Systems and methods for thermoelectrically cooling inductive charging stations

Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are incorporated by reference under 37 CFR 1.57 and made a part of this specification.

This application relates to a cooling device and, in some embodiments, to a thermoelectrically cooled inductive charging station, such as for charging a cell phone, and components thereof.

Portable electronic devices (PEDs), such as cell phones, music players, sound recorders, computers (e.g., tablets), radios, watches, and otherwise, generally require power for operation. As such, many PEDs include a rechargeable battery or other rechargeable power source, thereby allowing for the device to be powered and readily transported without being limited by the length of electrical power cords or the like. In some instances, the charging of PEDs is accomplished with a physical electrical connection, such as a plug or other electrical connection that is connected with the device during charging and then disconnected when charging is complete. However, such connections are inconvenient due to the requirement of connecting and disconnecting the physical electrical connection.

Some PEDs avoid the need for such a physical electrical connection by being configured to accept inductive charging. Inductive charging uses electromagnetic fields to transfer power from a base (e.g., a dock) to a receiver (e.g., the power source in the PED) that is in close proximity to the base. As power is transferred via the electromagnetic fields, a physical electrical connection between the base and the receiver is not required, thus eliminating the inconvenience associated with connecting and disconnecting the physical electrical connection.

Recently, it has been proposed to provide certain vehicles (e.g., cars, trucks, tractors, airplanes, boats, and otherwise) with an inductive charging station for PEDs. Such a design can allow users to place their PED in a dock (e.g., a pad, recess, slot, or otherwise) that has inductive charging functionality, thereby providing inductive charging of the PED without the inconvenience of a connecting and disconnecting a physical electrical connection.

One of the byproducts of inductive charging is heat, which can be unwanted in certain situations. For example, heat generated by inductive charging may place an additional load on the heating, ventilating, and air-conditioning system of the vehicle, which can result in decreased performance and/or reduced fuel economy. Further, heat produced by inductive charging may raise the temperature of the PED, which can degrade the performance of the PED and/or make the PED uncomfortable to use. For example, raising the temperature of a cell phone may make the phone uncomfortable to hold and/or to press against the user's ear.

Accordingly, for various reasons, it can be beneficial to cool the inductive charging station. In some embodiments, the inductive charging station is cooled by a thermoelectric device (TED), which has a hot side (also known as the waste side) and a cold side. A waste side heat exchanger can be thermally coupled to the hot side of the TED. Certain embodiments include a pump or fan to promote convective heat transfer from the cool side to the inductive charging station or the PED. In some implementations, the pump or fan also promotes convective heat transfer through the waste side heat exchanger. In some embodiments, air exits the waste side of the TED into a space in which the TED resides. In other embodiments, air exits the waste side of the TED and is ducted elsewhere, such as outside the vehicle.

FIG. 1 illustrates a perspective view of an embodiment of a cooling system for an induction charger with a thermal conditioning module connected with a dock.

FIG. 1A illustrates a front view of the dock of FIG. 1 .

FIG. 1B illustrates a cross-sectional view of the dock of FIG. 1A taken along the line 1 B- 1 B.

FIG. 2 illustrates a perspective view of another embodiment of a cooling system for an induction charger with a thermal conditioning module connected with a dock.

FIG. 2A illustrates a front view of the dock of FIG. 2 .

FIG. 2B illustrates a cross-sectional view of the dock of FIG. 2A taken along the line 2 B- 2 B.

FIG. 3 illustrates a front perspective view of another embodiment of a cooling system for an induction charger comprising a thermal conditioning module connected with an induction charging module, which is connected with a dock.

FIG. 3A illustrates a bottom perspective view of the system of FIG. 3 .

FIG. 3B illustrates an exploded bottom perspective view of the cooling system of FIG. 3A .

FIG. 4 illustrates a schematic view of a cooling system for an inductive charger according to an embodiment.

With reference to FIGS. 1 and 4 , in some embodiments, a cooling system for an induction charger 10 includes a thermal conditioning module 12 in fluid communication with an induction charging assembly 21 , which includes a dock 14 (e.g., a pad, recess, slot, opening, and/or the like) and an induction charging module 16 . As shown, the induction charging module 16 can be mounted on, near, or adjacent the dock 14 so as to provide inductive charging functionality to PEDs, such as PED 19 (e.g., smartphones, other mobile phones, music playing devices, tablets, personal digital assistants (PDAs), etc.) that are configured to accept inductive charging and are placed in and/or on the dock 14 .

In some embodiments, the thermal conditioning module 12 includes one more of the following: a fluid transfer device (such as, e.g., a pump, blower, or fan 17 ), ducting 18 (e.g., a fluid line, coupling, piping, etc.) thermal conditioning devices 20 (e.g., thermoelectric devices (TEDs), conductive heat transfer devices, other cooling or ventilation devices, etc.), sensors (e.g., temperature sensors, humidity sensors, condensation sensors, etc.), timers and/or the like. Any of various types of fluid transfer devices 17 (e.g., fans) can be used in such modules or devices, such as radial fans (e.g., squirrel cage fans), axial fans, propeller fans, and/or the like. In certain embodiments, the fluid transfer device 17 is configured to draw air from near a floor or lower portion of the vehicle 25 , which can be beneficial because such air may be cooler than air originating from other locations of the vehicle (e.g., due to a reduction in sun loading or otherwise). As illustrated, the ducting 18 can be in fluid communication with the fan 17 or other fluid transfer device. In addition, depending on the configuration of the module, such components can also be in fluid communication with a thermal conditioning device 20 (e.g., TED), the dock 14 , one or more sensors, and/or any other components or devices, as desired or required. In some variants, the ducting 18 is in fluid communication with the dock 14 via an opening 28 in the dock 14 . Certain implementations include the fan 17 and TED 20 in a single housing. However, in alternative embodiments, one or more components can be included in separate (e.g., adjacent or non-adjacent) housing or casings.

As noted above, the thermal conditioning device 20 can comprise a TED, for example, a Peltier device, which can include at least one pair of dissimilar materials connected electrically in series and thermally in parallel. In some embodiments, the dissimilar materials are mounted between a pair of plates positioned on the cold and hot sides of the device. The plates can provide for heat conduction and electrical insulation. A thermal interface material (e.g., grease, pad, or solder) can be used to conductively couple the cold or hot side plate to a conduction member, such as fins or the like. Fluid, such as air, can be passed over the conduction member to transfer heat by convection. In other embodiments, one or more intermediate elements (e.g., conduction elements) can be provided between the plates and the conduction element and/or the dock 14 , thereby transferring heat between the TED 20 and the dock 14 by conduction.

In some embodiments, the dissimilar materials comprise a series of n-type and p-type semiconductor elements that are connected electrically in series and thermally in parallel. An electrical circuit is configured to pass current through the dissimilar materials so as to selectively create a cooled (and an oppositely oriented heated) side. Depending on the direction of electrical current passing through the thermoelectric device, one side of the device will be heated and the opposing side will be cooled.

In some embodiments, a controller (not shown) controls the operation of the thermal conditioning module 12 . For example, the controller can allow the user to regulate when the thermal conditioning module 12 is activated and deactivated. In some embodiments, the controller receives an input from a sensor (e.g., a temperature sensor, a humidity sensor, a condensation sensor, etc.), which can be used in a control algorithm that helps regulate the operation (e.g., on or off, duty cycle, etc.) of the thermal conditioning device 20 (e.g., TED). Such an algorithm can be configured to provide for a desired cooling effect for the module, for fault protection, safety reasons, and/or the like. In certain variants, the controller is configured to communicate with, or receive signals from, other systems of the vehicle. For example, the controller can be in data communication with a signal that is indicative of whether the vehicle is in operation (e.g., the ignition has been activated), an occupant is positioned in the vehicle, and/or the like. Thus, in some such embodiments, the controller can be configured to allow the thermal conditioning module 12 to operate only if certain conditions are met (e.g., the vehicle is operating, an occupant is positioned in an adjacent seat, temperature/humidity levels are within a specific range, etc.). Electrical power from the vehicle's electrical system can be provided to the controller, fluid transfer device 17 (e.g., fan or blower), TED or other thermal conditioning device 20 , sensors and/or any other components via electrical wires and/or some other direct or indirect electrical connection (not shown).

In some embodiments, the dock 14 is sized, shaped and otherwise configured to accept a PED. For example, the dock 14 can be configured to contain, hold, and/or embrace the PED. Such a configuration can provide a place to store the PED, which can be helpful in restricting, partially or completely, inadvertent movement of the PED during operation of the vehicle (e.g., while driving). In certain embodiments, the dock 14 is configured such that a cell phone or other PED can be slidingly inserted into and removed from the dock 14 . Some implementations have the dock 14 positioned in a dashboard or center console of an automobile, although various other locations are contemplated as well (e.g., in or near a door, a glove box or other storage container, an armrest, a rear seat console and/or the like).

Some embodiments of the dock 14 comprise a cavity 22 , which can be sized, shaped and otherwise configured to receive a PED. For example, the cavity 22 can include an aperture 23 through which a cell phone or other PED can be inserted. In some embodiments, the aperture 23 has a width W and a length L that are sized and otherwise configured such that a cell phone or other PED can be inserted through the aperture 23 and at least partially into the cavity 22 . Some variants of the aperture 23 have a length L of at least about: 2.0 inches, 2.5 inches, 2.75 inches, 3.0 inches, 3.25 inches, values in between, or otherwise. Some embodiments of the aperture 23 have a width W of at least about: 0.25 inches, 0.38 inches, 0.50 inches, 0.62 inches, values in between, or otherwise. In other embodiments, however, the aperture can be sized and configured to accommodate a PED having a length and/or width greater than indicated above. For example, the aperture can be configured to receive a tablet or other relatively large PED therein. In certain implementations, the cavity 22 is in fluid communication with the ambient environment surrounding the dock 14 . In some embodiments, the cavity 22 can be configured to receive at least about 75% (e.g., about 70%, 72%, 74%, 76%, 78%, 80%, ranges between the foregoing percentages) of the volume of a cell phone or other PED. In other embodiments, however, the cavity 22 can be configured to receive greater than about 80% of the PED (e.g., about 80%, 85%, 90%, 95%, 100%, values between the foregoing percentages, etc.) or less than about 70% of the PED (e.g., about 40%, 45%, 50%, 55%, 60%, 65%, 70%, values between the foregoing percentages, less than about 40%, etc.), as desired or required. In some embodiments, the cavity 22 has a volume of at least about 4 cubic inches.

Some embodiments of the cavity 22 are configured to receive all or a substantial portion of the longitudinal length of a cell phone or other PED. Such a configuration can, for example, facilitate securing and/or concealing (e.g., partially or completely) the cell phone or other PED. Certain embodiments of the cavity 22 have a depth D (also called a height) of at least about: 3.0 inches, 3.5 inches, 4.0 inches, 4.5 inches, 5.0 inches, values in between, or otherwise. In some embodiments, the cavity 22 is configured to receive only a portion of the longitudinal length of a PED, thereby providing a region, portion, or section (e.g., the portion of the PED that is not received in the cavity 22 ) to grasp to facilitate moving or otherwise handling (e.g., removing) the PED relative to the cavity 22 . In other embodiments, the cavity 22 is configured to receive the entire or substantially the entire longitudinal length of the PED.

In some embodiments, the dock 14 comprises one or more stabilizing members, such as, for example, ribs or other protruding members 24 . In some variants, the ribs 24 protrude at least partially into the cavity 22 and are configured to contact a PED that is inserted into the cavity 22 , thereby reducing or restricting vibration and/or other movement of the PED relative to the dock 14 . In some embodiments, the ribs 24 comprise one or more resilient materials, such rubber, plastic and/or the like. The ribs or other protruding members 24 can comprise one or more other materials and/or components, either in addition to or in lieu of plastic and/or rubber, as desired or required. For example, the ribs can include one or more springs or other resilient members or materials. Certain variants of the ribs have a length (parallel to L) of less than or equal to about 2.0 mm. In some embodiments, the ribs 24 extend along generally the entire depth of the dock 14 . In some embodiments, the ribs 24 are configured to promote fluid flow when a PED is installed in the cavity 22 , as will be discussed in further detail below. As shown, certain variants of the dock 14 include sculpted or other special features, such as shoulders 26 , which also can be configured to facilitate stabilization and/or securement (e.g., grasping) of a PED that is inserted into the cavity 22 . Some variants of the shoulders 26 include curves or angles so as to direct a PED into general alignment with the dock 14 during installation of the PED into the dock 14 .

During operation of the cooling system for an induction charger 10 , and as indicated by the arrows in FIG. 1 , fluid (e.g., air) enters the fluid transfer device 17 (e.g., fan, blower, etc.) via an upper or lower aperture, and is encouraged into the ducting 18 . The air passes over and/or through the thermal conditioning device 20 (e.g., TED), causing heat transfer between the thermal conditioning device 20 and the air or other fluid passing through or near it, thereby decreasing the temperature of the air or fluid. In some embodiments, the cooled air is directed, at least partially, into the dock 14 . In certain implementations, the cooled air travels at least partially along at least some of depth of the dock 14 , and along some, substantially all, or all of the height of the PED positioned within the dock. Accordingly, heat from the inductive charging assembly and/or PED can be advantageously transferred via convection to the cooled air (e.g., to cool the air), thereby transferring heat away from the PED and at least partially offsetting the heat generated by the inductive charging assembly and/or PED. The air can emerge from the dock 14 into the ambient environment of the vehicle. In some embodiments, such discharged air can be routed to one or more portions of the vehicle (e.g., the exterior of the vehicle, below or away from the console or seat assembly, etc.), as desired or required.

As noted above, in some embodiments, the dock 14 comprises one or more ribs or other protruding members 24 , which can be configured to promote fluid flow even when a PED is positioned at least partially in the dock 14 . In some embodiments, the ribs 24 are positioned and otherwise configured to at least partially define and maintain one or more channels 30 . Thus, when a PED is positioned in the dock 14 , a substantial volume of the cavity 22 may be occupied by the PED, thus restricting fluid flow. However, the ribs 24 and the corresponding channels 30 that they help define can be configured to maintain a space between the PED and a wall of the dock 14 , and thus maintain a path through which air or other fluid may pass. In some embodiments, a bottom end 32 of the dock 14 (e.g., the portion which is adjacent or near a lower portion a PED that is positioned within the dock 14 ) comprises one or more ribs, dimples, grooves, protruding member and/or other features configured to promote airflow between the bottom of the PED and the bottom end 32 of the dock 14 . One or more spaces between the PED and certain adjacent portions of the dock can advantageously promote the cooling effect on the PED when the system is in use.

In certain embodiments, such as is shown in FIGS. 1, 1A, and 1B , air from the fluid transfer device is configured to enter at or near the bottom end 32 of the dock 14 . In such embodiments, the opening 28 in the dock 14 can be positioned at or near the bottom end 32 . As illustrated in FIG. 1B , the dock 14 can include a support member 34 that extends from one generally vertical wall of the dock 14 toward an opposite generally vertical wall. In some implementations, the support member is configured to receive the bottom of a PED that is received in the dock 14 . As shown, the support member 34 can be disposed a particular distance apart from the bottom end 32 , thus the support member 34 can space the PED away from the bottom end 32 to facilitate airflow underneath the PED. In certain embodiments, the support member directs air toward one or more of the channels 30 . As discussed herein, in at least some configurations, such spaces, channels, and other features can further facilitate in promoting efficient and effective cooling of a PED.

FIGS. 2, 2A, and 2B illustrate another embodiment of a cooling system for an induction charger 10 a . Several features and components of the cooling system for an induction charger 10 a illustrated therein are identical or similar in form and function to those described above with respect to the cooling system for an induction charger 10 , and have been provided with like numerals, with the addition of “a.” Any features and/or components of the disclosed embodiments can be combined or used interchangeably.

In some embodiments, air or other fluid enters the dock 14 a at a location between the top and bottom end 32 a of the dock 14 a . For example, the opening 28 a can be located about half-way along the depth D of the dock 14 a . Such a configuration can, for example, reduce the likelihood of spilled liquids or debris migrating into the fan 17 a , ducting 18 a , thermal conditioning device 20 a (e.g., TED), other electrical and/or other. Sensitive components. For example, as the opening 28 a is disposed a distance above the bottom end 32 a , spilled liquid (such as water, coffee, soft drinks, etc.) or debris (such as crumbs, other food items, dust, dirt, lint, etc.) can be contained in the bottom end 32 a , thereby facilitating clean-up and inhibiting such spills from entering the fan 17 a , ducting 18 a , and/or thermal conditioning device 20 a.

As illustrated in FIG. 2B , the dock 14 a can include one or more vanes 36 a , which can be positioned near or adjacent the opening 28 a . In certain embodiments, the vane 36 a extends partly from one wall of the dock 14 a and is configured to provide a desired space between the vane 36 a and the opposite wall such that a PED can be inserted therebetween. In some variants, the vane 36 a is configured to at least partially direct fluid flow, as desired or required. For example, the vane 36 a can direct some or all of the fluid (e.g., air) passing through the opening 28 a toward the bottom end 32 a . As shown, the ribs or other protruding members 24 a can extend along the bottom end 32 a , thereby providing an elevated support surface on which the PED can rest while allowing the fluid to flow under the PED and through the channels 30 a.

FIGS. 3, 3A, and 3B illustrate another embodiment of a cooling system for an induction charger 10 b . Several features and components of the cooling system for an induction charger 10 b are identical or similar in form and function to those described above with respect to the cooling systems for an induction charger 10 , 10 a and have been provided with like numerals, with the addition of “b.” Any features and/or components of the disclosed embodiments can be combined or used interchangeably.

With continued reference to FIGS. 3, 3A, and 3B , in certain embodiments, air or other fluid is directed through a portion of the induction charging module 16 b . As illustrated, the induction charging module 16 b can be disposed between the dock 14 b and the fan 17 b and/or the thermal conditioning device 20 b (e.g., TED). Such a configuration can, for example, reduce the space occupied by the system 10 b . Further, in certain embodiments, such a configuration can enhance the heat dissipation from the induction charging module 16 b . For example, in some embodiments, holes or other openings (not shown) in the ducting 18 b direct fluid toward and/or along fins 38 b of the induction charging module 16 b.

In some embodiments, a duct, coupling or other fluid passage 18 b fluidly connects the fluid transfer device 17 b (e.g., fan) and with an interior portion 40 b of the induction charging module 16 b . For example, the interior portion 40 b can be configured to receive or mate with the ducting 18 b . In certain variants, the interior portion 40 b is divided from another portion of the induction charging module 16 b by one or more baffles, dividing members and/or other barriers 42 b , which can prevent, inhibit or reduce the likelihood of the migration of dirt, dust, other particles, or other undesirable substances from reaching the electronic components of the induction charging module 16 b . In some embodiments, such a barrier 42 b is configured to direct the flow of fluid, for example, toward a front wall of the induction charging module 16 b . As illustrated in FIG. 3B , the interior portion 40 b can be positioned in a bottom portion of the induction charging module 16 b , but the interior portion can be located in any location, such as, for example, on a side or the top of the induction charging module 16 b and/or the like, as desired or required.

The front wall of the induction charging module 16 b can include an aperture or other opening 44 b that is configured to at least partially align or otherwise coincide with the opening 28 b of the dock 14 b when the induction charging module 16 b and the dock 14 b are mounted together. Such a configuration can allow fluid in the interior portion 40 b to flow into the dock 14 b . Accordingly, during operation of the system 10 , and as is shown by the arrows in FIG. 3A , air or other fluid can flow from the fan or other fluid transfer device 17 b along and/or through the TED or other thermal conditioning device 20 b , thereby thermally conditioning (e.g., cooling and/or dehumidifying) the air in a desired manner. The conditioned air can flow through the ducting 18 b into the interior portion 40 b , through the aperture 44 b and the opening 28 b , and ultimately into the dock 14 b . As previously discussed, conditioned air can be warmed by, and this its cooling effect at least partially offset, heat generated from the induction charging module 16 b and/or the PED. In some embodiments, air exits the dock 14 b and enters the vehicle's ambient environment, for example, by flowing through the channels 30 b and between the ribs 24 b.

Various embodiments of the cooling systems for an induction charger 10 , 10 a , 10 b are configured to operate with an ambient air temperature of less than or equal to about 85° C. In some implementations, the cooling systems for an induction charger 10 , 10 a , 10 b are configured to provide at least about: 4 watts, 5, watts, 6 watts, 7 watts, 8 watts, 9 watts, values in between the foregoing, and/or the like of heat dissipation. In other embodiments, the cooling system is configured to provide less than 4 watts or greater than about 9 watts of heat dissipation. In some embodiments, the cooling systems for an induction charger 10 , 10 a , 10 b are configured to dissipate at least about 4 watts generated by the induction charging module 16 , 16 a , 16 b and at least about 3 watts generated by the PED. In certain embodiments, the cooling systems for an induction charger 10 , 10 a , 10 b are configured to offset at least about: 50%, 60%, 70%, 80%, 85%, 90%, 95%, 99%, 100%, values in between, or otherwise, of the heat generated by the induction charging assembly during induction charging of the portable electronic device. In certain variants, the cooling systems for an induction charger 10 , 10 a , 10 b are configured to offset all or substantially all of the heat generated by the induction charging assembly during induction charging of the portable electronic device. In some implementations, the cooling systems for an induction charger 10 , 10 a , 10 b are configured to offset more than the heat generated by the induction charging assembly during induction charging of the portable electronic device.

For purposes of summarizing the inventions disclosed herein and the advantages achieved over the prior art, certain objects and advantages of the inventions are described herein. Of course, it is to be understood that not necessarily all such objects or advantages need to be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the inventions may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught or suggested herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

As will be apparent, the features and attributes of the specific embodiments disclosed herein may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.

Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or states. Thus, such conditional language is not generally intended to imply that features, elements and/or states are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without author input or prompting, whether these features, elements and/or states are included or are to be performed in any particular embodiment.

Many variations and modifications may be made to the herein-described embodiments, the elements of which are to be understood as being among other acceptable examples. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.