Direct current fast charger system with low standby power

Patent metadata

Field	Value
Publication number	US-12365255-B2
Application number	US-202117546146-A
Country	US
Kind code	B2
Filing date	Dec 9, 2021
Priority date	Dec 9, 2021
Publication date	Jul 22, 2025
Grant date	Jul 22, 2025

Abstract

A direct current fast charge (DCFC) system and associated method that lower standby power dramatically when the DCFC system is not in operation, and that provide a reset capability for communication needs. The DCFC system utilizes an appropriate load disconnection switch and an associated control and communication circuit, timer circuit, and automatic turn on system. This improves the reliability of the electronics by removing voltage stress during the standby mode. The DCFC system prevents energy waste, and therefore provides a “green” alternative to conventional DCFC systems.

First claim

What is claimed is:

1. A battery charging system, comprising:
a voltage input;
one or more secondary power supplies coupled to the voltage input and configured to receive the voltage input and output a voltage lower than the voltage input;
direct loads coupled to the voltage input;
indirect loads configured to be coupled to the one or more secondary power supplies;
a switch disposed between the indirect loads and the one or more secondary power supplies; and
a control and communications circuitry coupled to the switch to control the switch with the battery charging system in a standby mode, the control and communications circuitry including a timing circuit,
the timing circuit configured to cause the control and communications circuitry to selectively disconnect certain of the indirect loads from the one or more secondary power supplies, while maintaining at least some of the direct loads coupled with the voltage input, with the battery charging system in the standby mode and subsequently reconnect the certain of the indirect loads to the one or more secondary power supplies after a predetermined period of time.

2. The battery charging system of claim 1 , wherein the control and communications circuitry is configured to control the switch to selectively disconnect all of the indirect loads from the one or more secondary power supplies with the battery charging system in the standby mode.

3. The battery charging system of claim 1 , wherein at least a portion of the control and communications circuitry is powered by the one or more secondary power supplies.

4. The battery charging system of claim 1 , wherein at least a portion of the control circuit and communications circuitry is powered by an auxiliary power supply coupled to the voltage input.

5. The battery charging system of claim 1 , wherein certain of the one or more secondary power supplies are turned off in the standby mode.

6. The battery charging system of claim 1 , wherein the timing circuit is configured to, after the predetermined period of time, restore a charging mode of the battery charging system after the battery charging system is put into the standby mode by selectively reconnecting the certain of the indirect loads to the one or more secondary power supplies.

7. The battery charging system of claim 1 , wherein at least a portion of the control and communications circuitry is directly coupled with the switch.

8. The battery charging system of claim 1 , wherein the direct loads operate at a voltage of the voltage input and the indirect loads operate at a voltage lower than a voltage of the voltage input.

9. The battery charging system of claim 8 , wherein the direct loads are 300-500V loads.

10. A battery charging system, comprising:
a voltage input;
direct loads configured to be coupled to the voltage input;
one or more secondary power supplies coupled to the voltage input and configured to receive the voltage input and output a voltage lower than the voltage input;
indirect loads configured to be coupled to the one or more secondary power supplies;
a switch disposed between the voltage input and the direct loads, the one or more secondary power supplies, and the indirect loads; and
a control and communications circuitry coupled to the switch to control the switch with the battery charging system in a standby mode, the control and communications circuitry including a timing circuit,
the timing circuit configured to cause the control and communications circuitry to selectively disconnect certain of the direct loads, the one or more secondary power supplies, and the indirect loads from the voltage input, while maintaining at least some of the direct loads coupled with the voltage input, with the battery charging system in the standby mode and subsequently reconnect the certain of the direct loads, the one or more secondary power supplies, and the indirect loads with the voltage input after a predetermined period of time.

11. The battery charging system of claim 10 , wherein the control and communications circuitry is configured to control the switch to selectively disconnect all of the direct loads, the one or more secondary power supplies, and the indirect loads from the voltage input with the battery charging system in the standby mode.

12. The battery charging system of claim 10 , wherein at least a portion of the control and communications circuitry is powered by the one or more secondary power supplies.

13. The battery charging system of claim 10 , wherein one or more of the control circuit and the communications circuit are powered by an auxiliary power supply coupled to the voltage input.

14. The battery charging system of claim 13 , further comprising a surge protector coupled to the auxiliary power supply.

15. The battery charging system of claim 10 , further comprising one or more additional direct loads coupled to the voltage input between the voltage input and the switch.

16. The battery charging system of claim 10 , wherein the timing circuit is configured to, after the predetermined period of time, restore a charging mode of the battery charging system after the battery charging system is put into the standby mode by selectively reconnecting the certain of the direct loads, the one or more secondary power supplies, and the indirect loads to the voltage input.

17. The battery charging system of claim 10 , wherein at least a portion of the control and communications circuitry is directly coupled with the switch.

18. The battery charging system of claim 10 , wherein the direct loads operate at a voltage of the voltage input and the indirect loads operate at a voltage lower than a voltage of the voltage input.

19. The battery charging system of claim 18 , wherein the direct loads are 300-S00V loads.

20. A battery charging method, comprising:
selectively disconnecting, by a switch disposed between indirect loads and one or more secondary power supplies, certain indirect loads from the one or more secondary power supplies coupled to a voltage input and configured to receive the voltage input and output a voltage lower than the voltage input with the battery charging system in a standby mode;
wherein direct loads are also coupled to the voltage input; and
wherein the certain indirect loads are selectively disconnected from the one or more secondary power supplies using a control and communications circuitry coupled with the switch, wherein a timing circuit causes the control and communications circuitry to selectively disconnect certain of the indirect loads from the one or more secondary power supplies with the battery charging system in the standby mode, while maintaining at least some of the direct loads coupled with the voltage input, and subsequently reconnect the certain of the indirect loads to the one or more secondary power supplies after a predetermined period of time.

21. A battery charging method, comprising:
selectively disconnecting, by a switch disposed between indirect loads and one or more secondary power supplies, certain of direct loads, one or more secondary power supplies configured to receive a voltage input and output a voltage lower than the voltage input, and indirect loads coupled to the one or more secondary power supplies from the voltage input when the battery charging system is in a standby mode;
wherein the certain of the direct loads, the one or more secondary power supplies, and the indirect loads are selectively disconnected from the voltage input using a control and communicatio

Assignees

• Rivian Ip Holdings Llc

Inventors

• Li Ming
• Liu Yang
• Erikson Tyler
• Wei Lixiang
• Schulz Steven E

Classifications

• H02J7/663

  using battery or load disconnect circuits (H02J9/002 takes precedence) · CPC title

• H02J7/865

  Battery or charger load switching, e.g. concurrent charging and load supply (H02J7/50 takes precedence) · CPC title

• H02J7/855

  with circuits adapted for supplying loads from the battery · CPC title

• H02J7/44 Primary

  between battery management systems and power sources · CPC title

• H02J9/005

  using a power saving mode (for copiers G03G15/5004) · CPC title