Off the shelf SMD Ferrite coils are widely available and popular .The power ratings are adequate for many applications.The manufacturers are clear about the current ratings for saturation and copper heating .What the manufacturers often dont state is the repeatitive peak voltage rating.This is a potential trap because you could design a boost convertor producing hundreds of volts that works fine on the simulator and subsequently works fine on the bench.However it could fail down the track due to coil breakdown .This fail could be between turns or from terminal A to core to terminal B .Using a larger SMD coil than what is needed from a current ,Inductance standpoint should help.How much would overframing the coil help? Is there a curve for peak volts Vs time?Sharply rising voltages which commonly occur in SMPS would probably make breakdown more likely .Is there an equation that relates rate of rise of voltage to breakdown volts? What is the temperature dependance of this possible breakdown ? Could a coil thermaly runaway and expire ingloriously?
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