Inductive Charging Thermal Management via Phase Change Materials

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Solution Overview

Problem

Existing electromagnetic induction power-transfer systems face challenges in managing heat generated during the charging process, leading to undesirable temperature increases in electronic devices.

Innovation Solution

A charging apparatus with a housing, a power-transferring coil, and a thermal mass, where a thermal path conducts heat from the interface surface to the thermal mass for controlled dissipation, and a thermally conductive cable aids in further heat dissipation, along with adaptive power management to optimize efficiency and reduce heat production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If inductive power transfer is used to charge electronic devices, then wireless charging convenience is improved, but heat generation increases causing temperature management issues

Engineering Contradiction:

Improvewireless charging convenienceVSAvoidinterface surface temperature

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

A thermal management layer is introduced as an intermediary component between the power-transferring coil and the interface surface. This layer includes phase change materials that absorb excess heat during charging, preventing direct heat transfer to the device being charged while maintaining wireless charging functionality.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Phase change materials are utilized to manage heat through phase transitions (e.g., solid to liquid). These materials absorb heat when phase-changing, effectively controlling the temperature at the interface surface during inductive charging operations without interfering with power transfer.

Inventive Principle:

Principle #36Phase transitions

2Productivity

If higher power is transmitted through the power-transferring coil, then charging speed is improved, but heat generation increases

Engineering Contradiction:

Improvecharging speedVSAvoidheat energy loss

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

The heat energy that would normally be wasted as a byproduct of high-power transmission is converted into a useful function. Phase change materials absorb this excess heat, transforming the harmful thermal energy into stored potential energy during the phase transition, thereby enabling higher power transmission without proportional heat damage.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The thermal properties of the management layer are dynamically adjusted based on operating conditions. The phase change materials change their thermal absorption characteristics based on temperature, automatically adapting to different power transmission levels and charging speeds to optimize the balance between charging performance and heat management.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If the power-transferring coil is positioned closer to the interface surface, then power transfer efficiency is improved, but heat transfer to the device increases

Engineering Contradiction:

Improvepower transfer efficiencyVSAvoidheat transfer to device

Core Design Contradiction:

Use of energy by moving objectVSObject-affected harmful factors

Solution Approach 1:

A thermal management layer is positioned between the power-transferring coil and the interface surface, serving as a mediator that allows the coil to remain close to the interface for efficient power transfer while preventing harmful heat transfer to the device. This intermediary layer selectively manages thermal energy.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The charging apparatus is segmented into distinct functional layers: a power-transferring coil layer for efficient energy transfer, a thermal management layer with phase change materials for heat control, and an interface surface layer for device contact. This segmentation allows each layer to optimize its specific function without interfering with others.

Inventive Principle:

Principle #1Segmentation

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

Effectively manages temperature by dissipating heat away from the interface surface, reducing unnecessary heating in electronic devices and enhancing power transfer efficiency.

Implementation Method 1

a thermal path adapted to conduct heat from the interface surface to the thermal mass

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

the power-transferring coil may be configured to inductively couple to a power-consuming coil within the power-consuming apparatus

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentEP3123486B1Temperature management for inductive charging systems

Publication Date: 2022.03.30 APPLE INC

Figure 1A~1B
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AI summary

A thermal management system for an electromagnetic induction-power transfer system. The system may include a charging apparatus including a housing that defines an interface surface. An accessory or induction-power consuming apparatus may be positioned proximate to the interface surface. The housing of the charging apparatus may include a power source and a power-transferring coil coupled to the power source and positioned below the interface surface. A thermal mass may be positioned within the housing and spaced apart from the interface surface. The housing may include a thermal path that is configured to conduct heat from the interface surface to the thermal mass.