PFC Filter Direct Charging for High-Voltage Traction Batteries

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Solution Overview

Problem

Charging devices for electric and hybrid vehicles are costly, heavy, and experience significant power loss due to the use of converters and intermediate circuit storage units for voltage adaptation during AC charging.

Innovation Solution

Directly connecting an AC charging connection to a high-voltage rechargeable traction battery via a power factor correction filter, which provides both rectification and DC voltage conversion, eliminating the need for additional converters and rectifiers, and allowing for step-up or step-down functions to match the battery voltage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If converters and intermediate circuit storage units are used to adapt voltage levels between power factor correction filter and rechargeable battery, then voltage level adaptation is achieved, but manufacturing costs, weight, and power loss increase significantly

Engineering Contradiction:

Improvevoltage level adaptationVSAvoidpower loss

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent merges the voltage adaptation function into the power factor correction filter itself, eliminating the need for separate converters and intermediate circuit storage units. The PFC filter is designed to directly provide output voltage within the rechargeable battery's voltage range, combining rectification and voltage adaptation in a single integrated component.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power factor correction filter is designed to perform multiple functions simultaneously: it provides power factor correction, rectification, and direct voltage adaptation to match the rechargeable battery's voltage requirements. This multi-functional design eliminates the need for additional dedicated voltage conversion components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If converters and intermediate circuit storage units are used to adapt voltage levels, then voltage matching is achieved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improvevoltage matchingVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (PFC, rectification, voltage adaptation) into a single integrated power factor correction filter, eliminating the need for separate converters and intermediate storage units, thereby reducing device complexity and manufacturing costs.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The PFC filter is designed as a universal component that handles power factor correction, rectification, and voltage matching simultaneously, reducing the overall number of components needed in the charging system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If converters and intermediate circuit storage units are used, then voltage level conversion is achieved, but weight increases significantly

Engineering Contradiction:

Improvevoltage level conversionVSAvoidcharging device weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The patent merges voltage level conversion functionality into the power factor correction filter, eliminating the need for separate heavy converters and intermediate circuit storage units, thereby significantly reducing the overall weight of the charging device.

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

This configuration reduces manufacturing costs, weight, and power loss by eliminating unnecessary components, while enabling efficient and adjustable charging current delivery to the battery, optimizing energy transfer and reducing the complexity of the charging system.

Implementation Method 1

A power factor correction filter is regularly used here to convert the AC voltage into DC voltage

Methodology Applied

Scientific EffectRectification:

Implementation Method 2

the power factor correction filter itself has a step-down or step-up function in addition to rectification

Methodology Applied

Scientific EffectVoltage conversion:

Data Source

PatentUS11993164B2Vehicle on-board electrical system having a rechargeable traction battery directly connected to power factor correction filter

Publication Date: 2024.05.28 VITESCO TECHNOLOGIES GMBH

AI summary

A vehicle on-board electrical system having an AC voltage charging connection, a rechargeable traction battery, which is designed as a high-voltage rechargeable battery, and a power factor correction filter. The power factor correction filter connects the AC voltage charging connection directly to the rechargeable traction battery. The operating voltage range of the rechargeable traction battery is within the output voltage range of the power factor correction filter.