Summary
- Patent allows for higher charge rates from lower-voltage DC fast chargers
- Solution includes relay switches and a capacitor to boost output
- Works as a workaround for Tesla V3 Superchargers unable to charge at 800 volts
- Stellantis working on hardware to boost output of low-power DC fast-chargers for EVs
- Solution proposes using relay switches and capacitor to take advantage of 800-volt vehicle architectures while charging at 400-volt stations
Article
Stellantis has patented a solution that allows for higher charge rates from lower-voltage DC fast chargers, specifically designed for electric vehicles that can handle the extra power while minimizing added weight and complexity. This solution involves adding a series of relay switches and a capacitor to the charging system, providing a smart workaround for Tesla V3 Superchargers that are unable to charge at 800 volts. The patent does not specifically mention Tesla but could have significant implications for real-world charging scenarios, particularly for 800-volt EVs like the upcoming Ram 1500 REV.
The proposed boost system described in the patent filing by Stellantis aims to take full advantage of the charging capabilities of 800-volt vehicle electrical architectures when charging at 400-volt DC fast-charging stations. While there are existing dedicated DC boost modules, these can add significant cost and weight to the vehicle, making them difficult to integrate. Instead, Stellantis suggests using a series of relay switches and a small DC capacitor as the only additional components needed to increase voltage during charging. This approach could be applied to both plug-in hybrids and EVs, offering a cost-effective and practical solution for boosting charging capabilities.
The relay switches in the system would allow current to flow through the vehicle’s inverter and electric motor during charging, generating two AC phase currents that can be converted into a third, higher-power DC current for the battery. This innovative approach could enable 800-volt vehicles to charge at a higher rate when connected to sub-800-volt fast-charge connectors, such as those found on the Tesla Supercharger network. Stellantis confirmed plans to adopt the Tesla-based charge port, known as NACS, as part of the SAE J3400 standard in February, signaling a strategic alignment with industry best practices.
Although most near-term EVs from Stellantis will use a 400-volt architecture, the company has confirmed that larger Ram EVs will operate at 800 volts. This shift towards higher-voltage architectures reflects a broader industry trend towards maximizing charging efficiency and performance. Stellantis has made streamlining charging hardware a key focus, with discussions in 2023 about eliminating onboard chargers and inverters to simplify future EVs. This patent represents a step towards enhancing charging capabilities for electric vehicles, ensuring compatibility and efficiency with a broad range of charging infrastructure.
By introducing a simple yet effective solution to boost charging output from lower-voltage DC fast chargers, Stellantis is addressing a critical challenge in the EV industry. The use of relay switches and a capacitor as additional components provides a cost-effective and practical alternative to dedicated DC boost modules, enabling 800-volt vehicles to charge at a higher rate. This innovation aligns with Stellantis’ commitment to enhancing charging capabilities and streamlining charging hardware, reflecting the company’s focus on sustainable and efficient electric mobility solutions. As the automotive industry continues to evolve towards electrification, patents like these play a crucial role in driving innovation and advancing the adoption of electric vehicles.
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