Swappable EV Charging Units With Detachable Cables for Portable Fast Charging
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Solution Overview
Problem
Conventional electric vehicle charging systems are limited by their stationary nature and inefficiencies in energy storage and delivery, particularly in providing a modular and efficient solution for charging electric vehicle batteries across various applications.
Innovation Solution
A modular electric vehicle charging system comprising a swappable energy storage unit, a charger unit, and a detachable cable assembly, with control mechanisms for unidirectional DC-DC conversion, inrush current limiting, and integrated cooling systems, enabling flexible and efficient charging of electric vehicle batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional stationary chargers with wire-wound transformers are used, then power transformation from AC grid is achieved, but the system lacks portability and flexibility
Solution Approach 1:
The charging system is divided into separate modular components: a portable charger unit with power transformation capabilities, detachable cable assemblies, and swappable energy storage units. This segmentation allows the system to maintain full charging functionality while improving portability and flexibility, as each module can be independently handled and reconfigured.
Solution Approach 2:
The system transitions from a fixed stationary charger to a dynamic portable configuration. The charger unit can be moved between different locations, the cable assemblies can be detached and reconnected, and energy storage units can be swapped during operation. This dynamic adaptability resolves the contradiction between portability and charging capability.
2Productivity
If high-power charging is provided to electric vehicle batteries, then charging speed is improved, but heat generation and safety risks increase
Solution Approach 1:
The patent introduces intermediate protective components including thermal management systems, current-limiting circuits, and safety control mechanisms between the power source and the battery. These intermediaries manage the high-power transmission by controlling current flow, dissipating heat, and monitoring system conditions, thereby enabling fast charging while mitigating safety risks.
Solution Approach 2:
The system incorporates preventive safety measures before high-power charging begins, such as pre-cooling thermal management systems, pre-checking battery temperature and voltage conditions, and pre-configuring current-limiting protection. This beforehand cushioning allows the system to safely handle high-power delivery by preparing protective mechanisms in advance.
3Duration of action of moving object
If energy storage units are designed for long-duration operation, then power delivery is sustained, but component lifespan is reduced
Solution Approach 1:
The system employs swappable energy storage units that can be replaced when depleted or degraded. Instead of attempting to extend the life of individual battery cells beyond their natural lifespan, the system discards exhausted units and recovers capacity by deploying fresh units. This approach maintains sustained power delivery capability while preserving the long-term reliability of individual components through controlled replacement rather than continuous stress.
Solution Approach 2:
The system implements periodic maintenance and replacement cycles for energy storage units. Rather than continuous operation at maximum capacity, the system cycles through charging, discharging, and replacement phases, allowing components to rest and be replaced before failure occurs. This periodic action pattern sustains overall system power delivery while extending the effective service life of individual components.
4Adaptability or versatility
If modular design with detachable components is implemented, then system flexibility and portability are improved, but connection reliability and contact stability may be compromised
Solution Approach 1:
The patent combines multiple connection functions into integrated detachable cable assemblies that merge power transmission, signal communication, and mechanical coupling into a single unified connector system. This merging ensures that when components are connected, all electrical and control connections are established simultaneously through a single reliable interface, maintaining connection stability while preserving modular flexibility.
Solution Approach 2:
The system incorporates feedback mechanisms in the detachable connections, including contact detection circuits that verify proper connection before enabling power flow, and interlock mechanisms that prevent disconnection during active charging. These feedback systems ensure connection reliability by monitoring and confirming the stability of detachable interfaces before and during operation.
Data Source
AI summary
Modular electric vehicle charging systems and methods are provided which include a swappable energy storage unit and a charger unit. The swappable energy storage unit and the charger unit are operatively coupled via a detachable cable assembly, and at least one control is provided to control charging of an electric vehicle battery by the modular electric vehicle charging system.