Powder core , non-linear inductors for Boost PFC?

[zenerbjt]

Above what power level, and at 240VAC input , would you say that Powder core, non-linear inductors (invariably they will be torroids) would be pretty essential to use instead of gapped ferrite core inductors?

 

[Akanimo]

You might have to compare datasheet core loss density data (or curves) for ferrite and powder cores of the same volume for several core volumes to find out.

 

[Easy peasy]

Usually the ferrite solution, is lighter, smaller, and lower losses - at any power level - Fe-powder may well be a bit cheaper though ....

 

[zenerbjt]

Thanks...though big ferrite cores like the PM114/93 are more awkward to mount on the PCB than a big torroid?
Also, the ferrite cores have bobbins which tend to make you wind turns in multiple layers, which is bad for proximity loss?
Whereas torroids let you spread the turns out.
Powder cores come in these advantageous torroid shapes, as they can be "integrated gapped".
PM114/93

https://www.tdk-electronics.tdk.com/inf/80/db/fer/pm_114_93.pdf

--- Updated Nov 25, 2020 ---

also, is the attached the best way to design inductors with a powder core?

--- Updated Nov 25, 2020 ---

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