Wiki article · Collection 03

High-Power Coil Design

Engineering reference on High-Power Coil Design for wireless power system design, integration, and deployment.

6 minArticle 43/50Coil Design

High Power Coil Design — educational diagram — Fig.: Educational diagram for “High Power Coil Design”.

High-power coil design pushes current density, flux density, and thermal limits simultaneously. At 10–50 kW class docks, transmitter coils carry hundreds of amperes of resonant current; receivers must handle induced voltages and currents without exceeding insulation or capacitor ratings.

Scaling from a 3 kW prototype to 30 kW is not linear — Rac, ferrite saturation, and leakage flux often force new geometry rather than proportionally larger wire.

01Key limits

AC current density in inner turns after proximity model.
Ferrite Bpeak at min gap and max current.
Thermal steady state at fleet duty cycle.
EMC and leakage at full magnetomotive force.

High Power Coil Design — supporting diagram — Fig.: Supporting illustration for “High Power Coil Design”.

02Architecture choices

Split power across multiple coils or phases. Use thicker foil or parallel litz bundles. Active cooling on spreader plates for extreme cases. Co-design with inverter so coil MMF matches ZVS window — not maximum possible current.

03Qualification

Extended soak at 110% rated power until thermal equilibrium.
Impulse tests for vehicle approach mis-hit without damage.
Insulation system aged samples before production release.