Wireless Charger Thermal Isolation via Remote Converter
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Solution Overview
Problem
Inductive wireless charging devices generate excessive heat, leading to overheating of electronic devices and increased charging times, as existing solutions often require reducing or stopping the charging current to prevent overheating.
Innovation Solution
The DC-to-AC converter and associated electronic circuitry are relocated out of the housing of the wireless charger, away from the charging coil, and placed in a separate component, with a cable connecting them, allowing for thermal isolation and reduced heat transfer to the charging assembly, which includes a heatsink and electromagnetic shield for improved thermal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the DC-to-AC converter is placed inside the housing with the charging coil, then the device structure is simpler, but heat is generated near the electronic device causing overheating
Solution Approach 1:
The DC-to-AC converter is extracted from the housing and placed in a separate location. The housing now contains only the charging coil and necessary thermal management components, while the converter is positioned remotely and connected via cable. This separation removes the primary heat-generating component from proximity to the electronic device being charged, directly resolving the overheating issue.
Solution Approach 2:
The wireless charging device is segmented into distinct functional modules: the housing with charging coil and thermal management, the cable for power transmission, and the DC-to-AC converter in a separate location. This modular segmentation allows each component to be optimized independently for its specific function while managing thermal characteristics.
2Productivity
If the charging current is increased to reduce charging time, then charging speed improves, but heat generation increases causing overheating
Solution Approach 1:
By extracting the DC-to-AC converter from the housing, the system can sustain higher charging currents without transferring excessive heat to the electronic device. The converter operates in a thermally independent zone, allowing high-power operation while the housing remains cool enough for safe device charging.
Solution Approach 2:
The cable acts as an intermediary that transmits high-current AC signals from the remote converter to the charging coil while physically separating the heat-generating conversion process from the charging interface. This intermediary structure enables high power transmission while managing thermal distribution.
3Object-affected harmful factors
If the DC-to-AC converter is moved outside the housing, then heat transmission to the electronic device is reduced, but the device complexity increases
Solution Approach 1:
The converter extraction is implemented with a cable connection that provides both power transmission and structural simplicity. The housing design is streamlined to contain only essential components, and the external converter connects through a standardized cable interface, minimizing the increase in overall system complexity while achieving thermal separation.
4Volume of moving object
If the housing size is reduced to make the charger more compact, then portability improves, but space for thermal management components is reduced
Solution Approach 1:
By removing the DC-to-AC converter from the housing, significant internal space is freed up. This space can be utilized for enhanced thermal management components such as larger heatsinks, improved airflow channels, or additional shielding, thereby improving thermal management capability while maintaining or reducing housing size.
Solution Approach 2:
The segmentation of the converter from the housing allows the housing to be optimized independently for compactness and thermal management. The housing can be designed as a small, efficient thermal zone while the converter operates in a separate, thermally independent location, with the cable bridging the two optimized zones.
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 configuration enables longer and higher-power wireless charging sessions, reducing charging time and preventing overheating, while also allowing for a smaller charger housing size.
Implementation Method 1
A DC-to-AC converter for converting a DC power signal to AC+ and AC− signals
Implementation Method 2
The charging coil receives the AC+ and AC− signals and can generate a time-varying electromagnetic field to charge electronic devices
Implementation Method 3
a heatsink to further improve the thermal efficiency of the charger
Implementation Method 4
an electromagnetic shield and a heatsink to further improve the thermal efficiency of the charger
Data Source
AI summary
This application relates to a wireless charger with reduced heat generation during operation. The wireless charger includes a connector, a charging assembly and a cable connecting the connector and the charging assembly. A converter component has been moved away from the charging assembly, where an electronic device is placed for charging, to the connector. In some embodiments, one or more electromagnetic shielding components protect the components of the wireless charger.