Battery Charger Fan Layout for Compact Pack Cooling
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Solution Overview
Problem
Existing battery chargers face challenges in efficiently managing air intake and exhaust while maintaining a compact size, which affects the cooling of battery packs and internal components.
Innovation Solution
The design incorporates a vertical and horizontal section with strategically positioned air inlets and a fan that overlaps the battery pack, providing effective cooling and air management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple air inlets are used to provide cooling air to internal components, then cooling effectiveness is improved, but device complexity and size constraints are worsened
Solution Approach 1:
The patent combines multiple air inlet functions into a single integrated fan assembly. The fan assembly includes multiple air inlets that draw cooling air from different locations (front, top, and side of the battery pack) and directs all air flows through a single exhaust outlet. This merging approach maintains effective cooling of internal components while reducing the complexity of controlling multiple separate air intake systems.
Solution Approach 2:
The fan assembly serves multiple functions simultaneously: it draws cooling air through multiple inlets, directs airflow across internal components for cooling, and exhausts all air through a single outlet. This multi-functional design achieves comprehensive cooling effectiveness while avoiding the complexity of multiple independent air intake control systems.
2Volume of moving object
If a compact charger size is maintained, then size constraints are improved, but air exhaust control and cooling effectiveness are worsened
Solution Approach 1:
The patent utilizes three-dimensional space efficiently by positioning the single exhaust outlet on the rear face of the battery pack, while air inlets are distributed across the front, top, and side surfaces. This spatial arrangement allows compact charger dimensions while maintaining effective airflow paths for cooling internal components through the battery pack structure.
Solution Approach 2:
The fan assembly is integrated within the battery pack structure, with the exhaust outlet positioned on the rear face and air inlets distributed across other surfaces. This nested configuration allows the cooling system to be compact while maintaining effective cooling by utilizing the existing battery pack geometry rather than adding external cooling components.
3Ease of operation
If air intake control is improved, then airflow management is improved, but device complexity and size are worsened
Solution Approach 1:
The fan assembly operates as a self-contained unit that automatically manages airflow through its multiple inlets and single outlet. The system uses the natural pressure differential created by fan operation to draw cooling air through the various inlets and exhaust it through the rear outlet, without requiring complex external control mechanisms for each air inlet.
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 configuration enhances cooling efficiency for both the battery pack and internal components, while also addressing size and airflow control constraints.
Implementation Method 1
The fan is disposed on the horizontal surface and cools the battery pack. The fan pulls air through the vertical section. The fan also cools the circuit board using the air pulled from the vertical section.
Implementation Method 2
The fan also exhausts the air from the outlet.
Data Source
AI summary
A charger including a vertical section including a first surface, the first surface facing a front direction and including an attachment portion configured to a receive a battery pack, and a horizontal section configured to protrude, in the front direction, from a bottom portion of the vertical section. The charger further including a second surface disposed on the horizontal section, the second surface facing an upward direction, and a fan disposed proximate the horizontal surface, the fan configured to cool the battery pack.