Design of an EMF Suppressing Magnetic Shield for a 100-kW DD-Coil Wireless Charging System for Electric Vehicles

This study investigates the electromagnetic field (EMF) emissions of a 100-kW Double-D (DD) wireless charging system (WCS). A shielding technique is proposed to suppress the magnetic field emissions below the limits set by the International Commission on Non-Ionizing Radiation Protection (ICNIRP). The leakage pattern produced by the DD coil is different than unipolar (circular, rectangular, etc.) pads and traditional eddy current based aluminum shields are not effective at suppressing this leakage field. Therefore, a methodically designed magnetic shield could be more effective. This study proposes a shielding technique for DD coils using a combination of aluminum shielding and a low reluctance magnetic shield to suppress the magnetic field emissions. The shielding effectiveness is evaluated through finite element analysis (FEA) models and tested experimentally. The effectiveness of the proposed magnetic shielding and the limits of the conventional aluminum shielding are studied. A prototype 11-kW DD coil wireless charging system is used to experimentally validate the proposed shielding technique. The experimental results show that the aluminum shield increases the emissions of DD coils by 25% and the proposed magnetic shield can be employed to suppress the emission by 60%.