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In order to design a high efficiency Wireless Electric Vehicle Charging (WEVC) system, the design of the different system components needs to be optimized, particularly the design of a high-coupling, misalignment-tolerant inductive link (IL), comprising primary and secondary charging coils. Different coil geometries can be utilized for the primary and the secondary sides, each with a set of advantages and drawbacks in terms of weight, cost, coupling at perfect alignment and coupling at lateral misalignments. In this work, a Finite Element Method (FEM)-based systematic approach for the design of double-D (DD) charging coils is presented in detail. In particular, this paper studies the effect of different coil parameters, namely the number of turns and the turn-to-turn spacing, on the coupling performance of the IL at perfect alignment and at ±200 mm lateral misalignment, given a set of space constraints. The proposed design is verified by an experimental prototype to validate the accuracy of the FEM model and the simulation results. Accordingly, FEM simulations are utilized to compare the performance of rectangular, DD and DDQ coils. The FEM results prove the importance of utilizing an additional quadrature coil on the secondary side, despite the added weight and cost, to further improve the misalignment tolerance of the proposed inductive link design.

We present in this paper a new topology of inductively-coupled links based on a monolithic multi-coils receiver. A model is built to characterize the proposed structure using Matlab and is verified employing simulation tools under ADS electromagnetic environment. This topology accounts for the losses associated with the receiver micro-coil including substrate and oxide layers. The geometry of micro-coils significantly desensitizes the link to both angular and side misalignments. A custom fabrication process using 1 micron metal thickness is also presented by which two sets of micro-coils varying in the number of coils are realized. The first set possesses one coil 4 mm of diameter and represents a power efficiency close to 4% while the second set possesses multi-coils with an efficiency of 18%. The resulting optimized link can deliver up to 50 mW of power to power up an implantable device either sensor or stimulator. The experimental results for the prototypes are remarkably in agreement with those obtained from simulated models and circuits.