Dual Active Bridge Charger Heating for Condensation Prevention

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Electric vehicle charging stations need to withstand harsh weather conditions without using separate heaters, particularly to prevent condensation in outdoor installations.

Innovation Solution

A dual active bridge converter is controlled to enter a heat generation mode based on environmental conditions, such as temperature and humidity, to generate heat and ameliorate conditions within the electric charger.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate heater element is used to prevent condensation in outdoor electric chargers, then the environmental conditions can be maintained, but the device complexity and cost increase

Engineering Contradiction:

Improvecondensation preventionVSAvoidheater element addition

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the heating function with the existing dual active bridge converter by repurposing it to operate in heat generation mode. The converter's switching elements are controlled to create intentional power losses that generate heat, merging the power conversion function with the heating function into a single integrated system, thereby eliminating the need for a separate heater element.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dual active bridge converter is designed to perform multiple functions: normal power conversion operation and heat generation operation. By controlling the switching elements to operate in different modes, the same hardware component serves both as a power converter and as a heating element, achieving multi-functionality without additional components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a separate heater element is installed in the electric charger, then heating capability is provided, but the ease of manufacture decreases

Engineering Contradiction:

Improveheating capabilityVSAvoidassembly complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The heating capability is merged into the existing converter structure by utilizing the same switching elements and circuit topology. This eliminates the need for separate heater assembly, reducing manufacturing steps and assembly complexity while maintaining the heating function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The dual active bridge converter generates its own heat internally through controlled power losses during operation. The system serves its own heating needs without requiring external heater components, simplifying the manufacturing process and reducing the number of parts that need to be assembled.

Inventive Principle:

Principle #25Self-service

3Reliability

If the dual active bridge converter operates in heat generation mode, then condensation is prevented, but energy efficiency decreases

Engineering Contradiction:

Improvecondensation preventionVSAvoidenergy efficiency

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent converts the normally harmful power losses (energy dissipation) in the converter into a beneficial heating effect. By intentionally controlling the switching elements to generate controlled power losses, the energy that would otherwise be wasted is transformed into useful heat for preventing condensation, turning a negative factor into a positive one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The operating parameters of the dual active bridge converter are changed to enable heat generation mode. By adjusting the switching control parameters and operating point of the converter, the system transitions from efficient power conversion mode to controlled heat generation mode, allowing the same hardware to serve different functions based on environmental conditions.

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively maintains optimal environmental conditions within the charger, preventing condensation and enhancing the resilience and longevity of the charging station.

Implementation Method 1

cause the dual active bridge converter to enter a heat generation mode that causes the dual active bridge converter to generate heat

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

the dual active bridge converter comprises a transformer, a primary side bridge comprising a first plurality of switches, and a secondary side bridge comprising a second plurality of switches

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12592646B2Systems and methods for heating an electric charger for electric vehicle

Publication Date: 2026.03.31 RIVIAN HOLDINGS LLC

AI summary

Systems and methods for controlling a dual active bridge converter are disclosed herein. An environmental condition associated with an electric charger for an electric vehicle may be determined, where the electric charger comprises a dual active bridge converter. Based on the environmental condition associated with the electric charger, the dual active bridge converter may be caused to enter a heat generation mode that causes the dual active bridge converter to generate heat to ameliorate the environmental condition associated with the electric charger.