Modular EV Charging Architecture for Incremental V2H and V2G Upgrades

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Solution Overview

Problem

Existing home charging systems for BEVs and PHEVs require complete replacement when upgrading to newer technologies, leading to waste of hardware and installation costs.

Innovation Solution

A modular charging system comprising a base charging module and optional AC backup and DC grid integration modules, allowing for incremental upgrades to add AC discharging and DC charging/discharging capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a complete charging system is replaced to upgrade to newer technologies, then the system gains access to newer features and capabilities, but hardware waste increases and installation costs increase

Engineering Contradiction:
Improvecharging system capabilitiesVSAvoidhardware waste
Core Design Contradiction:
Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The charging system is divided into modular components: a base charging module and separate optional modules (AC backup module, DC grid integration module). This segmentation allows individual modules to be upgraded or added without replacing the entire system, reducing hardware waste while maintaining adaptability to newer technologies.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The system is designed with dynamic configurability, allowing users to selectively connect different modules based on their needs. The base charging module can operate independently or be enhanced by adding AC backup or DC grid integration modules, enabling the system to adapt to evolving requirements without complete replacement.

Inventive Principle:
Principle #15Dynamics

2Adaptability or versatility

If a complete charging system is replaced to upgrade to newer technologies, then the system gains access to newer features and capabilities, but installation costs increase

Engineering Contradiction:
Improvecharging system capabilitiesVSAvoidinstallation costs
Core Design Contradiction:
Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By segmenting the charging system into modular components with standardized interfaces, the patent enables incremental upgrades. Users can start with a base module and add functionality later, spreading installation costs over time and avoiding the need for expensive complete system replacements.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The base charging module is designed with universal compatibility to work with both AC and DC modules. This multi-functionality allows a single base unit to support multiple charging modes and grid integration options, reducing overall installation costs by eliminating the need for separate dedicated systems for each function.

Inventive Principle:
Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If modular modules are added to base charging module, then system versatility improves and upgrade costs decrease, but device complexity increases

Engineering Contradiction:
Improvesystem versatilityVSAvoidsystem complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent segments complex functionality into separate, independently manageable modules. Each module performs a specific function (AC charging, AC backup, DC grid integration) with standardized connection interfaces to the base module. This segmentation reduces perceived complexity by allowing users to add only the functionality they need while maintaining a simple base unit.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The base charging module acts as an intermediary between the vehicle battery and various optional modules. It provides standardized interfaces and control logic that simplify the integration of additional modules, managing the complexity internally while presenting a simple user interface and connection scheme.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS20250269744A1Modular charging system
Publication Date: 2025.08.28 TOYOTA MOTOR ENG & MFG NORTH AMERICA INC
  • US20250269744A1 patent drawing
  • US20250269744A1 patent drawing
  • US20250269744A1 patent drawing

AI summary

Described are examples of a modular charging system. In one example, a modular charging system includes a base charging module configured to provide alternating current (“AC”) charging capabilities to charge a battery via a charging port. The base charging system is configured to be selectively connected to an AC backup module that additionally enables AC discharging capabilities to send electricity from the battery to a residential electrical system and/or a direct-current (“DC”) grid integration module that additionally enables DC discharging capabilities to send electricity from the battery to a utility grid and DC charging capabilities to charge the battery.