after "completing" The clock I decided that I wanted it to also have a wireless charger. I ordered a QI module (unboxed board and coil only) to install.

The 5v dc2dc provides enough current to run the clock and charger so I split the internal 5v out to the QI module as well as the clock, this prevents needing multiple inputs or a second 5v regulator off the 12v input.

The charge coil was glued to the lid of the box on the inside and aligned so that my phone would sit neatly on top of the clock, after drying I checked alignment and reassembled the box.

DANGER! It turns out that the QI charger generates a LOT of heat. The phone gets hot but also the heat builds up inside the clock. I didn't provide vents or airflow because I used the box as a sealed speaker cavity. This is a mistake.

When charging the whole thing gets too hot inside and causes problems, not the least of which being the BT audio module "crashing" and needing a power cycle to reset.

For now I am not using the QI charger but the solution is to somehow cool the components while not breaking the "seal" for the speaker. Maybe some kind of heat pipe to a heat sink on the back?