Modular Battery Charger Cooling Structure for Multi-Pack Heat Dissipation
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Solution Overview
Problem
Existing modular charging devices for electric tools lack efficient cooling systems and modular designs that simplify assembly, use, and control, leading to reduced cooling efficiency and increased production costs.
Innovation Solution
A modular charging device with a housing featuring battery package sockets for plug-in connection, a PCB with wiring lugs and springs for secure electrical connection, and a cooling structure with an air inlet, outlet, and airflow pathway between PCBs, including a fan and heat sinks to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular design with plug-in battery packages is implemented, then adaptability and ease of operation are improved, but device complexity increases due to multiple connection interfaces and wiring systems
Solution Approach 1:
The PCB is designed with multiple battery package sockets that can accommodate different battery package types through a standardized connection interface. The wiring lugs and springs are configured to establish electrical connections with multiple battery packages simultaneously, enabling the device to function with various battery configurations (e.g., single battery, dual battery in series or parallel) without requiring separate connection systems for each configuration.
2Power
If multiple battery packages are connected in series to increase voltage output, then power output capability is improved, but the risk of electrical connection failures and overheating increases
Solution Approach 1:
Wiring lugs are introduced as intermediary connection elements between the battery packages and the PCB. These wiring lugs provide a robust mechanical and electrical connection point that distributes current flow and reduces stress on direct PCB traces. The wiring lugs are strategically positioned to ensure proper current distribution when multiple battery packages are connected in series, thereby improving connection reliability and reducing the risk of overheating at connection points.
3Temperature
If a cooling system is added to manage heat from multiple battery packages, then temperature control is improved, but device complexity and production cost increase
Solution Approach 1:
The cooling system is merged with the existing housing structure of the device. Cooling channels are integrated into the housing to form a unified thermal management system that cools multiple battery packages simultaneously. The fan is positioned to create airflow that passes through these integrated cooling channels, providing efficient heat dissipation without requiring separate cooling components for each battery package, thereby reducing overall system complexity.
4Reliability
If wiring lugs and springs are used for electrical connection, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The wiring lugs are pre-positioned and pre-assembled onto the PCB during the manufacturing process, establishing fixed reference points for battery package connection. The springs are pre-compressed to provide consistent contact force. This preliminary assembly ensures that when battery packages are plugged in, the electrical connections are reliably established without requiring high precision alignment during the plug-in operation, thereby reducing manufacturing precision requirements for the final assembly step.
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 a compact, versatile design with simplified assembly and use, allowing for efficient charging and detachable battery package fitting.
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
Implementation Method 2
a heat sink is provided on at least one of the first PCB and the second PCB
Data Source
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.