IP Library Granted Patent US 12,139,039
Granted Patent B2
US 12,139,039 · App. 18/195,352 · Granted Nov 12, 2024

Charging EV battery using parallel buck and boost converters

Inventors: Aaron Rogers (Newark, CA); Nathan Biesterfeld (Newark, CA); Nikola Milivojevic (Newark, CA)
Assignee: SPEED CHARGE, LLC
B60L58/18B60L50/60B60L53/11B60L53/53H02J7/00714H02J7/342H02M1/0009H02M3/1582B60L2210/10B60L2210/12B60L2210/14H02J2207/20
View Patent ↗
Loading inventors, assignments & file history…
Monitor This Case
Get email alerts when status or documents change.
Order Certified Copies
Most orders are placed with the USPTO same day — all within 24 business hours.
Order via The Patent Place →
Pre-filled with this patent's details
Quick Facts
Patent No.
US 12,139,039
App. No.
18/195,352
Granted
Nov 12, 2024
Kind
B2
Abstract

Controlling a charging current while transferring energy from a source battery to a target battery in an electric vehicle (EV) includes operating, by control circuitry, a buck converter at a fixed switching frequency to transfer power from the source battery to the target battery, in a first operational mode; in response to detecting a first trigger event, transitioning from the first operational mode to a second operational mode to operate the buck converter at a variable switching frequency; and in response to detecting a second trigger event, transitioning to a third operational mode to activate a boost converter coupled to the source battery and the target battery.

Claims (35)

1. A method for controlling a charging current while transferring energy from a source battery to a target battery in an electric vehicle (EV), the method comprising:

operating, by control circuitry, a buck converter at a fixed switching frequency to transfer power from the source battery to the target battery, in a first operational mode, wherein a pulse width modulation (PWM) duty cycle increases during the first operation mode;

in response to detecting a first trigger event, transitioning from the first operational mode to a second operational mode to operate the buck converter at a variable switching frequency to increase a resolution of the PWM duty cycle relative to the first operational mode; and

in response to detecting a second trigger event, transitioning to a third operational mode to activate a boost converter coupled to the source battery and the target battery.

2. The method of claim 1 , further comprising:

after transitioning to the third operational mode, regulating a charging current through the boost converter so as to substantially compensate for a differential between a desired charging current and a decaying current through the buck converter.

3. The method of claim 1 , wherein detecting the first trigger event includes determining that a voltage differential between the source battery and the target battery is below a threshold voltage value.

4. The method of claim 3 , wherein:

the source battery is a stationary charging battery; and

the threshold voltage value is 10V.

5. The method of claim 1 , wherein detecting the first trigger event includes determining that the duty cycle of the buck converter exceeds a threshold duty cycle value.

6. The method of claim 5 , wherein the threshold duty cycle value is 98%.

7. The method of claim 1 , wherein detecting the second trigger event includes determining that a voltage differential between the source battery and the target battery is substantially zero.

8. The method of claim 1 , wherein detecting the second trigger event includes determining that the duty cycle of the buck converter is substantially 100%.

9. The method of claim 1 , further comprising:

upon transitioning to the third operational mode, operating the boost converter at a variable switching frequency; and

in response to detecting a third trigger event, transitioning from the third operational mode to a fourth operational mode to operate the boost converter at a fixed switching frequency.

10. The method of claim 9 , wherein detecting the third trigger event includes determining that a voltage differential between the source battery and the target battery is below a second threshold voltage value.

11. The method of claim 1 , further comprising:

subsequently to transitioning to the fourth operational mode and in response to determining that no current flows through the buck converter, deactivating the buck converter.

12. A non-transitory computer-readable medium storing thereon instructions which, when executed by one or more processors, cause a circuit to control a charging current while transferring energy from a source battery to a target battery in an electric vehicle (EV), in a system that includes a buck converter configured to couple to the source battery and the target battery, a boost converter configured to couple to the source battery and the target battery, and a boost switch that connects an output to the boost converter to the target battery in a closed state, and disconnects the boost converter from the target battery in an open state; the instructions configured to:

(i) operate the buck converter at a fixed switching frequency in a first operational mode, wherein a pulse width modulation (PWM) duty cycle increases during the first operation mode,

(ii) in response to detecting a first trigger event, transition from the first operational mode to a second operational mode to operate the buck converter at a variable switching frequency and increase a resolution of the PWM duty cycle relative to the first operational mode, and

(iii) in response to detecting a second trigger event, transition to a third operational mode to activate the boost converter.

13. The non-transitory computer-readable medium of claim 12 , wherein the instructions are further configured to:

after transitioning to the third operational mode, regulate a charging current through the boost converter so as to substantially compensate for a differential between a desired charging current and a decaying current through the buck converter.

14. The non-transitory computer-readable medium of claim 12 , wherein to detect the first trigger event, the instructions are configured to determine that a voltage differential between the source battery and the target battery is below a threshold voltage value.

15. The non-transitory computer-readable medium of claim 12 , wherein to detect the first trigger event, the instructions are configured to determine that the duty cycle of the buck converter exceeds a threshold duty cycle value.

16. The non-transitory computer-readable medium of claim 12 , wherein the instructions are further configured to:

upon transitioning to the third operational mode, operate the boost converter at a variable switching frequency; and

in response to detecting a third trigger event, transition from the third operational mode to a fourth operational mode to operate the boost converter at a fixed switching frequency.

17. The non-transitory computer-readable medium of claim 16 , wherein to determine the third trigger event, the instructions are configured to:

determine that a voltage differential between the source battery and the target battery is below a second threshold voltage value.

18. The non-transitory computer-readable medium of claim 12 , wherein the instructions are further configured to:

subsequently to transitioning to the fourth operational mode and in response to determining that no current flows through the buck converter, deactivate the buck converter.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jul 17, 2024
From: FREEWIRE TECHNOLOGIES, INC.
To: SPEED CHARGE, LLC
Reel/Frame 068404/0655 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded May 11, 2023
From: ROGERS, AARON; BIESTERFELD, NATHAN; MILIVOJEVIC, NIKOLA
To: FREEWIRE TECHNOLOGIES, INC.
Reel/Frame 063617/0368 →
Continuity (3)
Continuation 17821368 · Aug 22, 2022
Provisional Application 63391703 · Jul 22, 2022
Related Publication 20240025296A1 · Jan 25, 2024