Battery Charger Cooling and Switch Sequencing to Prevent Arcing
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Solution Overview
Problem
Existing battery chargers face challenges in effectively managing heat dissipation and preventing arcing during battery engagement and disengagement, with limited control over charging current and fan speed based on temperature variations.
Innovation Solution
A battery charger design incorporating a tubular heat sink and a multi-speed fan, along with temperature sensors for both the charger and battery, adjusts charging current and fan speed dynamically based on temperature readings to enhance heat dissipation and prevent arcing through controlled engagement and disengagement of AC and DC micro switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a battery charger is used to charge a battery, then charging current is output to charge the battery, but heat is generated that requires dissipation
Solution Approach 1:
The patent extracts the harmful heat from the charging circuit by introducing a dedicated heat sink that draws heat away from the charging components and dissipates it through a heat dissipation fin array, separating the heat generation function from the charging function
Solution Approach 2:
The patent introduces an intermediary cooling system consisting of a heat sink and fan that mediates between the heat-generating charging circuit and the surrounding environment, transferring heat from the charging components to the air through the heat dissipation fins
2Ease of operation
If switches are used to control charging circuit connection, then electrical connection is established, but arcing may occur during engagement and disengagement
Solution Approach 1:
The patent applies preliminary action by using a make-before-break switch mechanism that establishes the new electrical connection before breaking the old connection, preventing arcing by ensuring continuous contact throughout the switching process
Solution Approach 2:
The patent introduces a specialized switch mechanism as an intermediary between the control signal and the charging circuit, using a make-before-break contact arrangement that mediates the transition without allowing direct arcing between disconnected contacts
3Temperature
If heat dissipation structures are added to the battery charger, then heat management is improved, but device complexity increases
Solution Approach 1:
The patent segments the heat dissipation function into distinct modular components: a heat sink attached to the charging circuit, a heat dissipation fin array attached to the heat sink, and a fan for air flow, allowing each component to be optimized independently and facilitating easier manufacturing and assembly
Solution Approach 2:
The patent creates a multi-functional integrated heat dissipation assembly where the heat sink serves both as a thermal conduction path and a structural mounting element, the fin array provides both heat dissipation surface and structural support, and the fan integrates cooling function with air flow management for the entire charging 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
This design improves heat management and prevents arcing by dynamically adjusting charging current and fan speed, ensuring efficient charging and extended battery charger lifespan.
Implementation Method 1
a tubular heat sink operable to dissipate heat in the housing
Implementation Method 2
a fan operable to cause air flow from the air inlet to the air outlet and along the heat sink
Implementation Method 3
a fan operable to cause air flow from the air inlet to the air outlet and along the heat sink
Data Source
AI summary
A battery charger and a method of operating a battery charger. The charger may include a housing defining an air inlet and an air outlet; a charging circuit operable to output a charging current to charge a battery couplable to the battery charger; a tubular heat sink; and a fan operable to cause air flow from the air inlet to the air outlet and along the heat sink. The charger may include a first switch operable to electrically connect the charging circuit to a power source when the battery engages the charger; and a second switch operable to electrically connect the charging circuit to a battery terminal after the charger terminal is electrically connected to the battery terminal. The charging current or a fan speed may be adjusted based on at least one of the temperature of the charger or a temperature of the battery.