EV Charge Connector Ejection for Rapid In-Vehicle Disconnect

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Solution Overview

Problem

Existing electric vehicle charging systems lack an operably controlled mechanism for rapid disconnection in time-critical circumstances, requiring operators to physically step out of the vehicle, which can be unsafe or impractical in certain situations.

Innovation Solution

A system comprising an ejector actuator, connector latch actuator, and a controller that responds to a user interface to unlatch and eject the charging connector from the vehicle, allowing safe and rapid disconnection without physically exiting the vehicle.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If the vehicle operator manually disconnects the charging cable by stepping out of the vehicle, then the connector can be disconnected, but valuable time is lost and safety is compromised in emergency situations

Engineering Contradiction:

Improvedisconnection timeVSAvoidautomatic disconnection capability

Core Design Contradiction:

Loss of timeVSEase of operation

Solution Approach 1:

The system enables self-service by allowing the vehicle to automatically disconnect the charging cable through the ejector actuator and controller, eliminating the need for manual intervention by the operator. The controller receives a disconnect command and automatically actuates the ejector mechanism to separate the connectors.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the manual mechanical disconnection process with an automated electromechanical system. The ejector actuator, controlled by the controller, substitutes for manual physical actions, enabling rapid and safe disconnection without requiring the operator to exit the vehicle.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If the vehicle operator remains inside the vehicle during disconnection, then safety is improved in emergency situations, but manual disconnection is required which slows down the process

Engineering Contradiction:

Improveoperator safetyVSAvoiddisconnection speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system performs the disconnection task itself through automated actuators and control systems, allowing the operator to remain safely inside the vehicle while the controller and ejector actuator handle the cable separation automatically.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The controller acts as an intermediary between the operator's disconnect command and the physical ejection mechanism. It coordinates the sequence of operations, first unlatching the connector latch actuator and then activating the ejector actuator to safely and rapidly separate the connectors.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Extent of automation

If a known system automatically ejects the charging cord when the vehicle is turned on, then disconnection occurs without operator intervention, but the operator cannot control the timing of disconnection

Engineering Contradiction:

Improveautomatic ejectionVSAvoidoperator control

Core Design Contradiction:

Extent of automationVSEase of operation

Solution Approach 1:

The system incorporates feedback through the user interface, which receives and processes the operator's disconnect command. This allows the automated ejection to occur only when the operator intentionally requests it, providing both automation and operator control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system transitions from static automatic ejection (triggered only by vehicle startup) to dynamic controlled ejection (triggered by operator command at any appropriate time). The controller enables flexible timing of the disconnection process based on operational needs and safety considerations.

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables safe and rapid disconnection of the charging connector, enhancing safety and convenience by allowing operators to drive away from the charger without manually disconnecting, especially in emergency or uncomfortable situations.

Implementation Method 1

an ejector actuator... controlling an ejector actuator to eject a charging connector from a vehicle connector

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

a connector latch actuator having a latched position and an unlatched position

Methodology Applied

Scientific EffectMechanical Fastening: Mechanical Fastener

Data Source

PatentUS20250329976A1System and method for disconnecting a charge cable from an electric vehicle

Publication Date: 2025.10.23 FCA US LLC

AI summary

A release system for an electric vehicle includes an ejector actuator, a connector latch actuator having a latched position and an unlatched position, a user interface generating a release signal and a controller coupled to the ejector actuator, the connector latch actuator, and the user interface. The controller, in response to the release signal, unlatches the connector latch actuator and controls the ejector actuator to eject a charging connector from a vehicle connector.