Portable EV Charger with External Cooling and Cable Retraction
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Solution Overview
Problem
Existing charge systems for plug-in hybrid and electric vehicles require integration of a charger device into the vehicle, occupying space and adding weight, and necessitate carrying additional cables for AC/DC conversion, limiting flexibility and efficiency in charging.
Innovation Solution
A portable charger device with DC-DC conversion capabilities, external cooling, and modular design, including a housing with cooling fins and ducts, automatic cable retraction, and thermal insulation, allowing charging from any AC power source and reducing vehicle weight and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charger device is permanently integrated into the vehicle, then charging reliability is improved, but vehicle weight and installation space increase
Solution Approach 1:
The charging system is divided into two independent parts: a portable charger device that can be detached and stored, and a fixed charging interface in the vehicle. This segmentation allows the vehicle to have minimal integrated components while maintaining charging capability through the portable unit.
Solution Approach 2:
The charger device is extracted from permanent vehicle integration and made into a separate, portable unit. This extraction reduces vehicle weight and installation space requirements while the charging function remains available through the detachable portable charger.
2Stability of the object's composition
If the charger device is permanently integrated into the vehicle, then charging stability is improved, but vehicle installation space is consumed
Solution Approach 1:
The charging system is divided into two independent parts: a portable charger device that can be detached and stored, and a fixed charging interface in the vehicle. This segmentation allows the vehicle to have minimal integrated components while maintaining charging capability through the portable unit.
Solution Approach 2:
The charger device is extracted from permanent vehicle integration and made into a separate, portable unit. This extraction reduces vehicle weight and installation space requirements while the charging function remains available through the detachable portable charger.
3Adaptability or versatility
If the charger device is made portable, then vehicle flexibility and space are improved, but heat dissipation becomes more difficult
Solution Approach 1:
The portable charger device utilizes the surrounding ambient air environment for heat dissipation rather than relying on vehicle-specific cooling systems. The external location of the portable charger allows it to leverage environmental airflow and convection for effective thermal management.
4Device complexity
If AC/DC conversion is performed externally, then vehicle complexity and weight are reduced, but additional cabling is required
Solution Approach 1:
The portable charger device integrates the AC power input, AC/DC conversion electronics, and output cabling into a single unified unit. This merging eliminates the need for separate AC input cables and DC output cables, reducing overall system complexity and cable management requirements.
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
Enables flexible and efficient charging from any AC power source, reducing vehicle weight and space usage, and providing universal compatibility and cost-effective manufacturing.
Implementation Method 1
The cooling fins and the at least one cooling duct bring about air cooling of the charger device. Since the latter is located outside the vehicle, the convective circulation of the ambient air permits the heat, which is produced during the rectification to be transported away.
Implementation Method 2
The cooling fins and the cooling duct improve the heat transfer by enlarging the surface which is in contact with the surroundings.
Implementation Method 3
Given a preferred vertical orientation, a directed flow is produced, i.e. a flow with a preferred flow direction counter to gravity, which is also referred to as a 'chimney effect' and which, additionally, promotes the heat transfer.
Data Source
AI summary
A system includes a vehicle with a charge socket and a contactor switching unit, and a charger for charging an electrical energy accumulator of the vehicle at a vehicle-external AC power system. The charger is a vehicle-external charger device. The charger is a portable charger. The charger has a DC-DC converter, and includes first and second charging cables. The first charging cable has an AC power system plug, and the second charging cable has a charge plug.