Power adapter

• US 10,284,106 B1
• Filed: 06/06/2016
• Issued: 05/07/2019
• Est. Priority Date: 06/05/2015
• Status: Active Grant

• Current Assignee: Vicor Corporation
• Original Assignee: VLT Incorporated (Vicor Corporation)
• Inventors: Vinciarelli, Patrizio, D'Amico, Andrew T.
• Primary Examiner(s): Smith, Courtney L
• Application Number:
  US15/174,083
• Time in Patent Office: 1,065 Days
• Field of Search: None
• CPC Class Codes: B60L 53/00 Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: H01R 31/06 Intermediate parts for linking two coupling parts, e.g. adapter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/94
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 7/04 by static converters
• CPC Class Codes: H05K 5/0247 Electrical details of casings, e.g. terminals, passages for cables or wiring
• CPC Class Codes: H05K 7/20436 Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence

Abstract

An efficient, high density, inline converter module includes a power conversion circuit and an input wiring harness for connecting the input of the power circuit to a unipolar source. A second wiring harness or electrical connectors may be provided for connecting the output of the power conversion circuit to a load. Connections between a wiring harness and the power conversion circuit may comprise conductive contacts, configured to distribute heat. The power circuit may be over molded to provide electrical insulation and efficient heat transfer to external ambient air. A DC transformer based inline converter module may be used in AC adapter, vehicular, and power system architectures. An input connector for connecting the input wiring harness to the input source may be provided. In some embodiments the input source may be an AC source and the input connector may comprise a rectifier for delivering a rectified, unipolar, voltage to the input of the power conversion assembly via an input wiring harness. By separating the rectifier from the power conversion assembly, the power conversion assembly may be packaged into a smaller volume than would be required if the rectifier, and its associated heat loss, were included in the power conversion assembly.

Claims

1. An apparatus comprising:

an in-line converter module assembly configured for cable-termination deployment, the in-line converter module assembly comprising;

a first power conversion module including a module body having an input terminal adapted to accommodate an electrical connection to an input of the first power conversion module, and an output terminal adapted to accommodate an electrical connection to an output of the first power conversion module;

the first power conversion module including circuitry adapted to convert power received from the input terminal at a unipolar input voltage, Vin, for delivery at the output terminal at a unipolar output voltage, Vo, at an essentially fixed voltage transformation ratio, K=Vo/Vin; and

a strain relief mechanism mechanically secured to the in-line converter module assembly, the strain relief mechanism being configured to mechanically engage an electrical cable electrically connected to the input terminal or the output terminal of the first power conversion module, the strain relief mechanism mechanically securing the electrical cable to the in-line converter module assembly;

wherein the inline converter module assembly is adapted to be used as part of a wire harness that includes the electrical cable, wherein the electrical cable has a first end adapted for connection to electrical equipment and a second end electrically connected to the input terminal or output terminal of the first power conversion module, and wherein the wire harness is configured to provide one or both of DC voltage transformation and galvanic isolation in-line between at least one of (i) the electrical cable and the output terminal of the first power conversion module when the second end of the electrical cable is electrically connected to the input terminal of the first power conversion module, or (ii) the electrical cable and the input terminal of the first power conversion module when the second end of the electrical cable is electrically connected to the output terminal of the first power conversion module.

2. The apparatus of claim 1, further comprising:

an input cable having a first end and a second end; and

wherein the input terminal is adapted to form an electrical and mechanical connection to the second end of the input cable, and the first end of the input cable is electrically and mechanically connected to the electrical equipment;

and

wherein the strain relief mechanism is configured to mechanically engage the input cable;

wherein the in-line converter module assembly and the input cable together form the wire harness; and

wherein the wire harness provides power transmission and one or both of DC voltage transformation and galvanic isolation in-line between the first end of the input cable and the output terminal of the first power conversion module.

3. The apparatus of claim 1, further comprising an output cable having a first end and a second end;

and

wherein the output terminal is adapted to form an electrical and mechanical connection to the first end of the output cable, and the second end of the output cable is electrically and mechanically connected to the electrical equipment wherein the strain relief mechanism is configured to mechanically engage the output cable;

wherein the in-line converter module assembly and the output cable together form the wire harness; and

wherein the wire harness provides power transmission and one or both of DC voltage transformation and galvanic isolation in-line between the input terminal of the first power conversion module and the second end of the output cable.

4. The apparatus of claim 1 further comprising:

a second power conversion module including a module body having an input terminal adapted to accommodate an electrical connection to an input of the second power conversion module, and an output terminal adapted to accommodate an electrical connection to an output of the second power conversion module;

the second power conversion module including circuitry adapted to convert power received from the input terminal at a unipolar input voltage, Vin, for delivery at the output terminal at a unipolar output voltage, Vo, at an essentially fixed voltage transformation ratio, K=Vo/Vin; and

a first cable having a first end electrically connected to the output terminal of the first power conversion module and a second end electrically connected to the input terminal of the second power conversion module;

wherein the apparatus is adapted to be used as part of the wire harness to provide one or both of DC voltage transformation and galvanic isolation in-line between the input terminal of the first power conversion module and the output terminal of the second power conversion module.

5. The apparatus of claim 4 wherein the first power conversion module provides voltage step-up and the second power conversion module provides voltage step-down.

6. The apparatus of claim 1, further comprising:

a connector having a first end and a second end; and

wherein the input terminal is configured to form an electrical and mechanical connection to the second end of the connector, and the first end of the connector is electrically and mechanically connected to an input power source;

wherein the strain relief mechanism is configured to mechanically engage the connector;

wherein the in-line converter module assembly and the connector together form the wire harness; and

wherein the wire harness provides power transmission and one or both of DC voltage transformation and galvanic isolation in-line between the first end of the connector and the output terminal of the first power conversion module.

7. The apparatus of claim 1, further comprising a connector configured to connect to the electrical cable and an input power source, the electrical cable having a first end electrically connected to the connector and a second end electrically connected to the input terminal of the first power conversion module,

wherein the strain relief mechanism is configured to mechanically engage the electrical cable;

wherein the in-line converter module assembly, the electrical cable, and the connector together form the wire harness;

wherein the wire harness provides power transmission and one or both of DC voltage transformation and galvanic isolation in-line between the first end of the connector and the output terminal of the first power conversion module, and

wherein the input power source comprises an AC source and the connector is adapted to mate with an AC outlet.

8. The apparatus of claim 7 wherein the connector further comprises a rectifier electrically connected to receive power from the AC source and deliver rectified power at the unipolar voltage to the input terminal of the first power conversion module via the electrical cable and wherein the connector is physically separated from the converter body by an electrical distance defined by the length of the electrical cable.

9. The apparatus of claim 6 wherein the connector is a plug having two or more conductive prongs.

10. The apparatus of claim 1 wherein the first power conversion module comprises a first pair of conductively plated holes adapted to receive input wires of the wire harness, and

a second pair of conductively plated holes adapted to receive mechanical fasteners for securing the first power conversion module to another module that comprises a load or is electrically coupled to a load.

11. The apparatus of claim 10 wherein the load comprises a second power conversion circuit that further comprises one or more outputs adapted to deliver power at one or more regulated output voltages.

12. The apparatus of claim 7 further comprising a second electrical cable having a first end connected to the output of the first power conversion module and a second end connected to the load, wherein the load comprises a second power conversion circuit having a controller for controlling the power factor of the power drawn from the output of the first power conversion circuit.

13. The apparatus of claim 1 wherein the module body further comprises a conductive member electrically connected to an input or output of the first power conversion module and being constructed and arranged to spread heat from the circuitry along a pre-defined region of the module body.

14. The apparatus of claim 13, comprising the electrical cable, in which the electrical cable is electrically connected to the input of the first power conversion module, the electrical cable is mechanically connected to the strain relief, and wherein the conductive member comprises a pair of conductive members connected between the electrical cable and the input and forming a heat spreading sheath around a selected portion of the circuitry.

15. The apparatus of claim 14, further comprising an output cable electrically connected to the output, and wherein the conductive member further comprises another conductive member connected between the output cable and the output and forming a heat spreading sheath around a selected portion of the circuitry.

16. The apparatus of claim 14 wherein the module body further comprises an electrically insulating covering surrounding the conductive members and a portion of the electrical cable.

17. The apparatus of claim 15 wherein the module body comprises an electrically insulating exterior molded around the conductive members, the first power conversion circuit, a portion of the electrical cable, and a portion of the output cable.

18. The apparatus of claim 1 wherein the module body further comprises one or more conductive members thermally connected to the circuitry and being constructed and arranged to spread heat from the circuitry along one or more pre-defined regions of the module body and an electrically insulating covering surrounding the conductive members and the circuitry.

19. The apparatus of claim 1 wherein the first power conversion module further comprises a transformer, a plurality of power switching elements connected to the transformer, and a switch controller adapted to operate the power switching elements in a series of converter operating cycles during which power received from the input terminal is converted for delivery to the output terminal via the transformer.

20. The apparatus of claim 1 wherein K is less than 1.

21. The apparatus of claim 20 wherein K is less than or equal to ¼

.

22. The apparatus of claim 20, further comprising:

an input cable, having a first end and a second end, the first end of the input cable being electrically connected to a power regulator, and the second end of the input cable being electrically connected to the input terminal of the first power conversion module; and

an output cable having a first end and a second end, the first end of the output cable being electrically connected to the output terminal of the first power conversion module, and the second end of the output cable being electrically connected to a load;

wherein a current carrying capacity of the output cable is greater than a current carrying capacity of the input cable,

wherein the strain relief mechanism mechanically secures the second end of the input cable or the first end of the output cable to the in-line converter module assembly, and

wherein the in-line converter module assembly, the input cable, and the output cable together form the wire harness.

23. The apparatus of claim 1, comprising:

a regulator having an output terminal and being configured to supply DC power at a controlled first voltage via the output terminal, and

the electrical cable, the first end of the electrical cable being electrically connected to the output terminal of the regulator, and the second end of the electrical cable being electrically connected to the input terminal of the first power conversion module;

wherein the electrical cable and the in-line converter module assembly together form the wire harness;

wherein the wire harness carries power from the output terminal of the regulator, and provides one or both of DC voltage transformation and galvanic isolation in-line between the first end of the electrical cable and the output terminal of the first power conversion module.

24. The apparatus of claim 23, wherein the first power conversion module is located at or near a point of load and the output terminal of the first power conversion module further comprises terminations adapted for mechanical and electrical connection to the load.

25. The apparatus of claim 24 wherein the terminations of the output terminal further comprise one or more conductive portions, each having a respective hole adaptive to be secured to the load.

26. The apparatus of claim 1 wherein the module assembly further comprises a housing surrounding the module body.

27. The apparatus of claim 1 wherein the module assembly further comprises an external surface at least a portion of which is defined by the module body.

28. An apparatus comprising:

a first power conversion module including a module body having an input opening adapted to accommodate an electrical connection to an input of the first power conversion module, an output opening adapted to accommodate an electrical connection to an output of the first power conversion module, and an internal space;

the first power conversion module including circuitry contained in the internal space and adapted to convert power received from the input at an input voltage, Vin, for delivery at the output at a unipolar output voltage, Vo, via a transformer at an essentially fixed voltage transformation ratio, K=Vo/Vin;

wherein the first power conversion module is adapted to be used as part of a wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input through the input opening and the output through the output opening,

wherein the module body further comprises a conductive member electrically connected to an input or output of the first power conversion module and being constructed and arranged to spread heat from the circuitry along a pre-defined region of the module body, and

wherein the input opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the input opening and electrically connected to the input of the first power conversion module and wherein the conductive member comprises a pair of conductive members connected between the first cable and the input and forming a heat spreading sheath around a selected portion of the circuitry.

29. The apparatus of claim 28 wherein the output opening is adapted to accommodate a cable and the apparatus further comprises a second cable routed through the output opening and electrically connected to the output, and wherein the conductive member further comprises another conductive member connected between the second cable and the output and forming a heat spreading sheath around a selected portion of the circuitry.

30. The apparatus of claim 29 wherein the module body comprises an electrically insulating exterior molded around the conductive members, the first power conversion circuit and portions of the first and second cables.

31. The apparatus of claim 28 wherein the module body further comprises an electrically insulating covering surrounding the conductive members and a portion of the first cable.

32. The apparatus of claim 28 in which the module body comprises at least two terminals adapted to form high current connections.

33. The apparatus of claim 28 wherein:

the input terminal is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the input opening and electrically connected to the input of the first power conversion module;

the output opening comprises an electrical connector having terminals connected to the output; and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the connector.

34. The apparatus of claim 28 wherein:

the input opening comprises an electrical connector having terminals connected to the input;

the output opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the output opening and electrically connected to the output of the first power conversion module; and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the connector.

35. The apparatus of claim 28 wherein the input opening and output opening each comprises an electrical connector having terminals connected to its respective input or output;

and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input connector and the output connector.

36. The apparatus of claim 28 wherein:

the input opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the input opening and electrically connected to the input of the first power conversion module;

the output opening is adapted to accommodate a cable and the apparatus further comprises a second cable routed through the output opening and electrically connected to the output of the first power conversion module; and

the apparatus is adapted to be used in the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the second cable.

37. The apparatus of claim 28 further comprising:

a second power conversion module including a module body having an input opening adapted to accommodate an electrical connection to an input of the second power conversion module, an output opening adapted to accommodate an electrical connection to an output of the second power conversion module, and an internal space;

the second power conversion module including circuitry contained in the internal space and adapted to convert power received from the input at an input voltage, Vin, for delivery at the output terminal at a unipolar output voltage, Vo, via a transformer at an essentially fixed voltage transformation ratio, K=Vo/Vin;

a first cable having a first end electrically connected to the output of the first power conversion module and a second end electrically connected to the input of the second power conversion module;

wherein the apparatus is adapted to be used as part of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input opening of the first conversion module and the output opening of the second power conversion module.

38. The apparatus of claim 37 wherein the first power conversion module provides voltage step-up and the second power conversion module provides voltage step-down.

39. An apparatus comprising:

a first power conversion module including a module body having an input opening adapted to accommodate an electrical connection to an input of the first power conversion module, an output opening adapted to accommodate an electrical connection to an output of the first power conversion module, and an internal space;

the first power conversion module including circuitry contained in the internal space and adapted to convert power received from the input at an input voltage, Vin, for delivery at the output at a unipolar output voltage, Vo, via a transformer at an essentially fixed voltage transformation ratio, K=Vo/Vin; and

a connector configured to connect to an input power source and a first cable having a first end electrically connected to the connector and a second end electrically connected to the input of the first power conversion module;

wherein the first power conversion module is adapted to be used as part of a wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input through the input opening and the output through the output opening,

wherein the apparatus is adapted for use as an in-line cable to connect a load to the input power source providing voltage transformation, galvanic isolation, or both there between;

wherein the input power source comprises an AC source and the connector is adapted to mate with an AC outlet; and

wherein the connector further comprises a rectifier electrically connected to receive power from the AC source and deliver rectified power at a unipolar voltage to the input of the first power conversion module via the first cable and wherein the connector is physically separated from the converter body by an electrical distance defined by the length of the first cable.

40. The apparatus of claim 39 wherein:

the input opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the input opening and electrically connected to the input of the first power conversion module;

the output opening comprises an electrical connector having terminals connected to the output; and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the connector.

41. The apparatus of claim 39 wherein:

the input opening comprises an electrical connector having terminals connected to the input;

the output opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the output opening and electrically connected to the output of the first power conversion module; and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the connector.

42. The apparatus of claim 39 wherein the input opening and output opening each comprises an electrical connector having terminals connected to its respective input or output;

and

the apparatus is adapted to be used at an end of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input connector and the output connector.

43. The apparatus of claim 39 wherein:

the input opening is adapted to accommodate a cable and the apparatus further comprises a first cable routed through the input opening and electrically connected to the input of the first power conversion module;

the output opening is adapted to accommodate a cable and the apparatus further comprises a second cable routed through the output opening and electrically connected to the output of the first power conversion module; and

the apparatus is adapted to be used in the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the first cable and the second cable.

44. The apparatus of claim 39, further comprising:

a second power conversion module including a module body having an input opening adapted to accommodate an electrical connection to an input of the second power conversion module, an output opening adapted to accommodate an electrical connection to an output of the second power conversion module, and an internal space;

the second power conversion module including circuitry contained in the internal space and adapted to convert power received from the input at an input voltage, Vin, for delivery at the output terminal at a unipolar output voltage, Vo, via a transformer at an essentially fixed voltage transformation ratio, K=Vo/Vin;

a first cable having a first end electrically connected to the output of the first power conversion module and a second end electrically connected to the input of the second power conversion module;

wherein the apparatus is adapted to be used as part of the wire harness to provide one or both of voltage transformation and galvanic isolation in-line between the input opening of the first conversion module and the output opening of the second power conversion module.

45. The apparatus of claim 44 wherein the first power conversion module provides voltage step-up and the second power conversion module provides voltage step-down.

46. The apparatus of claim 39 wherein the connector is a plug having two or more conductive prongs.

47. The apparatus of claim 39 further comprising:

a first cable routed through the input opening and electrically connected to the input of the first power conversion module, and

a second cable having a first end routed through the output opening and electrically connected to the output of the first power conversion module and a second end connected to the load, wherein the load comprises a second power conversion circuit.

48. The apparatus of claim 47 wherein the second power conversion circuit further comprises one or more outputs adapted to deliver power at one or more regulated output voltages.

49. The apparatus of claim 39 further comprising a second cable having a first end connected to the output of the first power conversion module and a second end connected to the load, wherein the load comprises a second power conversion circuit having a controller for controlling the power factor of the power drawn from the output of the first power conversion circuit.

50. The apparatus of claim 39 wherein the module body further comprises a conductive member electrically connected to an input or output of the first power conversion module and being constructed and arranged to spread heat from the circuitry along a pre-defined region of the module body.