{
  "schema": "gallery_item_v1",
  "id": "llc-3kw-telecom",
  "title": "LLC Resonant · 3 kW · Telecom",
  "topology": "llc",
  "blurb": "380→48 V / 62 A telecom rectifier reference. ZVS verified, Hurley §10 LLC.",
  "spec": {
    "topology": "llc",
    "p_out_w": 3000,
    "v_in_min": 380,
    "v_in_max": 410,
    "v_out": 48,
    "i_out_max": 62.5,
    "fsw_hz": 100000,
    "delta_t_max_c": 40,
    "isolation_v": 4000,
    "ambient_c": 25,
    "lifetime_years": 10,
    "application": "telecom",
    "rohs": true,
    "notes": "OnTel rectifier reference design"
  },
  "design": {
    "spec": {
      "topology": "llc",
      "p_out_w": 3000.0,
      "v_in_min": 380.0,
      "v_in_max": 410.0,
      "v_out": 48.0,
      "i_out_max": 62.5,
      "fsw_hz": 100000.0,
      "delta_t_max_c": 40.0,
      "isolation_v": 4000.0,
      "ambient_c": 25.0,
      "lifetime_years": 10.0,
      "application": "telecom",
      "rohs": true,
      "notes": "OnTel rectifier reference design"
    },
    "core": {
      "pn": "ETD_ETD49-Ferroxcube_3C95",
      "vendor": "Ferroxcube",
      "material": "3C95",
      "shape": "ETD",
      "ae_mm2": 211.0,
      "ve_mm3": 24000.0,
      "le_mm": 114.0,
      "aw_mm2": 273.0,
      "al_nh": 3837.7,
      "bsat_t_mt": {
        "25": 530.0,
        "60": 475.0,
        "100": 420.0,
        "120": 390.0
      },
      "pcv_steinmetz": {
        "k": 6.140341819368694e-08,
        "alpha": 1.4,
        "beta": 2.85,
        "t_ref_c": 100
      },
      "mu_i": 3000.0,
      "f_max_hz": 500000.0,
      "price_usd": 7.24,
      "rohs": true
    },
    "n_pri": 11,
    "n_sec": 3,
    "wire_pri": {
      "pn": "Litz_50x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 0.849,
      "od_mm": 1.002,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 50,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 1.129
    },
    "wire_sec": {
      "pn": "Litz_400x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 2.4,
      "od_mm": 2.832,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 400,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 8.752
    },
    "n_par_pri": 8,
    "n_par_sec": 6,
    "fringing_factor": 1.019,
    "air_gap_mm": 0.041,
    "b_peak_t": 0.2,
    "b_peak_safe": true,
    "pcv_w": 3.36,
    "pcu_w": 3.419,
    "p_total_w": 10.553,
    "eta_est": 0.9965,
    "delta_t_c": 55.3,
    "hotspot_c": 80.3,
    "lk_uh": 40.0,
    "lm_uh": 800.0,
    "cps_pf": 98.62,
    "mtbf_h": 20059567.0,
    "pdiv_v": 540.0,
    "pdiv_margin_ok": false,
    "fill_factor": 3.448,
    "bom": [
      {
        "item": "Core",
        "pn": "ETD_ETD49-Ferroxcube_3C95",
        "vendor": "Ferroxcube",
        "qty": 1,
        "price_usd": 7.24,
        "alternatives": [
          {
            "pn": "ETD_ETD49-DMEGC_DMR95",
            "vendor": "DMEGC",
            "material": "DMR95",
            "ae_mm2": 211.0,
            "al_nh": 4221.5,
            "price_usd": 5.26,
            "match_quality": "geometry+AL match (drop-in candidate)",
            "batch_variation_pct": 15,
            "verify_note": "§13.8 verify per-batch before swap; inter-batch drift up to ±15% typical."
          },
          {
            "pn": "ETD_ETD49-TDK_PC95",
            "vendor": "TDK",
            "material": "PC95",
            "ae_mm2": 211.0,
            "al_nh": 4221.5,
            "price_usd": 7.74,
            "match_quality": "geometry+AL match (drop-in candidate)",
            "batch_variation_pct": 15,
            "verify_note": "§13.8 verify per-batch before swap; inter-batch drift up to ±15% typical."
          }
        ]
      },
      {
        "item": "Wire-PRI",
        "pn": "Litz_50x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 0.71,
        "price_usd_per_m": 1.129
      },
      {
        "item": "Wire-SEC",
        "pn": "Litz_400x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 0.19,
        "price_usd_per_m": 8.752
      },
      {
        "item": "Bobbin",
        "pn": "BOB-ETD-PBT",
        "vendor": "Pretak",
        "qty": 1,
        "price_usd": 0.8
      },
      {
        "item": "Tape (Kapton 0.05mm)",
        "pn": "3M-5413",
        "vendor": "3M",
        "length_m": 1.0,
        "price_usd_per_m": 0.3
      }
    ],
    "warnings": [
      "Using 8 parallel strands of Litz_50x0_1_PEU for I_rms=11.1A.",
      "Using 6 parallel strands of Litz_400x0_1_PEU for I_rms=69.4A.",
      "Loss breakdown: Pcv=3.36W (iGSE), Pcu=3.42W (Dowell+Ferreira), Extras=3.77W (term=2.274W, gap_eddy=0.0W, stray=1.5W, cap=0.0W)",
      "§17 Window overfilled (effective): used_Ku=3.45 > target=0.30 (litz_manual_served, eff_area=53mm² of core.aw=273mm² — 81% lost to bobbin/margin/pins).",
      "⚠️ PDIV E-field corner concentration: F=3.4× → E_local=13854V/mm vs breakdown/2.0=2698V/mm. Margin 0.19 < 1.0. Reference IEC 60664-1.",
      "§13.3 Dowell margin: h/δ=3.7; recommend Tier B FEM to confirm AC resistance.",
      "§13.10 Litz strand oversized: f_opt = 1168kHz vs design 100kHz; switching to thinner strands would not help — switch to solid AWG.",
      "§11.12 LLC gain insufficient: peak=0.30 < required 0.93 at Vin_min. Increase Lm/Lk ratio or pick smaller Cr.",
      "§11.12 Q=3.00 > 0.8 (heavy-load): gain curve sharp, sensitive to Cr tolerance.",
      "⚠️ §11.11 Ringing overshoot 3140V > 30%·Vbus (123V). Snubber required.",
      "§11.11 Damping ζ=0.000 < 0.1 — under-damped, will ring for many cycles.",
      "⛔ §11.7 Lifetime 0.4y dominated by 'coffin_manson'. Below typical 5-year service requirement.",
      "§11.7 Thermal cycling dominates: ΔT=55.3°C/cycle. Reduce ΔT via better thermal management or pick more compliant potting."
    ],
    "citations": [
      "McLyman, Transformer & Inductor Design Handbook, 4th ed.",
      "Self-study_Hoang.docx §1.2 Fundamentals of Magnetics",
      "Gemini_Claude.md §99.5 (PDIV surrogate, Planar stackup)"
    ],
    "trust_score": 60.6,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 20.0,
      "reference_benchmark": 8.6,
      "datasheet_match": 12.0,
      "lab_measurement": 0.0
    },
    "trust_grade": "B",
    "reliability_matrix": {
      "Lm_pct": 10.0,
      "Lk_pct": 20.0,
      "Pcv_in_range_pct": 25.0,
      "Pcv_dc_bias_pct": 50.0,
      "Rac_near_gap_pct": 50.0,
      "T_hotspot_C": 5.0,
      "EMI_Cps_pct": null,
      "PDIV_margin_pct": null,
      "lifetime_factor": 3.0
    },
    "not_valid_for": [
      "UL 1446 insulation system certification",
      "IEC 61558 / 62368 transformer certification",
      "AEC-Q200 automotive component qualification",
      "CISPR 22/32 EMI compliance claim",
      "Lifetime claim > 5 years without HALT calibration"
    ],
    "uncertainty_envelope": {
      "Lm_uH": {
        "value": 800.0,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 640.0,
        "ci_high_2sigma": 960.0,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 40.0,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 24.0,
        "ci_high_2sigma": 56.0,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 3.36,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 1.68,
        "ci_high_2sigma": 5.04,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 3.419,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 6.838,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 80.3,
        "uncertainty_pct": 6.23,
        "ci_low_2sigma": 70.3,
        "ci_high_2sigma": 90.3,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 540.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 270.0,
        "ci_high_2sigma": 810.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 98.62,
        "uncertainty_pct": 25.35,
        "ci_low_2sigma": 48.62,
        "ci_high_2sigma": 148.62,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 20059567.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 18855992.98,
        "ci_high_2sigma": 21263141.02,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [
      "§13.3 Dowell margin: h/δ=3.7; recommend Tier B FEM to confirm AC resistance.",
      "§13.10 Litz strand oversized: f_opt = 1168kHz vs design 100kHz; switching to thinner strands would not help — switch to solid AWG."
    ],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 500,
        "mean": 1018.3739,
        "stdev": 1174.8265,
        "p5": 202.1534,
        "p50": 480.4872,
        "p95": 3800.5771,
        "cpk_lower": 0.085,
        "cpk_upper": -0.039
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 500,
        "mean": 3.3631,
        "stdev": 0.3316,
        "p5": 2.8298,
        "p50": 3.3478,
        "p95": 3.9312,
        "cpk_lower": 0.847,
        "cpk_upper": 0.841
      },
      "eta": {
        "metric": "eta",
        "n_samples": 500,
        "mean": 0.9965,
        "stdev": 0.0001,
        "p5": 0.9963,
        "p50": 0.9965,
        "p95": 0.9967,
        "cpk_lower": 30.243,
        "cpk_upper": 30.282
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 500,
        "mean": 80.3525,
        "stdev": 2.9213,
        "p5": 75.7806,
        "p50": 80.2183,
        "p95": 84.8554,
        "cpk_lower": 0.922,
        "cpk_upper": 0.91
      },
      "preset": {
        "al_nh_pct": 25.0,
        "gap_mm_abs": 0.05,
        "b_pk_pct": 5.0,
        "steinmetz_k_pct": 10.0
      }
    },
    "llc_tank": {
      "fr_kHz": 100.0,
      "fm_kHz": 21.8,
      "Q": 3.003,
      "k_lm_over_lk": 20.0,
      "gain_min": 0.435,
      "gain_max": 0.3,
      "zvs_ok": true,
      "Cr_recommended_nF": 63.33,
      "notes": [
        "§11.12 LLC gain insufficient: peak=0.30 < required 0.93 at Vin_min. Increase Lm/Lk ratio or pick smaller Cr.",
        "§11.12 Q=3.00 > 0.8 (heavy-load): gain curve sharp, sensitive to Cr tolerance."
      ]
    },
    "inrush": {},
    "advanced_analysis": {
      "bertotti": {
        "P_hysteresis_W_per_m3": 1.7514,
        "P_classical_eddy_W_per_m3": 0.0015,
        "P_excess_W_per_m3": 0.2546,
        "P_total_W_per_m3": 2.0074,
        "fraction_h": 0.8724,
        "fraction_c": 0.0008,
        "fraction_a": 0.1268,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 200000.0,
        "in_audible_band": false,
        "spl_db_estimate": 31.8,
        "lambda_s_ppm": -1.5
      },
      "ringing": {
        "f_ring_mhz": 2.53,
        "z_ring_ohm": 636.87,
        "v_ring_pk": 3140.4,
        "damping_ratio": 0.0,
        "overlaps_emi_band": false,
        "snubber_r_ohm": 636.87,
        "snubber_c_pf": 295.9
      },
      "aging": {
        "L_total_h": 3456.0,
        "L_total_y": 0.4,
        "dominant": "coffin_manson"
      },
      "paschen": {
        "v_breakdown": 12594.0,
        "altitude_derating": 1.0,
        "safe": true
      },
      "humidity": {
        "moisture_uptake_pct": 0.118,
        "pdiv_derate_pct": 0.6,
        "aging_factor": 1.006
      }
    },
    "window_breakdown": {
      "core_window_mm2": 273.0,
      "after_walls_mm2": 207.9,
      "after_margin_mm2": 62.37,
      "after_pin_leadout_mm2": 53.01,
      "deduction_pct": 80.6,
      "wall_loss_mm2": 65.1,
      "margin_loss_mm2": 162.0,
      "margin_note": "margin tape 6.0mm × height=27.0mm",
      "pin_loss_mm2": 6.24,
      "leadout_loss_mm2": 3.12,
      "interleave_loss_mm2": 0.0,
      "bobbin_pn": "Norwe_ETD49_14pin",
      "ku_target": 0.3,
      "ku_key": "litz_manual_served",
      "used_ku": 3.448,
      "a_winding_mm2": 182.78
    },
    "bobbin_pn": "Norwe_ETD49_14pin",
    "material_score": {
      "loss": 76.0,
      "saturation": 100.0,
      "freq_fit": 100.0,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 90.0,
      "cost": 53.3,
      "availability": 100.0,
      "ap_fit": 83.3,
      "thermal": 80.0,
      "total": 87.0,
      "rationale": [
        "Pcv≈140 mW/cm³ at design point",
        "Bsat margin=52% at 85°C",
        "fsw/f_res=0.04 (f_res≈2667kHz)",
        "no DC bias requirement",
        "f_acoustic=200000Hz outside audible",
        "telecom-class material",
        "$7.24/qty1k",
        "4 cross-vendor equivalents — supply resilient",
        "Ap ratio 2.33 oversized",
        "Ve=24000mm³ for 3000W (ratio=1.00)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "ETD_ETD49-Ferroxcube_3C95",
        "vendor": "Ferroxcube",
        "material": "3C95",
        "shape": "ETD",
        "ae_mm2": 211.0,
        "ve_mm3": 24000.0,
        "score_total": 87.0,
        "score_breakdown": {
          "loss": 76.0,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 53.3,
          "availability": 100.0,
          "ap_fit": 83.3,
          "thermal": 80.0,
          "total": 87.0,
          "rationale": [
            "Pcv≈140 mW/cm³ at design point",
            "Bsat margin=52% at 85°C",
            "fsw/f_res=0.04 (f_res≈2667kHz)",
            "no DC bias requirement",
            "f_acoustic=200000Hz outside audible",
            "telecom-class material",
            "$7.24/qty1k",
            "4 cross-vendor equivalents — supply resilient",
            "Ap ratio 2.33 oversized",
            "Ve=24000mm³ for 3000W (ratio=1.00)"
          ]
        },
        "rationale": [
          "Pcv≈140 mW/cm³ at design point",
          "Bsat margin=52% at 85°C",
          "fsw/f_res=0.04 (f_res≈2667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "telecom-class material",
          "$7.24/qty1k",
          "4 cross-vendor equivalents — supply resilient",
          "Ap ratio 2.33 oversized",
          "Ve=24000mm³ for 3000W (ratio=1.00)"
        ]
      },
      {
        "pn": "PQ_PQ40_40-Ferroxcube_3C95",
        "vendor": "Ferroxcube",
        "material": "3C95",
        "shape": "PQ",
        "ae_mm2": 201.0,
        "ve_mm3": 17600.0,
        "score_total": 86.8,
        "score_breakdown": {
          "loss": 76.0,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 58.1,
          "availability": 100.0,
          "ap_fit": 100.0,
          "thermal": 58.7
        },
        "rationale": [
          "Pcv≈140 mW/cm³ at design point",
          "Bsat margin=52% at 85°C",
          "fsw/f_res=0.04 (f_res≈2667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "telecom-class material",
          "$5.62/qty1k",
          "4 cross-vendor equivalents — supply resilient",
          "Ap ratio 1.24 optimal",
          "Ve=17600mm³ for 3000W (ratio=0.73)"
        ]
      },
      {
        "pn": "PQ_PQ50_50-Ferroxcube_3C95",
        "vendor": "Ferroxcube",
        "material": "3C95",
        "shape": "PQ",
        "ae_mm2": 328.0,
        "ve_mm3": 36400.0,
        "score_total": 86.6,
        "score_breakdown": {
          "loss": 76.0,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 90.0,
          "cost": 41.3,
          "availability": 100.0,
          "ap_fit": 64.9,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈140 mW/cm³ at design point",
          "Bsat margin=52% at 85°C",
          "fsw/f_res=0.04 (f_res≈2667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "telecom-class material",
          "$11.22/qty1k",
          "4 cross-vendor equivalents — supply resilient",
          "Ap ratio 3.51 much oversized",
          "Ve=36400mm³ for 3000W (ratio=1.52)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 99.65,
    "trust_grade": "B",
    "trust_score": 60.6,
    "core_pn": "ETD_ETD49-Ferroxcube_3C95",
    "bobbin_pn": "Norwe_ETD49_14pin",
    "n_pri": 11,
    "n_sec": 3,
    "air_gap_mm": 0.041,
    "p_total_w": 10.55,
    "hotspot_c": 80.3,
    "b_peak_t": 0.2
  },
  "screenshot_path": "/marketing/gallery/llc-3kw-telecom.png",
  "deep_link": "/calculator?gallery=llc-3kw-telecom",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}