5 Reasons Core-and-Wire RF Components Aren’t Going Anywhere

Many component suppliers continue to rationalize magnetic core and wire components to focus on developing newer technologies. Meanwhile these devices are still in high demand for a wide range of new and existing customer systems from wideband Rx/Tx chains at lower frequencies (<≈11 GHz) to reference designs for integrated SOCs.

Mini-Circuits has been designing and manufacturing essential RF passive components utilizing core-and-wire construction for more than 55 years, and our policy hasn’t changed: when a customer designs our part into their system, we’re committed to supports them through the life of their program and taking every measure to minimize risk of PCN or EOL.

Conventional wisdom might call that a losing investment strategy. That hasn’t been what we’ve observed in practice. Here are a few reasons why Mini-Circuits’ core and wire portfolio continues to be a mainstay for RF system designs:

Wideband Performance

Designing components for true wideband performance at lower frequencies such as HF, VHF, UHF and even ISM bands is challenging because nominal operating frequency range (specified in MHz and GHz) requires a much wider fractional bandwidth (in octaves or decades). Few technologies provide wideband flat response better than core and wire. That’s why core-and-wire couplers, diplexers and other devices remain so popular in DOCSIS® 4.0 broadband access systems, which typically operate from 5 to 684 MHz (>2 decades) upstream and 108 to 1794 MHz (>1.5 decades).

Tiny Footprint

The timeline of electronics always progresses in the direction smaller, lighter, more powerful and lower cost (SWAP-C). Fortunately, core and wire components were ahead of their time on these dimensions and still meet design requirements for even the most demanding modern systems where miniaturization is paramount. For example, the footprint of a Mini-Circuits TC-series core-and-wire transformer is only 0.15 x 0.15” (3.8 x 3.8mm).

Power Handling

They may be small, but they’re every bit as mighty. Core-and-wire parts achieve very high power handling without compromising on space requirements. Mini-Circuits’ SYBDC-27-82VHP+ high-power bi-directional coupler, for example, handles up to 100W RF input power while occupying only 0.5 x 0.38” of board space.

Cost

Performance doesn’t mean much if the finished product isn’t competitive in the marketplace. That means designers need to balance the performance of their system with the total cost of their BOM. Core-and-wire passives offer a proven solution to support critical functions in the signal chain without bloating material costs and eroding margins – or compromising on performance.

Quality and Reliability

The prevalence of RF systems in extreme operating conditions from military vehicles to spaceborne satellite payloads necessitates components that perform reliably under a whole battery of environmental stresses. Mini-Circuits’ core-and-wire components are designed into applications with some of the most stringent qualification requirements and environmental ratings, making them a trusted workhorse for tough jobs, whether off-the-shelf, or with upscreening for space or Hi-Rel systems.

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Bottom line, core-and-wire isn’t going anywhere soon and neither are we. While sourcing and supply chain management have become a challenge as much of the supply base reorganizes its resources for newer technologies, Mini-Circuits will continue to serve the market with one of the industry’s widest catalog selections plus custom parts, and over 55 years of in-house design and manufacturing experience.