TANDEM DC/DC CONVERTER FOR A VEHICLE BATTERY CHARGER

• US 20200136520A1
• Filed: 10/26/2018
• Published: 04/30/2020
• Est. Priority Date: 10/26/2018
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: JIMENEZ PINO, Rafael, ESCODA VALLDEPEREZ, Jordi, LUCIA GIL, Oscar, SARNAGO ANDIA, Hector, NAVAL PALLARES, Alejandro
• Granted Patent: US 10,862,401 B2
• Time in Patent Office: Days
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 53/20 characterised by converters located in the vehicle
• CPC Class Codes: B60L 53/22 Constructional details or arrangements of charging converters specially adapted for charging electric vehicles
• CPC Class Codes: B60L 53/30 Constructional details of charging stations
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00 Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 1/4208 Arrangements for improving power factor of AC input
• CPC Class Codes: H02M 3/33576 having at least one active switching element at the secondary side of an isolation transformer
• CPC Class Codes: H02M 3/33584 Bidirectional converters
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

In at least one embodiment, a charging apparatus for a vehicle is provided. The apparatus includes a power converter having a primary stage, a first secondary stage, and a second secondary stage. The primary stage is configured to receive an incoming voltage to generate a first input voltage. The first secondary stage includes a first plurality of electrical components configured to generate a first portion of an output voltage. The second secondary stage is in series with the first secondary stage and includes a second plurality of electrical components configured to generate a second portion of the output voltage. Each of the first plurality of electrical components and the second plurality of electrical components is rated to a voltage rating that is less than a total sum of the first portion and the second portion of the output voltage.

Claims

1. A charging apparatus for a vehicle, the apparatus comprising:

a power converter including;

a primary stage configured to receive an incoming voltage to generate a first input voltage;

a first secondary stage including a first plurality of electrical components configured to generate a first portion of an output voltage for charging at least one battery in a vehicle in response to the first input voltage; and

a second secondary stage in series with the first secondary stage including a second plurality of electrical components configured to generate a second portion of the output voltage in response to the first input voltage,

wherein each of the first plurality of electrical components and the second plurality of electrical components is rated to a voltage rating that is less than a total sum of the first portion and the second portion of the output voltage.

2. The apparatus of claim 1, wherein the power converter is a DC/DC converter.

3. The apparatus of claim 1, wherein the first portion of the output voltage is generally equal to the second portion of the output voltage.

4. The apparatus of claim 1, wherein the total sum of the first portion and the second portion of the output voltage is 800V.

5. The apparatus of claim 1, wherein primary stage includes a first plurality of switches and a primary side of a transformer to generate the first input voltage that corresponds to an alternating current (AC) voltage.

6. The apparatus of claim 5, wherein the first plurality of electrical components of the first secondary stage includes a plurality of capacitors, an inductor, a plurality of diodes, and a first secondary side of a transformer to rectify the AC voltage to generate the first portion of the output voltage that is a first DC voltage.

7. The apparatus of claim 5, wherein the first plurality of electrical components of the first secondary stage includes a second plurality of switches and a first secondary side of the transformer to rectify the AC voltage to generate the first portion of the output voltage that is a first DC voltage.

8. The apparatus of claim 7, wherein the second plurality of electrical components of the second secondary stage includes a third plurality of switches a second secondary side of the transformer to rectify the AC voltage to generate the second portion of the output voltage that is a second DC voltage.

9. The apparatus of claim 8, wherein the first DC voltage is equal to the second DC voltage.

10. A charging apparatus for a vehicle, the apparatus comprising:

a DC/DC converter including;

a primary stage configured to receive an incoming voltage to generate a first input voltage;

a first secondary stage including a first plurality of electrical components configured to generate a first portion of an output voltage for charging at least one battery in a vehicle in response to the first input voltage; and

a second secondary stage including a second plurality of electrical components configured to generate a second portion of the output voltage in response to the first input voltage,

wherein each of the first plurality of electrical components and the second plurality of electrical components is rated to a voltage rating that is less than a total sum of the first portion and the second portion of the output voltage.

11. The apparatus of claim 10, wherein the first secondary stage is in series with the second secondary stage.

12. The apparatus of claim 10, wherein the first portion of the output voltage is generally equal to the second portion of the output voltage.

13. The apparatus of claim 10, wherein the total sum of the first portion and the second portion of the output voltage is 800V.

14. The apparatus of claim 10, wherein primary stage includes a first plurality of switches and a primary side of a transformer to generate the first input voltage that corresponds to an alternating current (AC) voltage.

15. The apparatus of claim 14, wherein the first plurality of electrical components of the first secondary stage includes a plurality of capacitors, an inductor, a plurality of diodes, and a first secondary side of a transformer to rectify the AC voltage to generate the first portion of the output voltage that is a first DC voltage.

16. The apparatus of claim 14, wherein the first plurality of electrical components of the first secondary stage includes a second plurality of switches and a first secondary side of the transformer to rectify the AC voltage to generate the first portion of the output voltage that is a first DC voltage.

17. The apparatus of claim 16, wherein the second plurality of electrical components of the second secondary stage includes a third plurality of switches a second secondary side of the transformer to rectify the AC voltage to generate the second portion of the output voltage that is a second DC voltage.

18. The apparatus of claim 17, wherein the first DC voltage is equal to the second DC voltage.

19. A charging apparatus for a vehicle, the apparatus comprising:

a power converter including;

a primary stage configured to receive an incoming voltage to generate a first input voltage;

a first secondary stage including a first plurality of electrical components configured to generate a first portion of an output voltage for charging at least one battery in a vehicle in response to the first input voltage;

a second secondary stage in series with the first secondary stage including a second plurality of electrical components configured to generate a second portion of the output voltage in response to the first input voltage; and

a transformer operatively coupled to the primary stage, the first secondary stage, and the second secondary stage to transfer the first input voltage to the first secondary stage and the second secondary stage,

wherein each of the first plurality of electrical components and the second plurality of electrical components is rated to a voltage rating that is less than a total sum of the first portion and the second portion of the output voltage.

20. The apparatus of claim 19, wherein the power converter is a DC/DC converter.