Stellantis Patent Aims To Enhance Low-Power DC Fast Charging

Boosting Charging Efficiency For 800-Volt Electric Vehicles...

Robert S. Miller November 15, 2024

2025 Ram 1500 REV Prototype. (hi5_guy for MoparInsiders).

Stellantis (FCA US, LLC) is developing innovative hardware that could revolutionize how electric vehicles (EVs) charge at lower-powered DC fast-charging stations. This new system, described in a recently published U.S. patent on the United States Patent and Trademark Office (USPTO) website, aims to bridge the gap between 400-volt and 800-volt charging architectures, allowing high-voltage EVs like the 2025 Ram 1500 REV to charge faster at stations with less powerful outputs.

The Problem: 400-Volt Limitations –

2025 Ram 1500 REV Tungsten Crew Cab 4×4. (Ram).

Most existing DC fast-charging stations operate at 400 volts, which limits charging speeds for 800-volt EVs. Many automakers address this with dedicated DC boost modules, which add weight, cost, and complexity. Stellantis’ solution minimizes these downsides by rethinking the process.

The Proposed Solution –

Stellantis DC/DC Boost System For Recharging Higher Voltage Patent. (USPTO).

Instead of relying on bulky components, Stellantis proposes using a system of relay switches and a small DC capacitor. These components work with the vehicle’s inverter and electric motor to convert lower voltage into the higher power needed for fast charging.

Here’s how it works:

Relay Switches and Inverter Coordination: The relay switches direct the current through the inverter.
Motor-Assisted Conversion: The electric motor generates alternating currents (AC), which the inverter transforms into a boosted direct current (DC).
Efficient Charging: This boosted DC power is fed into the EV’s 800-volt battery for faster recharging.

Why This Matters –

This system reduces the need for expensive, heavy hardware while improving compatibility with 400-volt charging stations, including Tesla’s vast Supercharger network. It’s particularly relevant as Stellantis transitions to 800-volt architectures for its larger EVs, such as the Ram 1500 REV, while many future models on its STLA platforms will stick to 400 volts.

Streamlined Charging For Future EVs –

Stellantis has a history of exploring ways to simplify EV components. This patent aligns with the company’s broader strategy of reducing onboard hardware to make EVs lighter, more efficient, and cost-effective.

While this feature may not be immediately necessary for all upcoming models, it’s a step forward in making EVs more adaptable to the existing charging infrastructure.

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bill burke Nov 16, 2024 #1

Most knowledgeable people estimate that at best, all electric vehicles will consist of 15%-20% of the market. That is a sizable number so ongoing developments such as this fast charging system seem worth the investment. It is the huge financial and engineering costs in such a short timeframe that is questionable. As we look over the market today from the perspective of the Trump administration to roll back EPA standards and timeframes, it is evident too much money, time and resources were squandered on totally unattainable environmental false claims and a radical politically driven agenda. What is worse other traditional and more popular development was abandoned and now brands like Dodge, the performance marquee, sits with no V-8 in its lineup and a very dim future staring it in the face. Rumored all hands on board V-8 development plans are welcome but may be too late with one cause in the dunce spotlight, and the voters have soundly rejected that cause and its protagonist gang of idiots. Hooray, we have a fast charging device, really, I’d trade that for a new V-8 in a heartbeat. Bet everyone reading this would too.

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patfromigh Nov 16, 2024 #2

I worked at a gas station pumping gas when I was in high school. This job enabled me to regularly see and gas up various cars that would be true collector vehicles today. Anecdotally, I saw how much those old land yachts and muscle cars swilled fuel. In particular I remember a low line Dodge Coronet sedan with a 426 Hemi. The owner was using it as a winter beater, because at that point it was over 5 years old. They had no idea what was under the hood.

The reason I'm bring this up on this thread is because none of those gas hogs from the past can match the massive thirst for energy our Chevy Silverado EVs have. Yeah the thing is electric, but it is constantly needs to be plugged in. I'm supposed to bring the EVs up with a full charge to where the customers pick them up. Now that colder temperatures are upon us here, I have to turn off the climate control while I go up the parking ramp, so I'm not using up that fresh charge.

I hope Stellantis can do better than GM with electric pickup trucks.

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