Vehicle Charging Cable Current Profile for Thermal Management

The patent applies dynamics by transitioning from static continuous current rating to dynamic time-limited current operation. The controller dynamically adjusts current based on time elapsed since charging started, allowing the conducting element to operate at maximum current only during initial periods when temperature is low, then reducing current as time progresses to prevent overheating. This dynamic approach enables smaller conducting elements to safely handle peak charging currents without requiring continuous high-current capability.

The patent changes the current parameter over time through a charging current profile that defines maximum current for initial time periods and reduced current thereafter. This parameter change allows the system to optimize between peak power transfer (using high current initially) and thermal management (reducing current later), enabling smaller conducting elements to be used while maintaining both charging performance and thermal safety.

The dynamic time-limited current operation reduces the continuous current rating requirement for conducting elements, allowing use of smaller gauge wires and smaller connectors. This directly reduces material costs and manufacturing complexity while maintaining reliability through active current management that prevents thermal damage.

By changing current parameters over time rather than maintaining constant maximum current, the system enables use of less expensive conducting elements with lower continuous current ratings. The controller implements this through a charging current profile that limits current duration, allowing cost-effective conducting elements to safely handle peak charging currents.

The patent implements periodic action through time-limited current pulses followed by current reduction. The controller allows high current to flow only during initial time periods when thermal accumulation is minimal, then reduces current to prevent excessive temperature rise. This periodic high-current operation enables fast charging while managing thermal effects through time-based current modulation.

The system rushes through the high-current phase quickly by limiting its duration to only what is necessary for initial charging. The controller allows maximum current to flow only for the minimum time required to deliver significant charge before transitioning to reduced current mode, thereby achieving fast charging objectives while minimizing thermal accumulation in the conducting elements.

The patent applies dynamics by implementing time-limited current operation that matches the thermal capacity of smaller conducting elements. The controller dynamically adjusts current based on time elapsed, allowing smaller cables to temporarily handle peak currents during initial charging periods when temperature is low, then reducing current as time progresses to prevent thermal damage. This enables smaller cable cross-sections to achieve equivalent charging performance.

The system changes current parameters over time through a charging current profile specifically designed for smaller conducting elements. By defining maximum current for initial time periods and reduced current thereafter, the system enables smaller cable cross-sections to safely deliver peak charging power during critical initial phases while preventing thermal damage, effectively overcoming the current carrying capacity limitations of smaller cables.