Bourns Introduced High-Current Coupled Inductor for 48 V Hybrid and IBC Converters

Bourns has introduced the MAG-3002562, a high-current coupled inductor optimized for 48 V to 12 V DC-DC conversion in hybrid and intermediate bus converter (IBC) architectures.

This high-current inductor targets next-generation high-frequency GaN-based power stages in data center, telecom, and high-performance computing systems where power density, efficiency, and low profile are critical.

Key features and benefits

The MAG-3002562 is a single model, high-current coupled inductor specifically tailored for hybrid and IBC topologies operating from a 48 V input to a 12 V output. Its construction combines a low-profile magnetic stack, flat-wire winding, and low-loss ferrite core to minimize both AC and DC losses at elevated switching frequencies.

• Optimized for 48 V to 12 V hybrid converters – suited for architectures where a coupled inductor enables multiphase or hybrid conversion stages, improving efficiency in 48 V distributed power systems.
• High-frequency GaN-ready design – low-loss ferrite core and flat wire winding help reduce AC loss and copper loss at high switching frequencies typically used with GaN FETs.
• High saturation capability – typical saturation current around 86 A at 25 °C and 70 A at 100 °C (30% inductance drop), enabling high current operation with thermal margin.
• Low profile, compact footprint – height below 10 mm (9.75 mm) supports tight height constraints in quarter-brick and other low-profile power modules.
• Low DCR and low ESR construction – typical DC resistance of 1.77 mΩ helps reduce conduction losses and improves overall converter efficiency.
• Wide operating temperature range – specified operation from -40 °C to +125 °C for telecom and industrial environments.

In practice, this combination means designers can push higher current through a compact magnetics element without excessive temperature rise, while maintaining efficiency over a wide range of load and ambient conditions.

Typical applications

The MAG-3002562 is intended for 48 V distributed power architectures where an intermediate 12 V bus is used to feed downstream point-of-load converters. These applications increasingly rely on high-frequency GaN-based stages to reach higher power densities and reduce board area.

Typical use cases include:

• 48 Vin – 12 Vout hybrid converters in data center racks and cloud infrastructure where hybrid topologies (e.g., series resonant plus synchronous rectification with coupled inductors) are applied to optimize efficiency.
• High-frequency GaN converters used in telecom base stations and high-performance computing power shelves, where the inductor must tolerate high ripple current and fast switching transitions.
• Quarter-brick IBC modules that must fit into standard mechanical envelopes while delivering high current at 12 V for blade servers, networking equipment, and storage systems.

In these environments, a single coupled inductor like the MAG-3002562 can simplify magnetics design, support multiphase or interleaved structures, and help reduce the number of discrete inductors on the board.

Technical highlights

The inductor features coupled windings and specifies both main inductance and leakage inductance for the relevant pins.

Electrical parameters (summary)

All values and conditions are according to the manufacturer’s release and should be confirmed against the latest datasheet for detailed design work.

In practical terms, the relatively low inductance value combined with high saturation current is typical for coupled inductors used in high-current step-down applications, where the inductor must accommodate high ripple currents yet maintain sufficient inductance over the operating range.

Design-in notes for engineers

For power design engineers and component specifiers, the following points can help when integrating the MAG-3002562 into a new or existing 48 V distributed power platform.

• Confirm inductance and leakage requirements
  • Make sure the 2.6 µH main inductance and specified leakage inductance align with the intended hybrid or IBC topology, particularly if the design relies on leakage inductance for resonance or current sharing.
• Check thermal performance and derating
  • The typical saturation currents of 86 A at 25 °C and 70 A at 100 °C are specified at 30% inductance drop; for long-term reliability, consider derating current such that the inductor operates with additional headroom relative to these values.
• Evaluate loss budget at target frequency
  • The low-loss ferrite core and flat wire construction are optimized for high-frequency operation, but designers should still perform core-loss and copper-loss calculations at the intended switching frequency to validate efficiency targets.
• Mechanical integration and clearance
  • The <10 mm height (9.75 mm) is advantageous for low-profile modules; ensure adequate creepage/clearance and mechanical stability for the specified 300 VAC, 1 s isolation test condition.
• EMI and layout considerations
  • Coupled inductors can reduce loop area and help control EMI; place the MAG-3002562 close to the switching devices, use wide copper planes for current paths, and consider shielding or guard traces if the layout is particularly dense.
• Compatibility with GaN-based stages
  • For GaN-based designs, verify that voltage overshoots and dv/dt remain within the magnetics insulation and system limits, and that the coupled inductor behaves as expected under fast transient conditions.
• Supply chain and second-sourcing strategy
  • As this is a specific Bourns model, consider a supply chain strategy that includes stocking levels for critical power platforms and a review of potential second-source alternatives with compatible electrical and mechanical characteristics, using the MAG-3002562 data as the primary benchmark.

Because the press release is the initial announcement, detailed mechanical drawings, footprint recommendations, and additional electrical curves (such as L vs. I and temperature rise curves) should be taken from the official manufacturer datasheet once available.

Source

This article is based on information provided in the official Bourns new product release for the MAG-3002562 high-current coupled inductor, complemented by general design considerations for 48 V distributed power systems and hybrid/IBC converter architectures as typically found in data center, telecom, and high-performance computing applications.

References

1. Bourns New Product Release – Model MAG-3002562 High-Current Coupled Inductor
2. Bourns official website – Magnetic products overview