VP19-10 Soft magnetic composites casted from ferrites and construction binders with lowest core loss for high-efficient wireless charging
Creators: Ibrahim Ellithy
Mauricio Esguerra
Rewanth Radhakrishnan
Publisher: name: IEEE
Year: 2025

Transport decarbonization requires electrification with an efficient and widespread charging infrastructure. Road electrification with dynamic wireless charging can help to reduce the size of batteries reducing significantly the environmental impact of lithium mining. Robust and low-loss magnetic materials are required to allow for high-efficient inductive transmission comparable to plug-in charging with an added convenience which accelerates the adoption of electric vehicles. Traditional ferrites used, for example, in wireless power transfer, experiences a compressive pressure yielding a significant transmission efficiency drop, which makes it unsuitable for embedding them in load-bearing structures. Soft Magnetic Composites cast with recycled ferrites and cement, or asphalt, are highly robust and possess the lowest core losses at flux densities up to 50 mT in the range of up to 100kHz in a wide temperature range. This paper will show how by refining the particle size distribution of the aggregates and using precision-enhanced magnetic testing and sophisticated hysteresis modelling, the performance of these materials could be significantly improved with respect to the stress effect on losses. By correlating processing steps to a multi-linear regression model, the optimum particle size distribution is found, yielding a material grade with minimal losses. Compared to conventional best-in-class powder cores (containing Nickel), these composites feature lower core losses at a fraction of the cost. Industrialization based on existing building materials methods and equipment secures global high scalability.
Transport decarbonization requires electrification with an efficient and widespread charging infrastructure. Road electrification with dynamic wireless charging can help to reduce the size of batteries reducing significantly the environmental impact of lithium mining. Robust and low-loss magnetic materials are required to allow for high-efficient inductive transmission comparable to plug-in charging with an added convenience which accelerates the adoption of electric vehicles. Traditional ferrites used, for example, in wireless power transfer, experiences a compressive pressure yielding a significant transmission efficiency drop, which makes it unsuitable for embedding them in load-bearing structures. Soft Magnetic Composites cast with recycled ferrites and cement, or asphalt, are highly robust and possess the lowest core losses at flux densities up to 50 mT in the range of up to 100kHz in a wide temperature range. This paper will show how by refining the particle size distribution of the aggregates and using precision-enhanced magnetic testing and sophisticated hysteresis modelling, the performance of these materials could be significantly improved with respect to the stress effect on losses. By correlating processing steps to a multi-linear regression model, the optimum particle size distribution is found, yielding a material grade with minimal losses. Compared to conventional best-in-class powder cores (containing Nickel), these composites feature lower core losses at a fraction of the cost. Industrialization based on existing building materials methods and equipment secures global high scalability.