Compact High-Power Charger Circuit Layout for Heat Dissipation
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Solution Overview
Problem
Existing high-power charging devices for riding lawn mowers face challenges in achieving a balance between high output power and compact size, often resulting in increased volume and reduced heat dissipation efficiency.
Innovation Solution
The integration of a Power Factor Correction (PFC) circuit and a LLC resonant circuit with high voltage conversion efficiency within the charging apparatus circuitry, allowing for high-power output capability while maintaining a small overall volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power output capability of the charging device is improved, then the charging efficiency is increased, but the volume increases and heat dissipation effect is reduced
Solution Approach 1:
The charging device is divided into modular components including a charging module, a heat dissipation module, and a control module. The heat dissipation module is further segmented into multiple heat dissipation channels with independent airflow paths, allowing each segment to be optimized for its specific function while maintaining compact overall dimensions
Solution Approach 2:
The patent utilizes three-dimensional space optimization by arranging components in multiple layers and dimensions. The heat dissipation fins are arranged in a three-dimensional array structure, and the airflow channels are designed to flow through multiple levels, effectively utilizing vertical space to increase heat dissipation surface area without increasing the device's footprint
2Power
If the power output capability of the charging device is improved, then the charging efficiency is increased, but the heat dissipation effect is reduced
Solution Approach 1:
The patent converts the harmful heat generated by high-power charging operations into a manageable thermal flow by designing dedicated heat dissipation channels that guide hot air away from sensitive components. The heat dissipation fins are strategically positioned to maximize thermal exposure to airflow, transforming waste heat into a controlled thermal management system
Solution Approach 2:
The patent employs forced convection through pneumatic airflow management. A fan or blower creates controlled air currents that flow through designated heat dissipation channels, efficiently carrying heat away from high-power components. The airflow paths are optimized to maximize heat exchange between the air stream and heat dissipation surfaces
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 enables the charging apparatus to achieve high-power output with a compact size, enhancing both efficiency and heat dissipation, thus addressing the limitations of prior art.
Implementation Method 1
a PFC circuit and an LLC resonant circuit with high voltage conversion efficiency are disposed in the circuitry of the charging apparatus
Implementation Method 2
an LLC resonant circuit with high voltage conversion efficiency are disposed in the circuitry of the charging apparatus
Data Source
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AI summary
A charging apparatus includes: a housing formed with an accommodating space; and a circuit board assembly disposed in the accommodating space and including at least a printed circuit board provided with multiple electronic elements. The output power of the charging apparatus is greater than or equal to 500 W and less than or equal to 2000 W, and the ratio of the output power of the charging apparatus to the volume of the charging apparatus is higher than or equal to 20 W/in3 and lower than or equal to 30 W/in3. With the preceding solution, the charging apparatus with a small overall volume and high output power can be provided.