> A 0R025 RSENSE resistor means that we're ramping the current up to 4A before 
> releasing the energy stored in the inductor. 4A is a lot of current. The 
> magnetic field produced by the inductor is so strong that it affects 
> everything around it, even very carefully routed traces

> I did some experimenting and:
> 
> -- moving the inductor away is a solution, but it needs to be *far* away, 8cm 
> or so,
> 
> -- shielding the inductor, while improving the situation, increases the 
> current consumption 2x, produces audible noise and heats up the shield 
> considerably, so it is not a solution.
> 
> All in all, I don't think a circuit with an RSENSE of 0R025 is feasible, at 
> least not with a 5cm x 5cm board. I'll be going back to 0R050 and 0R100 and 
> smaller inductors.

Have you tried a toroidal inductor?  They're better behaved in this respect, 
even though they're physically large, especially for the high current one you'd 
need.

Here's a datasheet from one manufacturer:

http://www.cooperindustries.com/content/dam/public/bussmann/Electronics/Resources/Data%20Sheets/Bus_Elx_DS_PM%204304_LPCI_Series.pdf

- John

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