Portable V2V Charging Box for Direct DC Fast Charging

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Solution Overview

Problem

Existing electric vehicles (EVs) face challenges in efficiently and conveniently charging their batteries, particularly when offboard charging stations are not readily available.

Innovation Solution

A portable charging circuit accessory, referred to as a charging box, enables high-voltage energy transfer between a donor and a recipient system, facilitating direct current fast charging (DCFC) sessions between two EVs or between an EV and an EVSE charging station.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If offboard charging stations are used, then battery charging capability is improved, but dependency on fixed infrastructure and charging convenience deteriorates

Engineering Contradiction:

Improvebattery charging capabilityVSAvoidcharging convenience

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The charging box serves as a portable intermediary device between the donor EV and recipient EV, enabling direct DC fast charging without requiring fixed offboard charging infrastructure. The charging box contains necessary control circuitry, communication interfaces, and safety mechanisms to mediate the energy transfer while maintaining charging capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system enables EVs to charge each other directly through vehicle-to-vehicle energy transfer, eliminating dependency on external charging stations. The donor EV provides charging services to the recipient EV autonomously, with the charging box facilitating the connection and control.

Inventive Principle:

Principle #25Self-service

2Adaptability or versatility

If portable charging solutions are implemented, then charging accessibility is improved, but device complexity increases

Engineering Contradiction:

Improvecharging accessibilityVSAvoidcharging box complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The charging box is designed as a universal interface that can connect to different EV models and charging standards through standardized ports. It performs multiple functions including voltage regulation, current control, communication coordination, and safety monitoring within a single portable device.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The charging box contains nested functional modules including control circuitry, communication interfaces, and protection mechanisms within a compact portable housing. The system also nests the charging box within the existing EV electrical architecture, integrating with the EV's battery management system and charging protocols.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Speed

If direct current fast charging is performed, then charging speed is improved, but energy transfer efficiency and system reliability worsen

Engineering Contradiction:

Improvecharging speedVSAvoidenergy transfer reliability

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The system performs preliminary actions including pre-charging of capacitors, verification of connection integrity, and validation of communication protocols before initiating high-power DC fast charging. The charging box checks system readiness and establishes safe operating parameters before enabling rapid energy transfer.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The charging box implements real-time feedback monitoring of voltage, current, temperature, and communication status during DC fast charging operations. The system continuously adjusts charging parameters based on feedback from both donor and recipient EVs, and automatically terminates charging if anomalies are detected, maintaining reliability during high-speed energy transfer.

Inventive Principle:

Principle #23Feedback

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 charging box allows for efficient and flexible DCFC operations, reducing range anxiety by enabling charging on the go and enhancing mobility for EV users.

Implementation Method 1

one or more direct current-to-direct current (DC-DC) converters connected to the portable housing. The DC-DC converter(s) include a high-voltage-to-high-voltage (HV-HV) converter connected to the HV bus

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentUS20250026208A1Vehicle-to-vehicle charging box and method for direct current fast-charging using the same

Publication Date: 2025.01.23 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A charging box performs a direct current fast charging (DCFC) session of a recipient by a donor, e.g., during a vehicle-to-vehicle (V2V) charging session, and includes a portable housing, disconnect devices connected to a high-voltage (HV) bus to connect/disconnect respective inlet and outlet charging ports to/from the bus, and multiple direct current-to-direct current (DC-DC) converters. A high-voltage-to-high-voltage (HV-HV) converter is connected to the bus. An optional high-voltage-to-low-voltage (HV-LV) converter may be connected to the HV-HV converter. An optional low-voltage (LV) energy storage device is connected to the housing and HV-LV converter. A communication processing unit (CPU) establishes two-way communication between the donor and recipient. A system controller selectively pre-charges the bus, recharge the energy storage device, and selectively command offloading of a DC charging current from the donor, through the HV-HV converter, and to the recipient.