XEYAR Buffered Charging.
720 kW from 83 kW. No Grid Upgrade.
USPTO patent-pending clustered architecture for battery-buffered DC fast charging. 30 to 720 kW per port across five product families, all running on a standard 83.1 kW grid service. Two chemistry options — supercapacitor or sodium-ion — chosen per project. Deploy in 4–6 weeks while competitors wait 12–24 months for utility interconnection.
Trickle. Buffer. Burst.
XEYAR Buffered Charging breaks the kilowatt-for-kilowatt match between grid service and peak charging power. The grid only supplies the average daily energy throughput — the buffer absorbs the difference and delivers the burst to the vehicle.
The three-stage operating cycle
Conventional DC fast charging requires the grid service to match the peak charging power kilowatt-for-kilowatt. A 240 kW charger needs a 240+ kW service — typically a transformer upgrade, sometimes feeder reinforcement, often a 12–24 month interconnection study. This is why every public DCFC site has a multi-year project clock attached to it.
XEYAR's USPTO patent-pending Cluster architecture eliminates the kW-match. The Cluster draws a continuous low-rate trickle charge from a standard 100A × 480V three-phase service (~83.1 kW) — well below any utility interconnection threshold. Energy is stored in the integrated buffer (supercapacitor or sodium-ion, chosen per project). When a vehicle plugs in, the cluster's PCS draws from the buffer and delivers DCFC output at multiples of the grid service rating.
The grid never sees the burst. The vehicle gets the speed it needs. The utility never sees a demand spike. The site deploys in 4–6 weeks instead of 12–24 months — because the entire schedule is no longer gated by transformer procurement and utility study queues.
Three-stage flow
Trickle Charge from Grid
Continuous low-rate charge from a standard 100A × 480V three-phase service. Below utility interconnection thresholds. The grid sees a flat, predictable load.
Store in Integrated Buffer
Energy is stored in the buffer — chemistry chosen per project. Sized to the cluster's expected peak burst demand under Nexus's 30% utilization sizing methodology.
Burst Discharge to Vehicle
The PCS draws from the buffer and delivers DCFC output at multiples of the grid service. Up to 720 kW per port across the product family. The grid never sees the burst.
Three Standard Cluster Tiers.
Each tier is a standard, certified buffer-and-PCS configuration that drives one of the five XEYAR product families (PEGASUS, FALCAO, SPHINX, KOMODO, MAVERICK). Every tier runs on the same 83.1 kW grid service.
Compact Cluster
- Per-port output30–240 kW
- Port count2 ports
- Buffer (SC)25–50 kWh
- Buffer (Na-ion)20–80 kWh
- Footprint~3 m × 1.5 m
- Best fitPEGASUS · FALCÃO
Standard Cluster
- Per-port output60–240 kW
- Port count4 ports
- Buffer (SC)100–200 kWh
- Buffer (Na-ion)80–360 kWh
- Footprint~5 m × 2 m
- Best fitFALCÃO · SPHINX
Max Cluster
- Per-port output240–720 kW
- Port count4+ ports
- Buffer (SC)300–600 kWh
- Buffer (Na-ion)360–2,362 kWh
- FootprintContainerized
- Best fitKOMODO · MAVERICK
A FALCÃO Cluster, Sized End-to-End.
A real worked example from XEYAR's Engineering Playbook. This is exactly the math your site engineer will see in the proposal — transparent, reproducible, defensible.
240 kW × 2-port · Standard Cluster · Public DCFC Site
Highway corridor location, 30% utilization assumption, single 100A × 480V three-phase service.
How XEYAR Sizes a System.
Sizing is not guesswork — it's a documented methodology applied by Nexus and reviewed by XEYAR engineering. The same math, every project, every market.
The 30% utilization sizing model
XEYAR sizes every Cluster around a 30% utilization assumption, validated against three years of public-DCFC operating data across North America and the GCC. Above 30% utilization, customers see a meaningfully different traffic pattern and the system is upgraded to the next tier.
The sizing math:
Daily Energy Required = (Sessions × Avg Energy/Session) ÷ Utilization Factor
Buffer Capacity = Burst Energy × (Recharge Window / Inter-Session Gap)
Grid Service = Daily Energy Required ÷ 22 (assuming 22 hr/day useful charge window)
Each formula has a documented derivation in the Engineering Playbook §7.2 — and each input is calibrated from real site data, not vendor-spec optimism. The result: zero oversizing, zero under-provisioning, and a transparent capex story that survives utility review.
Why XEYAR Buffered Charging Wins.
Six engineering and project-economics properties that combine to make XEYAR the only practical answer for grid-constrained DCFC deployment.
No Grid Upgrade Required
Runs on a standard 100A × 480V three-phase service (83.1 kW). Below utility interconnection thresholds. No transformer upgrade, no feeder reinforcement, no 12–24 month interconnection study queue.
4–6 Week Deployment
Site deployment in weeks, not years. The schedule is dominated by civil works, not utility study. Compare to 12–24 months for conventional DCFC at the same per-port power rating.
Up to 720 kW Per Port
Across five product families (PEGASUS 30 kW · FALCÃO 240 kW · SPHINX 360 kW · KOMODO 480 kW · MAVERICK 720 kW). Heavy-duty, fleet, and highway corridor charging at speeds matching the fastest vehicles on the road.
Two Chemistries, One Architecture
Supercapacitor for power-dominant duty cycles, sodium-ion for energy-dominant — chosen per project, not stocked simultaneously. Same Cluster architecture, same Nexus orchestration, same certifications.
MURB & Indoor Code-Compliant
Both buffer chemistries are non-thermal-runaway. Compliant with NFPA 855, IBC, IFC, NEC Article 706, CEC, and CSA for indoor and multi-unit residential deployment without dedicated fire suppression infrastructure.
USPTO Patent Pending · 39 Claims
The Cluster architecture is XEYAR's defensible IP. 39 issued claims cover the trickle/buffer/burst topology, the chemistry-agnostic DC bus, and the Nexus orchestration interface. Every deployment is licensed, every install is protected.
Certified to Every Applicable Standard.
XEYAR Buffered Charging carries certifications for the integrated DC ESS buffer, the charge-point output stages, and the open-protocol communication stack. The DC ESS boundary is fully UL 9540 3rd Edition listed.
The Architecture Itself Is the Invention.
XEYAR Buffered Charging is protected by two USPTO provisional patent applications totaling 84 claims across hardware and software. The Cluster patent covers the modular battery-buffered architecture; the Nexus patent covers the chemistry-aware orchestration platform that runs on it. Together they form a complete, defensible IP stack — not a feature, not a configuration, the system itself.
The XEYAR Cluster Provisional Patent Application covers the modular battery-buffered clustered EV charging system. Its 39 claims protect the multi-source 120V to 600V AC input subsystem, the bidirectional PCS with shared DC bus, the field-selectable non-thermal-runaway energy storage module (Na-ion or supercapacitor, one per installation), the dedicated ESMS — BMS for Na-ion or CapMS for supercapacitor — and the cluster of two or more EV charging port modules served from a single buffer.
The architecture is the innovation. Battery-buffered DC fast charging is not new. Multi-port DCFC is not new. Single-chemistry stationary BESS is not new. What XEYAR claims is the specific combination: a clustered architecture serving 2 to 20+ charging ports from a single shared DC bus, with chemistry chosen at install time, governed by a chemistry-specific ESMS, and certified as a unified DC ESS boundary under UL 9540 3rd Edition. None of the cited prior art discloses this combination.
The patent's distinguishing claims — clustered topology, field-selectable chemistry, chemistry-specific ESMS, tiered C-rate spec, multi-source input, and DC ESS modular certification — make it structurally difficult to compete with at the architectural level. A competitor cannot match the deployment economics without infringing one or more independent claims.
- Claims
- 39 total
- Independent
- Claim 1 · Claim 13
- Method Claims
- 14 – 17
- Single-Port DCFC
- 27 – 30
- Networked VPP
- 31 – 33
- Inventor
- Sal Möten
- Filing Year
- 2026
- Status
- Patent Pending
What the Cluster Patent Protects
Multi-Source 120–600 V AC Input
Single-phase or three-phase input from utility grid, solar PV, wind turbine, generator, or building/dwelling panel — single-source or simultaneous multi-source — into a bidirectional PCS with independent conversion stages per source type.
HardwareBidirectional PCS · Shared DC Bus
All AC sources combine through independent conversion stages onto a single shared DC bus. Bidirectional design enables grid export, V2G, and VPP dispatch from the same hardware.
HardwareField-Selectable Chemistry
Energy storage module with field-selectable non-thermal-runaway cells — Na-ion or supercapacitor, one per installation — rated for discharge C-rate sufficient to sustain EV charging output. Chosen per project at install time.
Hardware · ChoiceDedicated ESMS (BMS or CapMS)
Energy Storage Management System resolving to a chemistry-specific control layer: BMS for Na-ion or CapMS for supercapacitor. Enforces chemistry-appropriate voltage, SOC, temperature, and C-rate limits on the PCS — never a generic BMS retrofit.
Hardware · ControlCluster of 2+ Charging Ports
Two or more EV charging port modules served from the shared DC bus — Level 2 only, DCFC only, or mixed L2/DCFC cluster. Port count is independently scalable from buffer capacity. UL 2202 + UL 2594 certified output stages.
Hardware · ClusterCMS Dynamic Load Distribution
Cluster Management System dynamically distributes stored energy across active ports using OCPP-aware priority, SOC-aware curtailment, and customer-defined session policies. Vehicles see graceful degradation, not faulted sessions, when buffer SoC is constrained.
Hardware · CMSHigh-Rise / MURB
Method claim covering deployment in high-rise residential and multi-unit residential buildings, where non-thermal-runaway chemistry enables NFPA 855 / IBC / IFC code compliance without dedicated fire suppression.
MethodOlder Home · 100 A Panel
Method claim covering deployment on existing 100 A residential service without panel upgrade — the buffer absorbs peak demand the service cannot deliver directly.
MethodRemote / Indigenous · Solar + Wind
Method claim covering off-grid and grid-edge deployment using simultaneous multi-source solar, wind, and optional generator input — paired with the buffer for sustained DCFC capability without grid presence.
Method · Off-GridThe Software Layer That Runs on Top
The Nexus patent extends the Cluster hardware system with the intelligent software platform — chemistry abstraction, hybrid orchestration, OCPP 2.0.1 bidirectional charger management, VPP dispatch, federated learning analytics, and automated revenue distribution. One platform manages either chemistry on any deployment, and any mix of chemistries across a fleet of deployments — through a unified abstraction layer.
OCPP 2.0.1 Charger Management
Bidirectional charger management with V2G capability, ISO 15118 Plug & Charge, dynamic load allocation across cluster ports, and coordination with VPP dispatch signals during charging sessions.
SoftwareVPP Dispatch Engine
Automated wholesale market participation: CAISO · ERCOT · PJM · NYISO · National Grid ESO. OpenADR 2.0 + IEEE 2030.5 protocols. Sub-100 ms frequency-regulation response (sub-millisecond when supercaps are deployed).
Software · Grid ServicesRevenue Distribution Engine
Automated settlement among platform operator (XEYAR), regional aggregator, certified installer, and asset owner. Configurable percentage splits per deployment. Metered energy contributions and availability tracking.
Software · SettlementNone of the cited prior art references discloses, alone or in combination: (1) clustered multi-port or single-port DCFC architecture; (2) with field-selectable non-thermal-runaway Na-ion or supercapacitor; (3) governed by a dedicated ESMS (BMS or CapMS); (4) tiered C-rate >1C / ≥5C / ≥10C; (5) multi-source 120 V to 600 V AC input; (6) deployment without electrical upgrade across six environments; (7) NFPA 855 / IBC compliance through chemistry alone; and (8) DC ESS modular certification under UL 9540 3rd Edition with separately certified PCS, L2 EVSE, and DCFC.
VPP-Ready Today.
Revenue-Enabled in 2026.
Every XEYAR battery-buffered system ships VPP-ready with a bidirectional Power Conversion System (UL 1741) and the communications stack required for grid-export participation. When XEYAR NEXUS — XEYAR's planned virtual power plant controller — launches in 2026, every deployed system will automatically enable grid arbitrage and ancillary services revenue. No hardware swap required. The figures below project what your system will earn once NEXUS activates.Projected model: $0.16/kWh net spread × multiple cycles per day × 264 weekdays = substantial revenue potential layered on top of EV charging income.
| Cluster Configuration | Ports | SuperCap kWh | Na-ion kWh | SC Projected/yr | Na Projected/yr |
|---|---|---|---|---|---|
| PEGASUS 30 kW | 4 | 25 | 20 | $3,168 | $4,224 |
| PEGASUS 40 kW | 8 | 50 | 40.6 | $6,336 | $8,575 |
| FALCÃO 120 kW | 8 | 150 | 162.4 | $19,008 | $34,299 |
| FALCÃO 240 kW | 4 | 150 | 121.8 | $19,008 | $25,724 |
| FALCÃO 360 kW | 4 | 150 | 121.8 | $19,008 | $25,724 |
| SPHINX 240 kW | 4 | 150 | 121.8 | $19,008 | $25,724 |
| KOMODO 480 kW | 6 | 150 | 121.8 | $19,008 | $25,724 |
| KOMODO 720 kW | 8–12 | 150 | 121.8 | $19,008 | $25,724 |
Future VPP Revenue Projector 2026 Roadmap
Project annual grid-export revenue for any XEYAR DCFC configuration once XEYAR NEXUS launches in 2026. Use this tool today to plan future earnings — your system ships VPP-ready and will enable these projections automatically when NEXUS activates.
Forward-looking projections. All revenue figures shown depend on the planned 2026 release of XEYAR NEXUS, XEYAR's virtual power plant controller. Specific availability dates, market participation rules, and feature scope are subject to regulatory approval and may change. Projections assume 264 weekdays/year × multi-cycle dispatch × 50% battery utilization at $0.16/kWh net TOU spread. Actual revenue once NEXUS activates will depend on local electricity market structure, TOU rates, ancillary service participation, capacity market enrollment, and grid operator agreements. Frequency regulation, demand response, and capacity market revenue stacking can further increase returns. Not financial advice. Not a guarantee of future earnings.
Choose the Right XEYAR Product.
Quick reference matrix for matching XEYAR products to applications. Every product available in supercapacitor or sodium-ion chemistry on the same patented DC ESS boundary.
| Product | Power / Capacity | Best Application | Chemistry | Key Differentiator |
|---|---|---|---|---|
| ⚡ Battery-Buffered DC Fast Chargers | ||||
| XEYAR-PEGASUS | 30–40 kW × 2–8 ports | Workplace, fleet, dealerships, ZEVIP small projects | SC or Na-ion | Compact footprint, low entry cost |
| XEYAR-FALCÃO | 120–360 kW × 1–16 ports | Highway corridors, gas stations, large commercial | SC or Na-ion | Most versatile, scalable port count |
| XEYAR-SPHINX | 240–360 kW Ultra-fast | Premium urban, dealerships, ultra-fast plazas | SC or Na-ion | 10–15 min charge times |
| XEYAR-KOMODO | 240–720 kW HPC × 4–12 dispensers | HD trucks, freight corridors, megawatt depots | SC or Na-ion | Most powerful ZEVIP-eligible system |
| XEYAR-MAVERICK | Custom (30–1000+ kW) | Non-standard projects, custom engineering | SC or Na-ion | Bespoke power, port count, chemistry |
| 🔋 Battery Energy Storage Systems | ||||
| XEYAR PHOENIX | 13–15 kWh wall-mount | Residential solar storage, home backup | SC or Na-ion | Wall-mountable, 100% DoD |
| XEYAR DRAGONFLY | 50–500 kWh modular | Commercial peak shaving, solar/wind co-location | SC or Na-ion | Up to 12C charge/discharge |
| XEYAR DRACO | 5C / <1 ms / 500K cycles | Data center UPS, hyperscale critical power | SuperCap | Sub-millisecond response, 45-yr life |
| XEYAR LEVIATHAN | 2,362 kWh per container | Grid-scale storage, frequency regulation | Na-ion | 20-ft container, IP55, gas suppression |
| XEYAR NOMAD | 100–500 kWh mobile | Disaster relief, events, construction | SC or Na-ion | Trailer-mounted, optional DCFC |
| XEYAR CORVUS | Cabinet UPS | 5G / 6G cell tower backup | SC or Na-ion | −40°C operation, no HVAC needed |
| XEYAR CETUS | Rack-mount UPS | AI / GPU compute transient buffering | SuperCap | Native to AI compute load profile |
| XEYAR WOLVERINE | Containerized microgrid | Indigenous communities, remote sites | SC or Na-ion | Off-grid microgrid in a box |
| XEYAR HELIOS | Integrated PV + BESS + EV | Solar + storage + EV charging hubs | SC or Na-ion | Single-skid integration |
| XEYAR TITAN | Custom (any kWh) | Non-standard BESS projects | SC or Na-ion | Custom configuration to project spec |
Note: Both BESS and EV charger product lines run on the same patented (pending) DC ESS architecture. You can deploy either family — or both together (e.g., LEVIATHAN BESS + KOMODO chargers on the same site) — with a single set of certifications and one chemistry choice per cluster.
The Engineering Questions We Hear Most.
Direct, engineering-grade answers to common questions about XEYAR Buffered Charging — how the architecture works, what it costs to deploy, how to choose chemistry, and what code-compliance pathways are available.
How does battery-buffered EV charging work?
Three stages. (1) The Cluster draws a continuous low-rate trickle charge from a standard 100A × 480V three-phase service — about 83.1 kW. This is well below the threshold that triggers utility interconnection studies. (2) Energy is stored in the integrated buffer — supercapacitor or sodium-ion, chosen per project. (3) When a vehicle plugs in, the cluster's PCS draws from the buffer and delivers DCFC output at multiples of the grid service rating — up to 720 kW per port.
The grid never sees the burst, the vehicle gets the speed it needs, and the utility never sees a demand spike on its transformer.
Why doesn't XEYAR Buffered Charging require a grid upgrade?
Conventional DCFC requires the grid service to match the peak charging power kilowatt-for-kilowatt. A 240 kW charger needs a 240+ kW service — typically a transformer upgrade, sometimes feeder reinforcement, often a 12–24 month interconnection study.
XEYAR breaks the kW-match. The grid only needs to supply the average daily energy throughput, not the instantaneous peak. The buffer absorbs the difference. Result: a 240 kW × 4-port site can run on the same 83.1 kW service that a single Level 2 charging stall already has — and deploys in 4–6 weeks instead of 12–24 months.
How fast is XEYAR Buffered Charging deployment?
4–6 weeks from contract to commissioning, in jurisdictions where the existing 100A × 480V service is already in place. The deployment timeline is dominated by site civil works (foundations, conduit, signage), not by utility interconnection.
Compare to 12–24 months for conventional DCFC at the same power rating, where the entire schedule is gated by transformer procurement and utility study queues. For multi-site rollouts, the deployment-velocity differential compounds dramatically — a 50-site network deploys in months rather than years.
Which chemistry should I choose — supercapacitor or sodium-ion?
Chosen per project based on duty cycle.
Supercapacitor is the right answer when sessions are short and frequent — fleet workplace charging, dealership service bays, taxi / rideshare rapid turnaround, regenerative-braking heavy industrial.
Sodium-ion is the right answer when sessions are sustained — long-haul truck charging, public DCFC corridors with extended sessions, multi-hour fleet charging, sites with significant solar-plus-storage tie-in.
The XEYAR Cluster supports both; the choice is made at engineering with no architectural rework. Each project uses one chemistry on the same DC bus — never both simultaneously.
Can I mix Level 2 (AC) and DC fast charging on a single XEYAR Cluster?
Yes. A single Cluster can simultaneously drive Level 2 AC charge points (UL 2594 listed) and DCFC ports (UL 2202 listed) from the same shared DC bus and the same grid service. Nexus orchestrates load distribution dynamically.
This is particularly valuable for MURB and workplace deployments where a single tenant might need a Level 2 overnight stall and an adjacent DCFC for visitor charging — running on a shared 83.1 kW service.
What happens if the buffer is depleted during peak demand?
Nexus dynamically re-allocates available power across active charge points to keep all sessions delivering — at reduced rates rather than zero. The shared DC bus and buffer State-of-Charge are continuously monitored.
When SoC falls below a defined threshold, output is curtailed proportionally rather than terminating any session. Vehicles charging at the cluster see a slowdown, not a fault. Once burst demand subsides, the trickle charge from the grid restores buffer SoC. This graceful-degradation behavior is part of what makes Cluster sites operationally superior to standalone DCFC.
Is XEYAR Buffered Charging code-compliant for MURB and indoor parking?
Yes — when configured with the supercapacitor buffer (and sodium-ion in markets where Na-ion has UL 9540A Pass acceptance for indoor). Both chemistries are non-thermal-runaway, meeting NFPA 855, IBC, IFC, NEC Article 706, CEC, and CSA requirements for indoor and multi-unit residential deployment without dedicated fire suppression infrastructure.
This is the regulatory edge that enables MURB and underground-parking deployments where lithium-based DCFC is restricted by fire code. A growing share of XEYAR's MURB pipeline is specifically motivated by this distinction.
What certifications does XEYAR Buffered Charging carry?
The integrated DC ESS buffer is UL 9540 3rd Edition listed and UL 9540A Pass. Charge-point output stages carry UL 2202 (DCFC) and UL 2594 (Level 2 EVSE). Power conversion is UL 1741 listed. Cells are UL 1973 listed. The entire system is CSA C22.2 certified for Canadian deployment.
Communication is OCPP 2.0.1 native with ISO 15118 Plug and Charge support. The XEYAR Cluster architecture is USPTO patent pending with 39 claims.
Stop waiting on the utility.
Start charging in 4–6 weeks.
Every XEYAR Buffered Charging project starts with a free site engineering consultation. Share your site profile, vehicle mix, expected session pattern, and existing electrical service — our team will run the 30% utilization sizing model and propose the right Cluster tier and chemistry. Transparent math, no grid upgrade, code-compliant for indoor and MURB.