Forced-Air EV Charging Adaptor for Overheating Control
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Solution Overview
Problem
Conventional cooling systems for electric vehicle charging fail to effectively manage heat generation during charging, particularly when incompatible charging modalities and vehicles are used, leading to safety hazards, component damage, and reduced charging efficiency.
Innovation Solution
A charging adaptor with integrated forced-air cooling system, featuring fan units and a heat sink to dissipate heat generated during charging, ensuring compatibility across different charging standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high electrical currents are passed during charging, then charging speed increases, but heat generation increases causing safety hazards and component damage
Solution Approach 1:
The patent converts the harmful heat generated during high-current charging into a manageable thermal management challenge by implementing active cooling systems. The cooling fans and thermal pathways transform the waste heat into a controlled parameter, allowing the system to maintain high charging speeds while preventing overheating through deliberate heat dissipation design.
Solution Approach 2:
The patent employs pneumatic cooling through fans that force air flow across heat sinks and through charging components. This forced convection cooling system uses pressurized air flow to enhance heat transfer efficiency, enabling the system to dissipate the heat generated during high-speed charging without compromising charging performance.
2Adaptability or versatility
If intermediary adaptors are used to couple incompatible charging modalities, then charging compatibility improves, but heat accumulation in the adaptor increases
Solution Approach 1:
The patent segments the thermal management function from the charging adaptor by incorporating dedicated cooling components (fans, heat sinks, thermal pathways) specifically within the adaptor. This segmentation allows the adaptor to independently manage its own heat accumulation, enabling it to serve as a compatible interface between different charging standards without compromising thermal safety.
Solution Approach 2:
The cooling system within the adaptor acts as an intermediary thermal management layer between the charging modality and the vehicle. The adaptor's integrated cooling components mediate the heat transfer process, absorbing and dissipating heat generated during charging while maintaining electrical connectivity and thermal safety across incompatible charging standards.
3Device complexity
If conventional passive cooling methods are used, then system complexity is reduced, but heat dissipation effectiveness is insufficient during high-power charging
Solution Approach 1:
The patent transitions from static passive cooling to dynamic active cooling by implementing fans that can adjust their operation based on thermal conditions. The cooling system dynamically responds to heat generation levels during charging, activating and adjusting fan speeds to match thermal demands, thereby ensuring reliable heat dissipation while maintaining reasonable system complexity through demand-based operation.
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
Enhances safety and reliability by preventing overheating, extending component lifespan, and maintaining efficient charging performance across various charging conditions and standards.
Implementation Method 1
at least one fan unit positioned within the housing proximate to the one or more vents and configured to draw outside air into the housing through the one or more vents and direct the outside air along the heat sink
Implementation Method 2
Heat is generated during electric vehicle charging due to the passage of high electrical currents between a charger and the electric vehicle
Implementation Method 3
a heat sink positioned within the housing proximate to the at least one fan unit and configured to absorb heat generated during electric vehicle charging
Data Source
AI summary
The present disclosure relates to heat dissipation during electric vehicle charging. Examples of the disclosure include a charging adaptor used as an intermediate coupling between a charging modality and an electric vehicle. Charging adaptors of the present disclosure can also include integrated cooling to dissipate heat generated during charging. In some examples, a charging adaptor may include a housing defining one or more vents, at least one fan unit positioned within the housing proximate to the one or more vents, and a heat sink positioned within the housing proximate to the at least one fan unit. The heat sink can absorb heat generated during electric vehicle charging. The at least one fan unit can draw outside air into the housing through the one or more vents and can direct the outside air along the heat sink to cool the charging adaptor.