Effect of ferrite addition above the base ferrite on the coupling factor of wireless power transfer for vehicle applications

Power transfer capability of wireless power transfer systems is highly dependent on the magnetic design of the primary and secondary inductors and is measured quantitatively by the coupling factor. The inductors are designed by placing the coil over a ferrite base to increase the coupling factor and reduce magnetic emissions to the surroundings. Effect of adding extra ferrite above the base ferrite at different physical locations on the self-inductance, mutual inductance and coupling factor is under investigation in this paper. The addition can increase or decrease the mutual inductance depending on the placement of ferrite. Also, the addition of ferrite increases the self-inductance of the coils and there is a probability for an overall decrease in the coupling factor. Correct placement of ferrite on the other hand can increase the coupling factor relatively higher than the base ferrite as it is closer to the other inductor. Ferrite being a heavy compound of iron increases the inductor weight significantly and needs to be added judiciously. Four zones have been identified in the paper which shows different sensitivity to addition of ferrite in terms of the two inductances and coupling factor. Simulation and measurement results are presented for different air gaps between the coils and at different gap distances between the ferrite base and added ferrite. This paper is beneficial in improving the coupling factor while adding minimum weight to wireless power transfer system.