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Ford Charging Cable Patent Could Greatly Reduce EV Recharge Times

In recent months, Ford has filed a number of patents related to EV charging, including one that outlines a flat-tow charging method, another for a range-extending generator for the Ford F-150, and even a somewhat bizarre inflatable, solar-powered charging bubble. Now, as the automaker continues to invest heavily in EVs, EV batteries, and EV motors, a new Ford charging cable patent has been filed that could break through a major barrier – enabling EVs to charge as quickly as it takes to refuel an ICE-powered vehicle at a gas station.

The Ford charging cable breakthrough was achieved with the help of Purdue University researchers and centers around an alternative cooling method so that the cable itself can deliver a much higher current. This method extracts more heat from the cable than the traditional liquid cooling method by converting the liquid to vapor.

“Today, chargers are limited in how quickly they can charge an EV’s battery due to the danger of overheating,” said Michael Degner, senior technical leader, Ford Research and Advanced Engineering. “Charging faster requires more current to travel through the charging cable. The higher the current, the greater the amount of heat that has to be removed to keep the cable operational.”

This innovation could lead to significantly more charging power than what is available today, ultimately leading to vastly faster charging times with additional advances in vehicle charging technology. Ford plans to begin testing a prototype charging cable in the next two years to determine more specific charging speeds for different types of EVs, drawing upon 37 years of research centered around taking advantage of how liquid captures heat when boiled into a vapor.

“Electric vehicle charging time can vary widely, from 20 minutes at a station to hours on an at-home charging station, and that can be a source of anxiety for people who are considering buying an electric vehicle,” said Issam Mudawar, Betty Ruth and Milton B. Hollander Family professor of mechanical engineering, Purdue University. “My lab has come up with a solution for situations where the amounts of heat that are produced are beyond the capabilities of today’s technologies.”

We’ll have much more on this new technology soon, so be sure and subscribe to Ford Authority for 24/7 Ford news coverage.

Brett's lost track of all the Fords he's owned over the years and how much he's spent modifying them, but his current money pits include an S550 Mustang and 13th gen F-150.

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Comments

  1. Stephen Ketterer

    If this is real it offers hope for the future of EVs. Now they need to work on ownership costs.

    Reply
  2. David Dickinson

    I’d be shocked if they actually get this to work.

    Reply
  3. Ford Owner

    “Charging faster requires more current to travel through the charging cable. The higher the current, the greater the amount of heat that has to be removed to keep the cable operational.” This is not true, because heat is caused by the cable resistance: P = I^2 X R.
    A thicker stranded cable has less resistance (such as welding cable) so no cooling system is needed. Ask the guys who have been building their own electric vehicles for decades.

    X R

    Reply
    1. Ford Owner

      I need to add that charging batteries at high currents will shorten and eventually damage batteries, and this is why Tesla owners don’t use the high powered Superchargers often . It is much better to use less current and charge overnight while you sleep.

      Reply
      1. American50

        I agree and that is correct for todays lead-acid batteries. Does that apply to the lithium type batteries used in vehicles?

        Reply
  4. R. Walker

    I do a lot of long distance driving on a regular basis. My concern is charging times. The current charging method could add hours and hours to a thousand mile trip. I need to count on roadside charging stations. I can’t plug in at home. Until they perfect the charging method and time, I will drive the ICE until the wheels fall off and all the fuel stations close.

    Reply
    1. Thurston Munn

      Exactly 100 % of your remarks. We just drove to 850 miles from Okla. to Wisconsin in 12 hours. Can’t imagine how long it would take in an EV. Plus there is no EV available that will haul what our extended SUV brought with us on this trip.

      Reply
      1. R. Walker

        I have no first hand experience but, what I’m reading is folks with EV pull into the charging stations and find many of them to be broken/out of service. So, they have to locate another charging station. This is a huge problem when you are out in middle America and need a recharge. They have some problems to correct.

        Reply
    2. Smokin Paul

      Drove several long distance drives in a Tesla long range model Y. Last trip from Wisconsin to Sedona Arizona, up to salt lake city Utah and back.
      Using the Tesla supercharging network and with FSD doing most of the freeway driving we arrived in around the same amount of time compared to an ICE car.

      Charging takes a bit longer than gassing up but in about the time to take a piss or get a coffee the car is ready to go.

      With FSD you arrive rested like you rode the bus. Driving longer hours is easy peasy lemon squeezy.

      After our long distance experience in a Tesla it is the only way to fly. 👍🙂

      Reply
  5. Gil D.

    First the average American drives less than 45 miles a day. Second there are so many locations where you can charge – get plug share app and you see places you can charge. Third I agree there is not a reasonable cost long distance hauler today – but soon – Ford. However for daily commute – my first BEV cost me $22,000 after tax rebates and selling my 2012 ice. Next year it could be $17k if Congress raises the $12k rebate.

    Reply
  6. Paul Villella

    Cool, a resistance heater and distillery in one. Next middle name may be : Whiskey Road!

    Reply
  7. Paul Villella

    Cool, a resistance heater and distillery in one! Next Ford Pickup may be named : Whiskey Road!

    Reply

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