Quick Charger Thermal Airflow Control for Cold Tool Batteries
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Solution Overview
Problem
Charging a battery at temperatures below a predetermined minimum temperature can adversely affect its lifespan and performance, making it difficult to use quick chargers in cold environments, and the process of warming the battery to the required temperature can be inconvenient.
Innovation Solution
A battery charging system with a heating element and controller that heats the battery before charging when it's below a threshold temperature, using a heating fan and heater to raise the temperature to the minimum required level, and then switches to a cooling fan to maintain the battery temperature within safe limits during charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a battery is charged at temperatures below the predetermined minimum temperature, then the charging speed can be increased, but the battery lifespan and performance are adversely affected
Solution Approach 1:
The system performs preliminary heating of the battery before charging begins. The controller detects when battery temperature is below the minimum threshold and activates the heating element to warm the battery to the required temperature range before allowing charging to proceed, thus preventing damage while enabling fast charging.
Solution Approach 2:
The system changes the temperature parameter of the battery by introducing a heating element that can raise the battery temperature from below-freezing conditions to the optimal charging temperature range. This parameter change enables the battery to accept fast charging without damage.
2Adaptability or versatility
If a heating element is added to warm the battery before charging, then the battery can be charged at low temperatures, but the device complexity increases
Solution Approach 1:
The heating element and cooling fan are integrated into the existing battery dock structure, allowing the same components to serve both heating and cooling functions depending on operational mode. The controller manages these components to provide temperature control during both heating and charging phases, maximizing component utilization.
Solution Approach 2:
The system uses the battery's own internal resistance and the heating element to generate heat for warming the battery. The controller automatically manages the heating process without external intervention, and the existing cooling fan can be reused for both cooling during charging and assisting in temperature management during heating.
3Temperature
If a cooling fan is used to maintain battery temperature during charging, then the battery temperature can be kept below maximum temperature, but the device complexity increases
Solution Approach 1:
The system uses the battery's own internal resistance and the heating element to generate heat for warming the battery. The controller automatically manages the heating process without external intervention, and the existing cooling fan can be reused for both cooling during charging and assisting in temperature management during heating.
Solution Approach 2:
The cooling fan operates periodically during charging based on temperature feedback from the controller. When battery temperature approaches the maximum threshold, the fan activates to provide cooling; when temperature is within acceptable range, the fan remains inactive, creating a periodic on-off action that maintains temperature control.
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
Enables quick and efficient charging of batteries at low temperatures, preserving battery performance and convenience by automatically adjusting heating and cooling modes to ensure safe charging conditions.
Implementation Method 1
supplying or maintaining a heat power to the heating element to emit heat into the airflow path
Implementation Method 2
supplying or maintaining a fan power to the heating fan to force air to flow along the airflow path
Implementation Method 3
Conventional battery chargers can include a cooling fan that blows air through the housing and along the cells during the charging process
Data Source
AI summary
A battery charging system can include each of a heating element, a heating fan, and a cooling fan located in an airflow path, and a controller configured to operate the heating mode when a battery is connected to the battery charging system and a sensed temperature of the battery is less than a predetermined low threshold. The controller can be configured to operate the heating mode by disconnecting a charging power from the battery, supplying a fan power to the heating fan to force air to flow along the airflow path, supplying a heat power to the heating element to emit heat into the airflow path, and disconnecting a cooling power from the cooling fan. In the heating mode, air flowing along the airflow path flows through the heating fan and enters the heating element, and subsequently exits the heating element and passes along the cooling fan.