Battery Charger Air Cooling at the Pack Interface
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Solution Overview
Problem
Existing power tool systems face challenges in efficiently managing heat generated during operation, which can lead to reduced performance and battery life.
Innovation Solution
The integration of an air conditioning assembly within the charger and power tool housings, which includes a blower and evaporative member, to draw ambient air, cool it, and direct the cooling airflow to the battery pack interface and charger electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional charging circuits are used without active cooling, then the device structure remains simple, but heat accumulation reduces battery life and charging performance
Solution Approach 1:
The patent employs phase change materials (ice) that transition from solid to liquid state to absorb heat during charging. The ice pack melts as it absorbs thermal energy from the battery and charger electronics, providing passive cooling without requiring complex active cooling systems with compressors or fans.
Solution Approach 2:
The patent introduces an intermediary cooling medium (ice pack with coolant) that mediates between the heat-generating components (battery, charger electronics) and the surrounding environment. This intermediary absorbs heat through phase change and conducts it away, protecting sensitive components from thermal damage.
2Temperature
If active cooling systems are implemented, then heat management improves, but the device becomes more complex and larger
Solution Approach 1:
The cooling system is designed to be self-regulating through the natural phase change properties of ice. As temperature increases, the ice automatically melts and absorbs heat; as temperature decreases, melting stops and cooling reduces. This eliminates the need for thermostats, sensors, or control circuits.
Solution Approach 2:
The patent extracts the cooling function from the main charging circuit by using a separate, independent ice pack cooling system. This modular approach allows the cooling function to be added without complicating the electrical charging circuitry, and the ice pack can be easily removed or replaced.
3Temperature
If cooling airflow is directed to battery interface, then battery temperature control improves, but charging terminals and rails must be precisely positioned
Solution Approach 1:
The patent applies cooling locally at the battery interface area where heat generation is most intense. The ice pack is positioned to directly contact or closely approach the battery terminals and rails, providing targeted cooling where it is most needed rather than attempting to cool the entire charger uniformly.
Solution Approach 2:
The cooling system is segmented into distinct zones: the ice pack cooling chamber, the battery interface area, and the charger electronics area. This segmentation allows independent optimization of each zone's thermal management without requiring precise coordination across the entire device.
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
This solution effectively reduces the temperature of the air flow to create a cooling effect, enhancing the performance and longevity of the battery pack and power tool electronics.
Implementation Method 1
an air conditioning assembly coupled within the housing adjacent the interface. The air conditioning system is operable to suck an ambient air flow into the housing from outside the housing, reduce a temperature of the air flow to create a cooling air flow
Implementation Method 2
The air conditioning system is operable to suck an ambient air flow into the housing from outside the housing, reduce a temperature of the air flow to create a cooling air flow, and guide the cooling air flow to the battery pack interface
Data Source
AI summary
A charger including a housing including a front wall, a rear wall, a top wall, a bottom wall, a first side wall, and a second side wall, an interface configured to engage a battery pack, and an air conditioning assembly coupled within the housing adjacent the interface. The air conditioning system is operable to suck an ambient air flow into the housing from outside the housing, reduce a temperature of the air flow to create a cooling air flow, and guide the cooling air flow to the battery pack interface.