Series	On-Board Charger (OBC) Magnetically Integrated Module Series	Energy Storage Inverter Magnetically Integrated Module Series	Industrial Power Supply Magnetically Integrated Module Series
Product Model	MI-OBC-3.3kW	MI-ESS-5kW	MI-IPS-1kW
	MI-OBC-6.6kW	MI-ESS-10kW	MI-IPS-3kW
	MI-OBC-22kW	MI-ESS-20kW	MI-IPS-5kW
Integration Type	3.3kW: Main Transformer + 1 Resonant Inductor (2-in-1)	5kW/10kW: Common-Mode Inductor + Differential-Mode Inductor + Isolation Transformer (3-in-1)	1kW: Filter Inductor + Auxiliary Transformer (2-in-1)
	6.6kW: Main Transformer + 2 Resonant Inductors (3-in-1)	20kW: Dual-Set Common/Differential-Mode Inductors + Dual Isolation Transformers (6-in-1)	3kW/5kW: Main Inductor + Filter Inductor + Main Transformer (3-in-1)
	22kW: 3-Phase Main Transformer + 3 Resonant Inductors (6-in-1)	-	-
Core Material	Magnetic Core: High-Bs Mn-Zn Ferrite (PC44/PC50)	Magnetic Core: Low-Loss Mn-Zn Ferrite (PC47) + Amorphous Alloy	Magnetic Core: High-Frequency Low-Loss Mn-Zn Ferrite (PC40)
Core Material	Winding: 150-Class Temperature-Resistant Enameled Copper Wire	Winding: 180-Class Temperature-Resistant Enameled Copper Wire	Winding: 150-Class Temperature-Resistant Enameled Copper Wire
Rated Power	3.3kW / 6.6kW / 22kW	5kW / 10kW / 20kW	1kW / 3kW / 5kW
Input Voltage Range	220V±10% AC (50/60Hz)	220V/380V±10% AC (50/60Hz)	110V/220V±10% AC (50/60Hz)
Input Voltage Range	380V±10% AC (3-Phase, for 22kW only)	220V/380V±10% AC (50/60Hz)	110V/220V±10% AC (50/60Hz)
Output Voltage Range	280-450V DC (3.3kW/6.6kW)	400-800V DC (Energy Storage Inverter Side)	12V/24V/48V DC (Auxiliary Output)
Output Voltage Range	500-800V DC (22kW)	400-800V DC (Energy Storage Inverter Side)	200-400V DC (Main Output)
Insulation Class	3kV AC (No Breakdown in 1min)	5kV AC (No Breakdown in 1min)	2kV AC (No Breakdown in 1min)
Insulation Class	22kW: 5kV AC (No Breakdown in 1min)	5kV AC (No Breakdown in 1min)	2kV AC (No Breakdown in 1min)
Magnetic Loss	≤300mW/cm³ (100kHz, 25℃)	≤250mW/cm³ (50kHz, 25℃)	≤350mW/cm³ (150kHz, 25℃)
Magnetic Loss	22kW: ≤280mW/cm³ (80kHz, 25℃)	≤250mW/cm³ (50kHz, 25℃)	≤350mW/cm³ (150kHz, 25℃)
Dimensions (L×W×H)	3.3kW: 105×48×45mm	5kW: 130×65×55mm	1kW: 85×40×38mm
	6.6kW: 115×52×50mm	10kW: 150×75×62mm	3kW: 100×45×42mm
	22kW: 195×88×60mm	20kW: 200×90×70mm	5kW: 120×50×48mm
Operating Temperature Range	-40℃~125℃	-30℃~105℃	-25℃~110℃
Protection Class	IP40 (Module Body)	IP54 (Outdoor Type) / IP40 (Indoor Type)	IP30 (Module Body)
Certification Standards	IEC 61558-2-16, GB/T 18487.1	IEC 62109-1, GB/T 34120	IEC 61558-2-4, GB/T 19212.1
Mounting Method	PCB Through-Hole Soldering / Bolt Fixing	DIN Rail Mounting / Bolt Fixing	PCB Through-Hole Soldering / Snap Fixing

Packing of Magnetically Integrated Power Module:

Standard Packaging

Each module is wrapped with anti-static foam, and protective caps are fitted on terminals to prevent short circuit, leakage and oxidation. Every module is placed individually into a reinforced box with EPE foam to fix the core, leads and terminals. Each box contains a certificate of conformity, test report and product label.

Multiple boxes are neatly stacked with dividers inside a thickened export corrugated carton. The carton is sealed and reinforced with packing straps. For sea freight, cartons are loaded onto IPPC-marked fumigated wooden pallets, wrapped with stretch film and affixed with shipping marks and labels.

Shipping

We support FCL/LCL sea freight, air freight and international express, selected based on cargo quantity, volume, gross weight and destination. Applicable trade terms: EXW, FOB, CIF. Other terms are available upon request. Freight cost is calculated by actual cargo volume, gross weight, destination and transportation method. Shipping documents include packing list, commercial invoice, bill of lading and IPPC fumigation certificate.

Lead Time

Sample orders: 15–25 working days

Standard batch orders: 15–25 working days

Customized dimension & material orders: 25–40 working days

Q1: Can the magnetically integrated power module work continuously under high ripple current?

A: Yes. Our integrated magnetic assemblies are designed with optimized core and winding structure. It can sustain high ripple current as long as operation stays within the rated current and temperature range.

Q2: What core materials are available for custom integrated magnetic modules?

A: Ferrite, nanocrystalline, amorphous and powder cores are optional. We select suitable material based on your switching frequency, power level and loss budget.

Q3: Can you provide design simulation report before mass production?

A: Yes. We can deliver magnetic simulation, thermal simulation and loss analysis reports after confirming your specification, to verify performance before formal manufacturing.

Q4: What tests will be performed on the integrated magnetic module before delivery?

A: We carry out inductance test, Hi-pot insulation test, winding resistance measurement and temperature rise test. Full test reports can be supplied together with shipment.

Q5: What are the main advantages of integrated magnetics compared with multiple discrete components?

A: Integrated magnetics combines transformer, inductors and chokes into one core, saving space and cutting stray losses. Discrete magnetics are simpler for maintenance but occupy larger PCB area and bring higher EMI risk. Integrated design is preferred for high power density energy storage converters.

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