Power Conversion Device Frame Packaging Apparatus and Methods

• US 20090091897A1
• Filed: 05/02/2008
• Published: 04/09/2009
• Est. Priority Date: 03/10/2004
• Status: Active Grant

• Current Assignee: PEI-Genesis, Inc.
• Original Assignee: PEI-Genesis, Inc.
• Inventors: CAMPBELL, Robert E., CARLSON, Kent, WILLING, Steven Lee, AVENDANO, Alberto
• Granted Patent: US 7,940,532 B2
• Time in Patent Office: Days
• US Class Current: 361/752
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 1/0263 High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 2201/09954 More mounting possibilities, e.g. on same place of PCB, or by using different sets of edge pads
• CPC Class Codes: H05K 2201/10424 Frame holders
• CPC Class Codes: H05K 2201/1059 Connections made by press-fit insertion
• CPC Class Codes: H05K 2201/2018 Presence of a frame in a printed circuit or printed circuit assembly

Abstract

The present invention relates, generally, to electrical power conversion devices and to the universal packaging of those devices for a wide range of applications yielding cost efficient inventory management of product lines consisting of a group of power conversion devices each with minor variations. More specifically, the present invention relates to a universal mounting frame for receiving a printed circuit board in a switch mode power supply. The universal frame is adapted for receiving an open frame or printed circuit board and securing the open frame within a plurality of known packaging configurations. To this end, only a single size printed circuit board is necessary for any type of switch mode power supply configurations, thereby, reducing costs associated with manufacture and testing.

Claims

1. ) A mounting frame for mounting a printed circuit board within a switch mode power supply comprising:

a base having four side walls forming an interior chamber sized to receive a printed circuit board;

a plurality of mounting studs molded within the interior chamber such that the mounting studs support the printed circuit board within the base; and

a mounting extension extending from each of two opposing sides of the base.

2. ) The mounting frame of claim 1 further comprising a plurality of clips integrally mounted within at least one of the four side walls of the base wherein the plurality of clips couple the printed circuit board to the base.

3. ) The mounting frame of claim 1 further comprising a plurality of first mounting holes extending through at least end of the mounting extension wherein the mounting holes couple the base to an element of a switch mode power supply.

4. ) The mounting frame of claim 3 wherein the plurality of first mounting holes are pass through a wall of the mounting extension such that the base and printed circuit board are coupled to the switch mode power supply by one of the four side walls of the base.

5. ) The mounting frame of claim 3 wherein the plurality of first mounting holes are pass through a wall of the mounting extension such that the base and printed circuit board are coupled to the switch mode power supply by all four side walls of the base.

6. ) The mounting frame of claim 1 further comprising a bottom wall molded to the four side walls of the base.

7. ) The mounting frame of claim 6 wherein the bottom wall is coated with an electrically conductive material

8. ) The mounting frame of claim 6 wherein the bottom wall is coupled to a metallic foil.

9. ) The mounting frame of claim 6 wherein the four side walls and the bottom wall form one half of the switch mode power supply.

10. ) The mounting frame of claim 1 further comprising an AC input electrical connection and a DC output electrical connection each on one of the four side walls of the base wherein the AC input electrical connection and DC output electrical connection each align with an AC input connection and DC output connection on the printed circuit board wherein the AC input electrical connection and DC output electrical connection of the frame are comprised of metallic clips.

11. ) The mounting frame of claim 10 wherein the AC input connection and DC output connection on the printed circuit board are both independently comprised of contact pads adapted to slidingly engaged with the metallic clips of the AC input electrical connection and the DC output electrical connection on at least one of the four side walls of the base.

12. ) The mounting frame of claim 10 wherein the AC input connection and DC output connection on the printed circuit board are both independently comprised of pin header type electrical connections adapted to slidingly engaged with the metallic clips of the AC input electrical connection and the DC output electrical connection on at least one of the four side walls of the base

13. ) The mounting frame of claim 1 wherein the base is mountable to one or more rails by way of one or more brackets.

14. ) The mounting frame of claim 1 wherein one side of the four walls of the base recessed so as to from a slot that is receivable by one or more rails.

15. ) The mounting frame of claim 1 further comprising a plurality of opposing mounting studs extending from at least two side walls of the base wherein the mounting studs are receivable by one or more chassis of the switch mode power supply.

16. ) The mounting frame of claim 1 further comprising a plurality of mounting studs extending from at least one side wall of the base wherein the mounting studs are receivable by a chassis of the switch mode power supply.

17. ) The mounting frame of claim 1 further comprising a cap receivable by the four side walls of the base wherein the cap is comprised of four side walls and a ceiling such that, when the cap is received by the base, the cap substantially encloses one side of the printed circuit board therewithin.

18. ) A mounting frame for mounting a printed circuit board on a chassis of a switch mode power supply comprising:

a base having four side walls forming an interior chamber sized to receive a printed circuit board;

a plurality of mounting studs molded within the interior chamber such that the mounting studs support the printed circuit board within the base;

an AC input electrical connection on one of the four side walls of the base wherein the AC input electrical connection aligns with similarly placed AC input connection on the printed circuit board;

a DC output electrical connection on one of the four side walls of the base wherein the DC output connection aligns with similarly placed DC output connection on the printed circuit board;

a mounting extension extending from each of two opposing sides of the base.

19. ) The mounting frame of claim 18 wherein the mounting extension is comprised of two opposing side walls and a bottom wall with a recess passing therebetween wherein a plurality first mounting holes are horizontally oriented and pass through the two opposing side walls of the mounting extension such that the base may be vertically coupled to the chassis of a switch mode power supply.

20. ) The mounting frame of claim 18 wherein the mounting extension is comprised of two opposing side walls and a bottom wall with a recess passing therebetween wherein a plurality of second mounting holes are vertically oriented and pass through opposing ends of the bottom wall such that the base may be horizontally coupled to the chassis of a switch mode power supply.

21. ) A mounting frame of claim 18 wherein the mounting extension is comprised of two opposing side walls and a bottom wall with a recess passing therebetween wherein a plurality first mounting studs extend horizontally from the two opposing side walls such that the base may be coupled to the chassis of a switch mode power supply.

22. ) The mounting frame of claim 18 further comprising a plurality of clips integrally mounted within at least one of the four side walls of the base wherein the plurality of clips couple the printed circuit board to the base.

23. ) The mounting frame of claim 18 further comprising a plurality of first mounting holes extending through at least one of the four side walls of the base wherein the mounting holes couple the base to an element of a switch mode power supply.

24. ) The mounting frame of claim 23 wherein the plurality of first mounting holes are positioned on the base such that the base and printed circuit board are coupled to the switch mode power supply by one of the four side walls of the base.

25. ) The mounting frame of claim 23 wherein the plurality of first mounting holes are positioned on the base such that the base and printed circuit board are coupled to the switch mode power supply by all four side walls of the base.

26. ) The mounting frame of claim 18 further comprising a bottom wall molded to the four side walls of the base.

27. ) The mounting frame of claim 26 wherein the bottom wall is coated with an electrically conductive material

28. ) The mounting frame of claim 26 wherein the bottom wall is coupled to a metallic foil.

29. ) The mounting frame of claim 26 wherein the four side walls and the bottom wall form one half of the switch mode power supply.

30. ) The mounting frame of claim 18 wherein the AC input electrical connection and the DC output electrical connection on at least one of the four side walls of the base is comprised of a metallic clip.

31. ) The mounting frame of claim 30 wherein the similarly placed AC input connection and DC output connection on the printed circuit board are both comprised of contact pads adapted to slidingly engaged with the metallic clips of the AC input electrical connection and the DC output electrical connection on at least one of the four side walls of the base.

32. ) The mounting frame of claim 30 wherein the similarly placed AC input connection and DC output connection on the printed circuit board are both comprised of pin header type electrical connections adapted to slidingly engaged with the metallic clips of the AC input electrical connection and the DC output electrical connection on at least one of the four side walls of the base

33. ) The mounting frame of claim 18 wherein the base is mountable to one or more rails by way of one or more brackets.

34. ) The mounting frame of claim 18 wherein one side of the four walls of the base recessed so as to from a slot that is receivable by one or more rails.

35. ) A mounting frame for mounting a printed circuit board within a switch mode power supply comprising:

a base having four side walls and a bottom wall forming an interior chamber sized to receive a printed circuit board;

a plurality of mounting studs molded within the interior chamber such that the mounting studs support the printed circuit board within the base;

an AC input electrical connection coupled to one of the four side walls of the base wherein the AC input electrical connection is in electrical communication with an AC input connection on the printed circuit board;

a DC output electrical connection coupled to one of the four side walls of the base wherein the DC output connection is in electrical connection with a DC output connection on the printed circuit board; and

a cover comprising four side walls and a ceiling wherein the cover is received by the base such that the base and cover enclose the printed circuit board therein.

36. ) A mounting frame for mounting a printed circuit board within a switch mode power supply comprising:

a base having four side walls and a bottom wall forming an interior chamber sized to receive a printed circuit board;

a plurality of mounting studs molded within the interior chamber such that the mounting studs support the printed circuit board within the base;

an AC input electrical connection coupled to one of the four side walls of the base wherein the AC input electrical connection is in electrical communication with an AC input connection on the printed circuit board;

a DC output electrical connection coupled to one of the four side walls of the base wherein the DC output connection is in electrical connection with a DC output connection on the printed circuit board;

a tray comprised of four side walls and a floor wherein the tray is sized to receive the base; and

a cover comprising four side walls and a ceiling wherein the cover is received by the tray such that the tray and cover enclose the base and printed circuit board therein.