Modular Battery Charger Cooling Path for Compact Plug-In Packs
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Solution Overview
Problem
Existing modular charging devices for electric tools lack efficient cooling and modular design, leading to reduced performance and increased production costs, and do not facilitate easy and compact plug-in connections for battery packages.
Innovation Solution
A modular charging device with a housing featuring battery package sockets, a PCB with spring connections, and a cooling structure that includes an air pathway with a fan and heat sinks, optimizing assembly, use, and control methods to enhance cooling efficiency and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional non-modular charging devices are used, then assembly and manufacturing are simpler, but cooling efficiency is reduced and production costs increase
Solution Approach 1:
The charging device is divided into modular components including battery packages, PCB modules, and independent cooling units. Each module can be independently manufactured and assembled, maintaining ease of manufacture while enabling efficient cooling through standardized modular architecture
Solution Approach 2:
The cooling structure is integrated within the housing, with cooling channels nested between the PCB and housing walls. The fan is positioned within the housing to drive airflow through the nested cooling pathways, achieving compact integration without compromising cooling efficiency
2Reliability
If battery packages are permanently integrated, then connection reliability is higher, but adaptability and versatility are reduced
Solution Approach 1:
The battery package connection system transitions from fixed integration to dynamic plug-in/removable connections. Electrical contacts and connectors are designed to maintain reliable electrical connection while allowing flexible insertion and removal of battery packages, achieving both reliability and adaptability
Solution Approach 2:
The charging device incorporates universal battery package sockets that can accommodate different battery package types and configurations. The modular design allows the same device housing to support various battery arrangements, enhancing versatility while maintaining reliable standardized connections
3Productivity
If complex cooling systems are added, then cooling efficiency increases, but device complexity and production costs increase
Solution Approach 1:
The cooling system is designed to utilize the device's own operational characteristics - the inverter's operation generates heat that naturally drives convection currents, and the device's housing structure itself forms part of the cooling pathway. This self-service approach achieves effective cooling without requiring complex external cooling systems
Solution Approach 2:
Multiple functions are merged into the housing structure: it provides mechanical protection, forms cooling channels, supports the fan mounting, and serves as a thermal pathway. This integration achieves efficient cooling while reducing overall system complexity by eliminating separate cooling structure components
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 increases cooling efficiency, reduces production costs, and enables compact and versatile design with plug-in connections for battery packages, allowing for efficient charging and heat dissipation.
Implementation Method 1
a fan, and a first PCB and a second PCB located in the housing, the cooling structure comprising an air inlet disposed at one end of the housing, an air outlet at another end, and a pathway between the first PCB and the second PCB, the fan causing an airflow to flow through the pathway
Data Source
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AI summary
The present invention discloses a modular charging device and a cooling structure thereof. The modular charging device comprises a housing, at least one battery package socket located on the housing, and a PCB located in the housing, the at least one battery package socket being located at one or two sides of the PCB, at least one battery package being electrically connectable into the at least one battery package socket in a plug-in manner, and the battery package socket comprising a battery package insertion slot extending inwards from the housing to the PCB. A cooling structure for a modular charging device comprises an air inlet disposed at one end of a housing, an air outlet at another end, and a pathway between a first PCB and a second PCB, the fan causing an airflow to flow through the pathway. Methods of controlling and using the modular charging device comprise: battery packages being controllable for charging either separately or in combination, and each battery package being removable from the housing for charging.