Design of a Novel Composite Magnetic Coupler Structure for Electric Vehicles with Reduced Losses

To address the issues of heavy weight and excessive magnetic core materials in wireless charging magnetic couplers for electric vehicles, this study proposes a novel composite shielding layer magnetic coupler structure. The structure is composed of ferrite magnetic sheets, nanocrystalline ribbons, and aluminum plates. By analyzing and comparing the performance of ferrite and nanocrystalline magnetic cores using Maxwell software, the composite shielding layer structure and the material composition ratio of each component were optimized. Compared with traditional magnetic couplers composed of ferrite magnetic plates and aluminum plates, the proposed composite shielding layer magnetic coupler reduces the volume and weight of the magnetic core by 50% while maintaining essentially the same inductance and AC resistance. Finally, an experimental platform with a transmission distance of 20 cm was built to validate the design.