Rotation-Symmetric Contactless EV Connector for Misalignment

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Solution Overview

Problem

Existing electric vehicle charging systems face issues with power losses due to misalignment of coils, sensitivity to dirt and moisture, and the need for precise mechanical mating, as well as the complexity and cost of waterproof designs.

Innovation Solution

A contactless connector system with rotation-symmetric primary coils and axially symmetric secondary coils, allowing 360° freedom of rotation and hermetic sealing, enabling efficient inductive coupling without precise alignment and protecting against environmental exposure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If inductive coupling with primary and secondary coils is used for contactless charging, then protection against dirt and moisture intrusion is improved, but power losses occur due to misalignment of coils

Engineering Contradiction:

Improveprotection against dirt and moistureVSAvoidpower losses

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The connector employs asymmetric coil configuration where the primary coil is positioned in the connector and the secondary coil is positioned in the receptacle, creating a fixed geometric relationship that eliminates misalignment issues while maintaining contactless inductive coupling

Inventive Principle:

Principle #4Asymmetry

Solution Approach 2:

The invention transitions from planar coil alignment to three-dimensional spatial positioning, where the primary and secondary coils are arranged in overlapping configurations that maintain magnetic coupling regardless of rotational orientation, thereby eliminating power losses due to misalignment

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If mechanically contacting connectors are used for charging, then exact mechanical mating is required, but sensitivity to dirt and moisture intrusion increases

Engineering Contradiction:

Improvemechanical mating precisionVSAvoidsensitivity to dirt and moisture

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention replaces mechanical contact-based electrical connection with contactless inductive coupling between primary and secondary coils, eliminating the need for precise mechanical mating and the associated sensitivity to contaminants while maintaining reliable electrical energy transfer

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Loss of energy

If inductive charging with fixed orientation is used, then power transfer efficiency is improved, but ease of operation deteriorates due to strict orientation requirements

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidease of coupling

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The invention changes the geometric parameters of the coil arrangement to create rotation symmetry, allowing the connector to be coupled in any rotational orientation while maintaining optimal magnetic coupling and power transfer efficiency, thereby eliminating the need for precise alignment during operation

Inventive Principle:

Principle #35Parameter changes

4Ease of operation

If rotation-symmetric primary coil construction is used, then freedom of rotation and ease of coupling are improved, but device complexity increases

Engineering Contradiction:

Improvefreedom of rotationVSAvoidcoil construction complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The rotation-symmetric primary coil construction serves multiple functions: it enables freedom of rotation during coupling, maintains optimal magnetic coupling in all orientations, and simplifies the user interface by eliminating alignment requirements, while the modular design keeps manufacturing complexity manageable

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

The system provides efficient, safe, and cost-effective charging with reduced power losses, allowing for automatic coupling and enhanced user-friendliness, while eliminating the need for complex waterproof designs and precise alignment, and incorporating additional features like authentication and safety controls through data transmission.

Implementation Method 1

at least one primary side coil (106), which is connected to a feeding power source, for being inductively coupled to at least one secondary side coil (114)

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP2614980B1Contactless connector system for coupling an electric vehicle to a power supply

Publication Date: 2015.03.18 TYCO ELECTRONICS NETHERLAND BV

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AI summary

The present invention relates to a contactless connector for coupling an electric vehicle to a power supply, to a belonging receptacle and to a contactless connector system. A contactless connector (102) according to the present invention comprises at least one primary side coil (106) being connected to a feeding power source for being inductively coupled to at least one secondary side coil (114) being arranged at a receptacle (104), said receptacle (104) being formed to engage with the connector (102). The primary side coil (106) is constructed rotation-symmetrically with respect to a rotation axis (108) of the connector (102), said rotation axis (108) coinciding with a plug-in direction (109) of said contactless connector (102) into the receptacle (104).