In-Wall Wiring Device With Active Fan Cooling
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Solution Overview
Problem
Conventional USB charging devices in wall outlets often overheat when multiple devices are charged simultaneously, leading to reduced functionality due to limited current flow, which can cause channel shutdown.
Innovation Solution
An in-wall wiring device with a housing, fan, and thermal load, featuring intake and exhaust openings for air flow, where the fan is activated when the internal temperature exceeds a predetermined threshold to enhance heat removal and prevent overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If charging current is limited to prevent overheating, then device safety is improved, but charging functionality deteriorates due to channel shutdown
Solution Approach 1:
The patent converts the harmful heat generated during charging into a useful signal for controlling the cooling system. The heat that would normally cause channel shutdown is now utilized to activate the fan, which removes excess heat and prevents the harmful effect, thereby maintaining charging functionality while ensuring safety
Solution Approach 2:
The patent implements preliminary cooling action by activating the fan before the thermal load reaches critical temperatures that would cause channel shutdown. The temperature sensor detects rising temperatures early and triggers the fan to remove heat proactively, preventing the harmful effect before it occurs
2Productivity
If multiple devices are charged simultaneously, then charging capacity is improved, but heat generation increases causing overheating
Solution Approach 1:
The patent converts the harmful heat generated by simultaneous charging into a useful control signal. The temperature sensor detects the heat from multiple devices being charged and activates the fan, which then removes this excess heat, allowing the system to maintain high charging capacity without overheating
Solution Approach 2:
The patent changes the operational parameter of the cooling system based on the thermal load. When multiple devices are charged and temperature rises, the fan is activated to increase heat removal capacity, dynamically adjusting the cooling parameter to match the heating parameter
3Device complexity
If no active cooling is provided, then device simplicity is improved, but thermal management deteriorates leading to channel shutdown
Solution Approach 1:
The patent implements a self-service thermal management system where the wiring device monitors its own temperature and activates cooling only when needed. The temperature sensor and fan work together in an automatic feedback loop, eliminating the need for external thermal management systems while maintaining reliability
Solution Approach 2:
The patent transforms the static cooling system into a dynamic one by adding temperature-based control. The fan operates only when the temperature sensor detects elevated temperatures, creating a dynamic response that matches the actual thermal conditions, thereby improving thermal management without continuous operation
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 effectively manages heat dissipation within the wiring device, ensuring continuous operation and extending the lifespan of components by actively cooling the thermal load, thereby preventing overheating and maintaining functionality even when multiple devices are charged simultaneously.
Implementation Method 1
The fan may be operable to move air between the intake opening and the exhaust opening
Implementation Method 2
The thermal load may be positioned to receive the cooling air to reduce a temperature of the thermal load
Data Source
AI summary
A wiring device includes a housing that encloses a line voltage port and/or a low voltage port for providing power to at least one removable load. The housing has an intake opening and an exhaust opening for drawing cooling air into the housing and for exhausting heated air. A fan is disposed within the housing and operates to move the air through the housing. A thermal load such as a heat sink or a transformer is positioned within the housing and receives cooling air to reduce the temperature of the load. The fan is energized when a sensed temperature in the housing exceeds a first predetermined threshold. Power to the line and/or low voltage port is reduced or shut off if the sensed temperature in the housing exceeds a predetermined value that is greater than the first predetermined threshold.