Optimized Coupling Coil Geometry for High Wireless Power Transfer Efficiency in Mobile Devices

Wireless Power Transfer (WPT) enables efficient, contactless charging for mobile devices by eliminating mechanical connectors and wiring, thereby enhancing user experience and device longevity. However, conventional WPT systems remain prone to performance issues such as coil misalignment, resonance instability, and thermal losses. Addressing these challenges involves designing coil geometries that operate at lower resonant frequencies to strengthen magnetic coupling and decrease resistance. This work introduces a WPT system with a performance-driven coil design aimed at maximizing magnetic coupling and mutual inductance between the transmitting (Tx) and receiving (Rx) coils in mobile devices. Due to the nonlinear behavior of magnetic flux and the high computational cost of simulations, exploring the full design space for coils using ANSYS Maxwell becomes impractical. To address this complexity, a machine learning (ML)-based optimization framework is developed to efficiently navigate the design space. The framework integrates a hybrid sequential neural network and multivariate regression model to optimize coil winding and ferrite core geometry. The optimized structure achieves a mutual inductance of 12.52 μH with a conventional core, outperforming many existing ML models. Finite element simulations and experimental results validate the robustness of the method, which offers a scalable solution for efficient wireless charging in compact, misalignment-prone environments.