EV Charger Coupler Interface for Current Selection and Overcurrent Protection

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Solution Overview

Problem

Existing electric vehicle chargers require manual switching between different current levels, lacking user control and feedback, and do not prevent overheating or overcurrent effectively.

Innovation Solution

A user interface equipped coupler with a momentary switch and light display allows users to select and visually confirm output current levels, integrated with an in-cable control and protection device (ICCPD) that determines and limits the current level to prevent overheating and overcurrent.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual switching between different chargers is used to change output current levels, then the user can select different current levels, but the device complexity increases and the ease of operation deteriorates

Engineering Contradiction:

Improveoutput current level selectionVSAvoidcurrent level switching

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent combines multiple current level selection functions into a single coupler unit with integrated momentary switches. Instead of requiring separate chargers for different current levels, the system merges AC Level 1 and AC Level 2 charging capabilities into one device, allowing users to switch between current levels by pressing momentary switches on the coupler itself.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coupler automatically detects and adapts to the appropriate current level based on vehicle inlet type and user selection, eliminating the need for manual intervention to switch between chargers. The system self-configures the charging parameters based on the connected vehicle and selected mode.

Inventive Principle:

Principle #25Self-service

2Device complexity

If no visual feedback is provided for selected current level, then the device complexity is reduced, but the loss of information increases

Engineering Contradiction:

Improveuser interface componentsVSAvoidselected current level confirmation

Core Design Contradiction:

Device complexityVSLoss of information

Solution Approach 1:

The patent uses LED indicators that change color or illumination state to visually indicate the selected current level. Different LED patterns or colors correspond to different current level selections, providing immediate visual feedback to the user about the active charging mode without adding complex display components.

Inventive Principle:

Principle #32Color changes

Solution Approach 2:

The system provides real-time visual feedback through the light display that confirms the current level selection to the user. This feedback loop ensures the user can verify their selection and understand the system state, reducing information loss while maintaining simple interface components.

Inventive Principle:

Principle #23Feedback

3Device complexity

If no in-cable control and protection device is used, then the device complexity is reduced, but the reliability deteriorates due to overheating and overcurrent risks

Engineering Contradiction:

Improveprotection system componentsVSAvoidoverheating and overcurrent protection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent introduces an in-cable control and protection device (ICCPD) as an intermediary component within the charging cable. This device acts as a mediator between the power source and the vehicle, monitoring and controlling current flow to prevent overheating and overcurrent conditions while maintaining system reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The protection device is pre-integrated into the charging cable assembly, establishing protection mechanisms before charging begins. The ICCPD is positioned to detect and respond to abnormal conditions proactively, preventing overheating and overcurrent issues before they can cause damage.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If multiple separate controllers are used for current control, then the adaptability increases, but the device complexity increases and synchronization issues arise

Engineering Contradiction:

Improvecurrent control capabilityVSAvoidcontroller synchronization

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent consolidates current control functionality into a single integrated controller within the coupler that manages both AC Level 1 and AC Level 2 charging operations. This unified controller eliminates synchronization issues between multiple separate controllers while maintaining the adaptability to handle different current levels through software-based control.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20260027925A1Electric vehicle charger with human interface equipped coupler

Publication Date: 2026.01.29 AMPURE CHARGING SYSTEMS INC

AI summary

A charging system comprises a coupler configured to be coupled to an inlet of a vehicle and including a user interface, the user interface including a momentary switch mounted on the outer surface of the coupler and configured to receive a user input for an output current level selected by a user; and a light display mounted on the outer surface of the coupler and configured to illuminate a light to visually show the user selected output current level; and an in-cable control and protection device (ICCPD) disposed within a cable, the ICCPD configured to receive the user input from the momentary switch; determine an output current level that the charging system operates at, among the user selected output current level or a current limit level; and transmit back the user selected output current level to the coupler, wherein the vehicle is charged with the determined output current level.