POWER CHARGING MODULE AND METHODS OF USING SAME

• US 20170141608A1
• Filed: 11/15/2016
• Published: 05/18/2017
• Est. Priority Date: 11/16/2015
• Status: Active Grant

• Current Assignee: Molex LLC (KOCH Industries Incorporated)
• Original Assignee: Molex LLC (KOCH Industries Incorporated)
• Inventors: STENGER, Joseph D., BELLA, Gregory, CIARLETTE, Jeffrey
• Granted Patent: US 10,897,147 B2
• Time in Patent Office: Days
• CPC Class Codes: H01M 10/443 in response to temperature
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 7/0013 acting upon several batteries simultaneously or sequentially H02J7/1423 takes precedence
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: H02J 7/007192 in response to temperature
• CPC Class Codes: H02J 7/16 Regulation of the charging current or voltage by variation of field
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A power charging module includes a controller, a charging port, and a temperature sensor. The charging port delivers power to an external device plugged into the charging port. The temperature sensor provides a sensed temperature to the controller. A standard maximum power output is delivered to the charging port if the sensed temperature is categorized in a nominal thermal condition range, a modified maximum power output is delivered to the charging port if the sensed temperature is categorized in an intermediate thermal condition range, and power output to the charging port is discontinued if the sensed temperature is categorized in a critical thermal condition range.

Claims

1. A power charging module, the power charging module comprising:

a controller programmed to define at least three thermal condition ranges, wherein the at least three thermal condition ranges include a nominal thermal condition range, a critical thermal condition range, and an intermediate thermal condition range, the intermediate thermal condition range being between the nominal thermal condition range and the critical thermal condition range;

a charging port, each charging port being associated with the controller and being configured to deliver power to an external device plugged into the charging port; and

a temperature sensor, the temperature sensor configured to sense a temperature and to provide the sensed temperature to the controller,

wherein the controller is configured to determine in which thermal condition range the sensed temperature is categorized, and wherein the controller is configured to;

deliver a standard maximum power output to the charging port if the sensed temperature is categorized in the nominal thermal condition range,

deliver a modified maximum power output to the charging port if the sensed temperature is categorized in the intermediate thermal condition range, and

discontinue power output to the charging port if the sensed temperature is categorized in the critical thermal condition range.

2. The module of claim 1, further including a plurality of charging ports and a second temperature sensor adjacent one of the charging ports, the second temperature sensor being configured to sense a second temperature and to provide the second sensed temperature to the controller, and the controller is configured to:

deliver a standard maximum power output to each of the charging ports if the sensed temperatures from both temperature sensors are categorized in the nominal thermal condition range,

deliver a modified maximum power output to at least one of the charging ports if the sensed temperature from either temperature sensor is categorized in the intermediate thermal condition range and the sensed temperature from another of the temperature sensors is categorized in the nominal thermal condition range, and

discontinue power output to at least one of the charging ports if the sensed temperatures from either temperature sensor is categorized in the critical thermal condition range.

3. A method of charging devices, the method comprising the steps of:

providing a power charging module, the power charging module having a charging port and at least one temperature sensor;

defining a plurality of thermal condition ranges, wherein the plurality of thermal condition ranges include a nominal thermal condition range, a critical thermal condition range, and an intermediate thermal condition range, the intermediate thermal condition range being between the nominal thermal condition range and the critical thermal condition range;

sensing a temperature at the at least one temperature sensor;

determining a corresponding thermal condition range for the sensed temperature;

delivering a standard maximum power output to the charging port if the sensed temperature is within the nominal thermal condition range;

delivering a modified maximum power output to the charging port if the sensed temperature is within the intermediate thermal condition range; and

discontinuing power output to the charging port if the sensed temperature is within the critical thermal condition range.

4. The method according to claim 3, wherein the power charging module has a plurality of charging ports, and if the sensed temperature is within the intermediate thermal condition range, the standard maximum power output is delivered to a first charging port and the modified maximum power output is delivered to another of the charging ports.

5. The method according to claim 4, wherein the first charging port is defined by a prioritization method.

6. The method according to claim 5, wherein the prioritization method is a first plugged in method.

7. The method according to claim 5, wherein the prioritization method is a defined priority port.

8. A power charging system, the power charging system comprising:

a charging port, the charging port being configured to deliver power to a device operatively connected to the charging port;

a temperature sensor operative to generate temperature signals indicative of a sensed temperature; and

a controller configured to;

store a plurality of thermal condition ranges, the plurality of thermal condition ranges including a nominal thermal condition range, at least one intermediate thermal condition range, and a critical thermal condition range, the at least one intermediate thermal condition range being between the nominal thermal condition range and the critical thermal condition range;

store a standard maximum power output setting for the charging port and a modified maximum power output setting for the charging ports;

determine the sensed temperature at the temperature sensor based upon the temperature signals;

upon the sensed temperature being within the nominal thermal condition range, deliver power to the charging port based upon the standard maximum power output setting;

upon the sensed temperature being within the intermediate thermal condition range, deliver power to the charging port based upon the modified maximum power output setting; and

upon the sensed temperature being within the critical thermal condition range, discontinue power output to the charging port.

9. The system of claim 8, wherein each device is operative in a first charging configuration at a first power and in a second charging configuration at a second power, the second power being less than the first power, and the controller is configured to control power drawn by the pluggable device to the first power when the sensed temperature is in the nominal range and the second power when the sensed temperature is in the intermediate range.

10. The system of claim 9, wherein changing between the first charging configuration and the second charging configuration includes the controller generating signals to communicate a change in charging configuration to the device.

11. The system of claim 10, wherein the controller includes a host and the host is configured to generate a signal to communicate the change in charging configuration to the device.

12. The system of claim 9, wherein changing between the first charging configuration and the second charging configuration includes the controller reducing a voltage at the charging port.

13. The system of claim 8, wherein upon the sensed temperature being within the intermediate thermal condition range, the controller is configured to deliver power to the charging port according to the modified maximum power output setting.

14. The system of claim 8, further comprising a plurality of charging ports, and wherein upon the sensed temperature being within the intermediate thermal condition range, the controller is configured to deliver power to only some of the charging ports according to the modified maximum power output setting.

15. The system of claim 14, wherein the temperature sensor is a first temperature sensor for determining a first sensed temperature and further including a second temperature sensor adjacent at least one charging port for generating a second sensed temperature, and the controller is further configured to deliver power to each of the charging ports according to the standard maximum power output setting upon both of the first sensed temperature and the second sensed temperature being within the nominal thermal condition range and deliver power to each of the charging ports according to the modified maximum power output setting upon one of the first sensed temperature and the second sensed temperature being within the nominal thermal condition range and another of the first sensed temperature and the second sensed temperature being within the intermediate thermal condition range.

16. The system of claim 15, wherein the first temperature sensor is adjacent a second charging port.

17. The system of claim 15, further including a housing including an ASIC therein, the first temperature sensor being adjacent the housing.

18. The system of claim 17, wherein the first temperature sensor is integrated into the ASIC.

19. The system of claim 14, wherein the standard maximum power output setting includes a maximum power output to each of the charging ports, the maximum power output for each charging port being at an identical power output, and the modified maximum power output setting includes a first modified maximum power output to a first of the charging ports and a second modified maximum power output to a second of the charging ports, the first modified maximum power output being at a first maximum power output, the second modified maximum power output being at a second maximum power output, the second maximum power output being less than the first maximum power output.

20. The system of claim 8, wherein the controller is further configured to display a change in charging status.