Pennsylvania-based startup CorePower Magnetics is at the forefront of transforming electric vehicle (EV) charging infrastructure with its innovative compact transformers. In collaboration with Eaton, CorePower is testing lightweight, power-dense components designed to facilitate rapid charging for EV fleets operating in tight urban spaces.
Challenges in EV Fleet Charging:
EV fleets require high-power charging systems, which traditionally rely on large and inefficient transformers and inductors. This poses challenges, especially in urban areas where space is limited. CorePower Magnetics aims to address this issue by developing advanced transformers that are both lighter and more efficient.
CorePower’s Technological Innovation:
CorePower’s transformers leverage high thermal stability magnetic cores capable of withstanding temperatures of up to 250°C (482°F). These compact components not only enable fast charging systems but also hold potential for upgrading legacy distribution transformers and integrating renewable energy sources into EV powertrains.
Collaboration with Eaton and Techno-Economic Analysis:
Partnering with Eaton, CorePower is conducting real-world tests to assess the stability and performance of its transformative technology. The National Renewable Energy Laboratory (NREL) is also conducting a techno-economic analysis to evaluate the costs and benefits of CorePower’s components. This collaboration follows CorePower’s participation in the Wells Fargo Innovation Incubator (IN2) program, where it has been preparing and validating its components since 2022.
CorePower’s Compact and Power-Dense Technology:
CorePower’s innovative approach involves the development of metal amorphous iron-cobalt (FeCo) and iron-nickel (FeNi) nanocomposite alloys. These soft magnetic materials offer high permeability, density, corrosion resistance, and reduced eddy current losses, making them ideal for high-performance transformers. By targeting a frequency range of 10,000 Hz and above, CorePower’s transformers achieve significant reductions in size and weight while maintaining electrical performance.
Manufacturing Advancements and Future Plans:
CorePower’s manufacturing process allows for greater control and versatility in engineering magnetic core components, resulting in materials customized for specific transformer requirements. With significant funding from the U.S. Department of Energy (DOE) and venture capital rounds, CorePower plans to ramp up its manufacturing capacity to meet growing global demand for specialized magnetic metals. The company aims to play a pivotal role in accelerating the adoption of electric vehicles by revolutionizing charging infrastructure with its compact and efficient transformers.
CorePower Magnetics’ partnership with Eaton and its commitment to technological innovation signify a significant step forward in the electrification of transportation, paving the way for sustainable and efficient EV charging solutions in urban environments.