Thermal Analysis and Design of a 30kW EV Wireless Charger with Liquid-Cooled Shell for Magnetic Coupler and Integrated Power Converter

The thermal performance affects the reliability and safety of the inductive power transfer system. This paper studies the thermal design method of wireless chargers for the electric vehicle. The thermal resistance of materials is calculated, and the thermal networks of heating components are established. Then power losses are applied to the nodes in the form of heat sources. The calculated hotspot temperatures are close to those obtained by the finite element method in comparison. A prototype of a 30kW onboard wireless charger with a liquid-cooled shell is set up, and the steady-state temperature error of less than 10% proves the effectiveness of the thermal design scheme. This paper expands the application of the thermal network method in the field of the liquid-cooled onboard receiver of wireless chargers.