Smart design for next-gen wireless EV charging

This work presents an exposure-informed co-design of an 85-kHz Double-D (DD) wireless charging pad that preserves a target mutual inductance and installation footprint while minimizing losses in the conductive/ferromagnetic shielding. A finite-element electromagnetic model is coupled to a meta model-driven multi-objective search to generate a Pareto set; candidate designs are then screened by verifying magnetic- and electric-field compliance on prescribed paths. Relative to a reference geometry, the optimized pad halves shielding losses (≈56% reduction) at essentially constant mutual inductance (≈27.2–27.3 µH). A laboratory prototype confirms high DC-to-DC efficiency above 96% at 20 cm and measured magnetic-field profiles consistent with simulation, while electric-field exposure is assessed in simulation using a rolled-edge shield concept. The results show that surrogate-accelerated co-design can decouple electrical targets from exposure verification and deliver practical, compliant DD pads with materially lower shielding loss.