EV Charging Port Contactless Communication Units

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current electric vehicle charging systems lack efficient and reliable methods for high-bandwidth contactless communication between the vehicle and charging station, which is essential for secure and stable data transfer, particularly for vehicles equipped with numerous sensors and processing power.

Innovation Solution

Integration of contactless communication units (CCUs) within electric vehicle charging ports that ensure consistent and reliable operation by aligning power and communication connections, utilizing extremely high frequency (EHF) contactless communications to facilitate secure and high-speed data transfer between the vehicle and charging station.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If contactless communication units are integrated into charging ports, then data transfer speed and security are improved, but device complexity increases

Engineering Contradiction:

Improvedata transfer speedVSAvoidconnector assembly complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent combines contactless communication units (CCUs) with the charging port connector assembly, integrating multiple functions (power transfer and data communication) into a single unified interface. This merging eliminates the need for separate communication hardware while enabling high-speed EHF data transfer during charging operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The charging port connector assembly is designed to perform multiple functions simultaneously: electrical power transfer through conductive contacts and contactless data communication through integrated CCUs. This multi-functionality allows the same physical interface to handle both energy and information transfer, improving overall system efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If connector assemblies are fixedly aligned, then contactless communication reliability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecommunication reliabilityVSAvoidalignment precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The connector assembly incorporates asymmetric keying features and positioning structures that guide precise alignment during mating. The male and female connectors have complementary asymmetric geometries that naturally orient the CCUs in the correct relative positions, ensuring reliable communication while accommodating normal manufacturing tolerances.

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The connector design includes pre-aligned mounting structures and positioning features that establish the correct spatial relationship between CCUs before the actual mating operation. This preliminary alignment mechanism ensures that when connectors are coupled, the communication units are already positioned for optimal signal transmission.

Inventive Principle:

Principle #10Preliminary action

3Stability of the object's composition

If mechanical connectors are used for data transfer, then connection stability is improved, but wear and tear increase

Engineering Contradiction:

Improveconnection stabilityVSAvoidconnector lifespan

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

The patent replaces mechanical contact-based data transfer with contactless electromagnetic communication using EHF CCUs. This substitution eliminates physical wear on data transfer contacts while maintaining connection stability through the charging port's structural alignment features. The mechanical connector handles only power transfer, while data communication occurs wirelessly through integrated antennas.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 secure, high-speed data transfer between the vehicle and charging station, allowing for efficient logging and transmission of vehicle data, improving the reliability and security of communication while minimizing wear and tear on mechanical connectors.

Implementation Method 1

at least one contactless communication unit (CCU) that establishes a contactless communications link with a respective one of the at least one CCU of the second port connector

Methodology Applied

Scientific EffectElectromagnetic radiation: Electromagnetic Induction

Data Source

PatentUS11427097B2Charging ports with integrated contactless communication units

Publication Date: 2022.08.30 MOLEX INC

AI summary

Embodiments discussed herein refer to electric vehicle charging ports having integrated contactless communication units (CCUs). The electric vehicle charging ports include male and female connector assemblies that can be coupled together in a manner that enables consistent and reliable operation of contactless communications and power transfer. The connector integrates power and alignment such that when two connector assemblies are coupled together, power connections are made in combination with establishing contactless communications links between counterpart CCUs in both connector assemblies. The fixed alignment of the connector assemblies ensures that contactless communication channels, spanning between the connector assemblies, are aligned to enable consistent and reliable operation of contactless communications. The CCUs, which conduct contactless communications, may be integrated in the connector assemblies at fixed positions that enable CCUs of one connector assembly to be aligned with CCUs of another connector assembly when they are coupled together.