On-board Charger Temperature Detection via Insulating Heat Transfer Element
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Solution Overview
Problem
The existing temperature detection systems for on-board chargers suffer from slow response times due to high heat transfer resistance between power devices and temperature sensors, leading to inadequate protection against over-temperature damage.
Innovation Solution
A temperature detection system featuring a heat transfer element thermally connected to both the power device and temperature sensor on a printed circuit board, which reduces heat transfer resistance and enhances the response speed of temperature detection by using an electrically insulating heat transfer element, often made from materials like aluminum oxide or aluminum nitride.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor is placed around a power device to detect temperature, then electrical insulation is ensured through separation, but heat transfer resistance increases and response speed becomes slow
Solution Approach 1:
The patent introduces a heat transfer element as an intermediary component between the power device and temperature sensor. This element is made of thermally conductive material that is electrically insulating, allowing it to mediate both thermal transfer and electrical isolation. The heat transfer element directly contacts both the power device and sensor, enabling fast thermal response while maintaining electrical safety through its intrinsic insulating properties.
2Reliability
If the printed circuit board is used for heat transfer between power device and sensor, then electrical insulation is provided, but lateral heat transmission capacity is poor and heat transfer resistance is high
Solution Approach 1:
The heat transfer element serves as a dedicated intermediary pathway for thermal energy transfer. Unlike the PCB which has poor lateral heat conduction, the heat transfer element is specifically designed with high thermal conductivity material to efficiently bridge the thermal gap between power device and sensor while maintaining electrical insulation.
Solution Approach 2:
The patent changes the thermal conductivity parameter of the heat transfer path by introducing a material with high thermal conductivity specifically for heat transfer purposes. This material parameter optimization enables efficient thermal coupling between the power device and sensor without compromising electrical isolation.
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 solution effectively prevents power device damage from over-temperature by quickly transferring temperature data from the power device to the sensor, improving the response speed and reliability of the temperature detection system.
Implementation Method 1
the heat transfer element is configured to transfer a temperature of the power device to the temperature sensor
Data Source
AI summary
The present application provides a temperature detection system and an on board charger, the system including a heat transfer element and a temperature sensor; the heat transfer element and the temperature sensor are both located on a printed circuit board. The heat transfer element is thermally connected to the temperature sensor, and is also configured to thermally connect to the power device on the printed circuit board. The heat transfer element is configured to transfer a temperature of the power device to the temperature sensor, so that the temperature sensor detects the temperature of the power device. The heat transfer element is an electrically insulating element. The heat transfer element is thermally connected to the power device and temperature sensor.