Power Charging Module Thermal Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle power charging modules face challenges in dissipating heat generated from power inefficiencies, which can damage electronics and pose safety risks, leading to complete shutdowns when temperatures exceed predetermined levels, leaving users without charging capabilities.
Innovation Solution
A power charging module with a controller and multiple temperature sensors that defines thermal condition ranges to adjust power delivery in real-time, reducing power output to prevent critical temperature rises, allowing continued charging at reduced levels instead of complete shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher power charging modules are used to meet customer demand for faster charging, then charging power is improved, but heat generation increases causing damage to electronics and safety risks
Solution Approach 1:
The patent implements dynamic power adjustment by continuously monitoring temperature sensors and automatically modifying charging power levels. When temperature exceeds thresholds, the system reduces power dynamically rather than using fixed power levels, resolving the contradiction between maintaining high charging power and preventing excessive heat generation.
Solution Approach 2:
The system changes operating parameters (power levels) based on temperature conditions. By defining multiple temperature thresholds and corresponding power adjustment levels, the patent transforms the fixed parameter approach into a variable parameter system that adapts to thermal conditions, allowing high power charging when safe and reduced power when temperature rises.
2Reliability
If protection circuits shut down the device when temperature exceeds predetermined levels, then safety is improved, but charging capabilities are completely lost until temperature decreases
Solution Approach 1:
Instead of binary on/off protection, the patent implements dynamic power modulation with multiple threshold levels. When temperature exceeds the first threshold but remains below the second threshold, the system reduces power to a lower level rather than shutting down completely. This dynamic approach maintains partial charging functionality while ensuring safety, resolving the contradiction between safety and charging capability.
Solution Approach 2:
The patent applies partial protection action by reducing power rather than completely shutting down. When temperature rises above predetermined levels, the system applies a moderate protective measure (power reduction) rather than extreme protection (complete shutdown), maintaining sufficient safety while preserving charging functionality. This partial action resolves the contradiction by providing adequate protection without completely eliminating charging capability.
3Adaptability or versatility
If multiple high power charging ports are provided to meet customer demand, then charging versatility is improved, but heat generation and safety risks increase
Solution Approach 1:
The patent applies different power levels and protection thresholds to different charging ports based on local temperature conditions. Each port can be independently monitored and controlled, allowing high power delivery to ports with adequate cooling while reducing power to ports experiencing thermal stress. This localized quality approach enables multiple high-power ports while managing heat generation on a per-port basis.
Solution Approach 2:
The system dynamically adjusts power distribution across multiple ports based on real-time temperature monitoring. When temperature thresholds are exceeded at specific ports, the system automatically reduces power at those ports while maintaining or increasing power at other ports with acceptable thermal conditions. This dynamic power management enables versatile multi-port charging while preventing excessive heat generation.
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 solution effectively regulates temperature by dynamically adjusting power output, preventing damage to electronics and ensuring continuous charging capabilities while maintaining safety by reducing power to prevent overheating.
Implementation Method 1
a first temperature sensor located within or connected to the controller of the charging module... The first temperature sensor is configured to sense a temperature and to provide the sensed temperature to the controller... A second temperature sensor is adjacent one of the charging ports, the second temperature sensor being configured to sense a second temperature
Implementation Method 2
The controller is configured to deliver a standard maximum power output to each of the charging ports if the sensed temperatures from both temperature sensors are categorized in the nominal thermal condition range, deliver a standard maximum power output to the first charging port and a modified maximum power output to at least one of the charging ports if the sensed temperature from either temperature sensor is categorized in the intermediate thermal condition range... and discontinue power output to at least one of the charging ports if the sensed temperatures from either temperature sensor is categorized in the critical thermal condition range
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A power charging module includes a controller, a charging port, and a temperature sensor. The charging port delivers power to an external device plugged into the charging port. The temperature sensor provides a sensed temperature to the controller. A standard maximum power output is delivered to the charging port if the sensed temperature is categorized in a nominal thermal condition range, a modified maximum power output is delivered to the charging port if the sensed temperature is categorized in an intermediate thermal condition range, and power output to the charging port is discontinued if the sensed temperature is categorized in a critical thermal condition range.