Power Supply Cooling Apparatus and Configuration

• US 20080061048A1
• Filed: 12/21/2006
• Published: 03/13/2008
• Est. Priority Date: 09/13/2006
• Status: Active Grant

• Current Assignee: Hypertherm Incorporated
• Original Assignee: Hypertherm Incorporated
• Inventors: Kornprobst, Michael F., Borowy, Dennis M., Morris, Ronald E.
• Granted Patent: US 7,800,901 B2
• Time in Patent Office: Days
• US Class Current: 219/130.1
• CPC Class Codes: B23K 9/10 Other electric circuits therefor; Protective circuits; Remote controls
• CPC Class Codes: B23K 9/32 Accessories earthing connections H01R

Abstract

An improved system for cooling a power supply of a welding or plasma cutting system, and an improved configuration of a power supply. The system cools achieves the improvement in configuration and cooling by mounting electrical components to a circuit board and then to a heat sink. Electrical components are also mounted to a common panel that improves the circulation of air. A central panel supporting the power supply heat sink and components allows a smaller and more compact design while maintaining proper temperatures. Electromagnet cooling is improved by modifying electromagnetic cores to conduct heat to the heat sink, and by the use of thermally conducting polymers.

Claims

1. A method of assembling a power supply of a welding or plasma cutting system, comprising:

mounting a plurality of heat-generating components to a single circuit board; and

thermally connecting the mounted heat-generating components to a heat sink.

2. The method of claim 1, wherein the mounting step further comprises mounting at least one of a resistor, a silicon power device, or a magnetic device to the single circuit board.

3. A power supply of a welding or plasma cutting system, comprising:

a thermally-conductive plate having a first surface, a second surface opposed to the first surface, and edges located about a periphery of the plate; and

a plurality of heat-generating components mounted on the first surface of the plate,

wherein the plate is disposed between the plurality of heat-generating components and a wall of an enclosure surrounding the power supply, the plate being disposed to maintain a gap between the second surface and the wall, the gap facilitates a gas flow around an exposed surface area of the plate.

4. The power supply of claim 3, wherein the plurality of heat-generating components include at least one of the following:

an inductor, a transformer, or an electromagnet.

5. The power supply of claim 3, wherein the plurality of heat-generating components includes a thermally-conductive electrical polymer.

6. The power supply of claim 3, wherein the gas flow is an airflow.

7. A method of assembling a power supply of a welding or plasma cutting system, comprising:

positioning in the power supply a thermally-conductive plate having a first surface, a second surface opposed to the first surface, and edges located about a periphery of the plate; and

mounting a plurality of heat-generating components on the first surface of the plate,

wherein the plate is disposed between the plurality of heat-generating components and a wall of an enclosure surrounding the power supply, the plate being positioned to maintain a gap between the second surface and the wall, the gap facilitating a gas flow around an exposed surface area of the plate.

8. A power supply of a welding or plasma cutting system, comprising:

a panel positioned in a center location of the power supply, the panel approximately bisecting the power supply relative to a vertical axis extending therethrough;

a heat sink positioned within the power supply and mounted to the panel, the panel and heat sink together forming a mounting structure;

a plurality of components connected to the mounting structure; and

a power supply enclosure surrounding the mounting structure.

9. The power supply of claim 8, wherein the plurality of components include at least one of a carrying handle for the power supply, an inductor, a transformer, an electromagnet, a resistor, a silicon power device, or a magnetic device.

10. The power supply of claim 8, wherein the enclosure includes at least two end panels, a base, and a cover.

11. A method of assembling a power supply of a welding or plasma cutting system, comprising:

positioning a panel at a central location within the power supply, the panel at least substantially bisecting the power supply relative to a vertical axis extending therethrough;

mounting a heat sink to the panel, the panel and heat sink together forming a mounting structure;

connecting a plurality of components to the mounting structure; and

connecting a power supply enclosure to the mounting structure.

12. An electromagnetic component of a power supply for a welding or plasma cutting system, comprising:

a core having a length with a first end and a second end; and

a plurality of windings disposed around the core,

wherein the first end includes a surface adapted to engage a surface of a heat sink disposed in the power supply, the core being thermally connected to the heat sink.

13. The component of claim 12, wherein the component includes at least one of the following:

an inductor, a transformer, or an electromagnet.

14. The component of claim 12, wherein the component includes a thermally-conductive electrical polymer.

15. The component of claim 12, wherein the first end is formed to have a planar surface that engages a mating planar surface of the heat sink.

16. The component of claim 12, wherein the component abuts at least a portion of a circuit board, the component being electrically connected to the circuit board.