Integrated EV Charger with Shared Converter

Solution Overview

Problem

Existing battery recharging appliances for electric vehicles are bulky, heavy, and costly due to their complex and redundant components, which hinder efficient charging and power distribution between high voltage and low voltage batteries and user points.

Innovation Solution

An integrated appliance with shared AC/DC and DC/DC conversion means, a single input filter, and a shared power factor correction and step-up converter, utilizing an LLC resonant converter with relays or solid-state switches to alternate between battery charging and DC/DC functions, reducing component count and weight while maintaining efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If separate battery charger and DC/DC conversion line are used, then battery recharging function is reliable, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvebattery recharging functionVSAvoidappliance structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the battery charger and DC/DC conversion line into a single integrated appliance with a unified control unit. The converter can operate in different modes (battery charging mode and DC/DC conversion mode) depending on the position of a switching mechanism, eliminating the need for separate physical components while maintaining both functions reliably.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated appliance serves multiple functions: it can charge the high voltage battery when connected to AC power supply, and it can perform DC/DC conversion to charge the low voltage battery or power user points when connected to the high voltage battery. The single converter and control unit are designed to handle both operations, making the appliance universal and multi-functional.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If separate battery charger and DC/DC conversion line are used, then battery recharging function is reliable, but manufacturing cost increases

Engineering Contradiction:

Improvebattery recharging functionVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the battery charger and DC/DC conversion line into a single integrated appliance with a unified control unit. The converter can operate in different modes (battery charging mode and DC/DC conversion mode) depending on the position of a switching mechanism, eliminating the need for separate physical components while maintaining both functions reliably.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If separate battery charger and DC/DC conversion line are used, then battery recharging function is reliable, but appliance weight increases

Engineering Contradiction:

Improvebattery recharging functionVSAvoidappliance weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines the battery charger and DC/DC conversion line into a single integrated appliance with a unified control unit. The converter can operate in different modes (battery charging mode and DC/DC conversion mode) depending on the position of a switching mechanism, eliminating the need for separate physical components while maintaining both functions reliably.

Inventive Principle:

Principle #5Merging (Combining)

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

The integrated design reduces manufacturing costs, dimensions, and weight, while maintaining efficient charging and power distribution, minimizing losses from parasite capacities and requiring fewer semiconductor components.

Implementation Method 1

The converter is of the LLC resonant type and has a first output connected to the high voltage battery and a second output connected to the low voltage battery

Methodology Applied

Scientific EffectResonance: Resonance

Data Source

PatentEP3069430B1Appliance for recharging batteries of electric vehicles or the like

Publication Date: 2020.03.11 META SYSTEM SPA

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AI summary

The appliance (A) for recharging batteries of electric vehicles or the like, comprises: - AC/DC conversion means which can be connected at input to an alternate current power supply line (AC IN) and connected at output to a high voltage electric battery (HVB) of an electric vehicle; - DC/DC conversion means connected at input to the high voltage electric battery (HVB) and connected at output to a low voltage electric battery (LVB) of the electric vehicle; - wherein the AC/DC conversion means and the DC/DC conversion means can be activated alternatively for recharging the high voltage electric battery (HVB) and the low voltage electric battery (LVB), respectively; - and wherein the AC/DC conversion means and the DC/DC conversion means comprise a sole and shared DC/DC converter (CNV), having an input which can be connected alternatively to the power supply line (AC IN) and to the high voltage electric battery (HVB) and having a first output connected to the high voltage electric battery (HVB) and a second output connected to the low voltage electric battery (LVB).