Small form factor power supply

• US 5,636,110 A
• Filed: 12/04/1995
• Issued: 06/03/1997
• Est. Priority Date: 04/26/1994
• Status: Expired due to Term

• Current Assignee: Comarco Wireless Systems LLC (AppBrilliance, Inc.)
• Original Assignee: Comarco Wireless Technologies Incorporated (Comarco Incorporated)
• Inventors: Lanni, Thomas W.
• Primary Examiner(s): Wong, Peter S.
• Assistant Examiner(s): BERHANE, ADOLF D
• Application Number:
  US08/567,369
• Time in Patent Office: 547 Days
• Field of Search: 363/17, 363/20, 363/24, 363/21, 363/25, 363/78, 363/79, 363/80, 363/97, 363/98, 363/132, 363/144, 363/147, 323/212
• US Class Current: 363/21.08
• CPC Class Codes: H01R 13/24 resilient; resiliently-mounted
• CPC Class Codes: H01R 13/6675 with built-in power supply
• CPC Class Codes: H01R 2201/16 for telephony
• CPC Class Codes: H01R 2201/24 for radio transmission
• CPC Class Codes: H02J 2207/20 Charging or discharging characterised by the power electronics converter
• CPC Class Codes: H02J 7/00041 in response to measured battery parameters, e.g. voltage, current or temperature profile
• CPC Class Codes: H02J 7/00047 with provisions for charging different types of batteries
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H02J 7/02 for charging batteries from ac mains by converters
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H02M 3/28 using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate ac
• CPC Class Codes: H02M 3/3378 in a push-pull configuration of the parallel type H02M3/3374 takes precedence
• CPC Class Codes: H05K 1/16 incorporating printed electric components, e.g. printed resistor, capacitor, inductor
• CPC Class Codes: H05K 1/165 incorporating printed inductors
• CPC Class Codes: H05K 2201/086 for inductive purposes, e.g. printed inductor with ferrite core
• CPC Class Codes: H05K 2201/09063 Holes or slots in insulating substrate not used for electrical connections

Abstract

A new, small form factor power supply is disclosed that provides a regulated DC power supply in a package that radiates relatively little heat and that occupies 2.85×5.0×0.436 inches. The secondary coil of the transformer is positioned at the summing node of the flux of the primary coils and the phase of the drive signals provided to the secondary coils is regulated to control the current and voltage provided by the secondary circuit. Preferably, all circuit components are surface mount devices and the transformer cores are E block planar cores mounted on the printed circuit board.

Claims

1. A small form factor power supply capable of providing between about zero and seventy five watts DC, the small form factor power supply comprising:

a low profile magnetic core for a transformer;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns including the wiring patterns for primary and secondary coils of the transformer that are magnetically coupled to the core;

a driver circuit coupled to the wiring pattern for the primary coil;

a rectifier circuit formed on the printed circuit board and coupled to the secondary coil to provide a DC power source capable of delivering between zero and seventy five watts of DC power; and

a case enclosing the printed circuit board, the core and the circuit components such that a thickness of the case is less than about 0.436 inches, a length is less than about 5.0 inches, and a width is less than about 2.85 inches, wherein the case reaches a maximum temperature of less than about one hundred forty degrees Fahrenheit when the rectifier circuit delivers seventy five watts DC power.

2. The small form factor power supply of claim. 1, wherein the product of the length and width of the case is less than approximately fourteen square inches.

3. The small form factor power supply of claim 1, further comprising:

a voltage and current sensing circuit coupled to the output of the rectifier; and

feedback means coupling the voltage and current sensing circuit to the driver circuit.

4. The small form factor power supply of claim 2, wherein the feedback means includes an amplitude modulation circuit to amplitude modulate a signal based upon the sensed voltage and current flow;

and

a feedback transformer coupled to the amplitude modulation circuit.

5. The small form factor power supply of claim 4, wherein the feedback means includes a bias power supply to power the driver circuit.

6. The small form factor power supply of claim 1, for use in a volume having an ambient temperature, wherein during operation the maximum temperature on the surface of the case is less than about fifty degrees centigrade when the ambient temperature is operating is about twenty-two degrees centigrade.

7. The small form factor power supply of claim 1, wherein the primary coils include first and second primary coils electromagnetically coupled to the core to induce magnetic flux in the core;

wherein the secondary coil electromagnetically is coupled to the core to generate an electromotive force based upon the magnetic flux in the core, wherein the secondary coil is positioned relative to the primary coils such that the flux generated by the primary coils destructively interfere;

wherein the driver circuit is coupled to each of the primary coils to provide separate driving signal to each primary coil and each driving signal having a phase, a phase relationship existing between the driving signals;

wherein the rectifier is coupled to the secondary coil to provide a regulated DC signal; and

wherein a feedback circuit is coupled between the output of the rectifier circuit and the driver circuit to alter the phase relationship between the driving signals to regulate the DC signal.

8. The small form factor power supply of claim 1, wherein the primary coil includes first and second primary coils electromagnetically that are coupled to the core to induce magnetic flux in the core;

and

wherein the secondary coil electromagnetically is coupled to the core to generate an electromotive force based upon the magnetic flux in the core, and wherein the secondary coil is positioned relative to the primary coils such that the flux generated by the primary coils constructively interfere;

wherein the driver circuit is coupled to each of the primary coils to provide separate driving signal to each primary coil and each driving signal having a phase, a phase relationship existing between the driving signals;

wherein the rectifier circuit is coupled to the secondary coil to provide a regulated DC signal; and

wherein a feedback circuit is coupled between the output of the rectifier circuit and the driver circuit to alter the phase relationship between the driving signals to regulate the DC signal.

9. The small form factor power supply of claim 8, wherein the feedback circuit includes:

a current sensing circuit coupled to the secondary coil to sense current flow through the secondary coil;

a voltage sensing circuit coupled to the regulated DC signal;

an amplitude modulation circuit to amplitude modulate a signal based upon the sensed voltage and current flow; and

a feedback transformer coupled to the amplitude modulation circuit.

10. The small form factor power supply of claim 8, wherein the magnetic core is an E block type and each primary coil is mounted on an outer leg of the core and the secondary coil is mounted on an inner leg.

11. The small form factor power supply of claim 1, further including at least one heat sink coupled to the various circuit components and the case to maintain the maximum temperature of the case at less than about one hundred forty degrees Fahrenheit.

12. The small form factor power supply of claim 1, wherein the case includes flat top and bottom surfaces.

13. The small form factor power supply of claim 1, wherein at least one surface of the case includes louvers to improve heat dissipation from the various components enclosed in the case.

27. The small factor power supply of claim 1, further including at least one heat sink thermally coupled to at least one of the various circuit components and the case, and wherein at least one surface of the case includes louvers defining openings to improve heat dissipation from the various components and the at least one heat sink enclosed in the case.

28. The small form factor power supply of claim 27, wherein the at least one heat sink is positioned in the case adjacent to the louvers of the at least one surface of the case.

29. The small form factor power supply of claim 27, wherein the at least one heat sink covers the openings defined by the louvers on the at least one surface of the case to resist penetration of liquids into the case.

44. The small form factor power supply of claim 1, wherein the small form factor power supply is programmable to provide different power and current characteristics to match particular devices utilizing power from the small form factor power supply.

45. The small form factor power supply of claim 44, wherein the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

46. The small form factor power supply of claim 44, wherein the small form factor power supply includes an output for connecting to various cables to deliver power to the different devices, wherein the cables are formed to effect the output of the small form factor power supply.

14. A small form factor power supply capable of providing between about zero and seventy five watts DC, the small form factor power supply comprising:

a low profile magnetic core for a transformer;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns including the wiring patterns for primary and secondary coils of the transformer that are magnetically coupled to the core;

a driver circuit coupled to the wiring pattern for the primary coil;

a rectifier circuit formed on the printed circuit board and coupled to the secondary coil to provide a DC power source capable of delivering between zero and seventy five watts of DC power; and

a case enclosing the printed circuit board, the core and the circuit components, wherein the case has a thickness, a length, and a width such that the product of the length and width of the case is less than about fourteen square inches, and wherein the case reaches a maximum temperature of less than about one hundred forty degrees Fahrenheit when the rectifier circuit delivers seventy five watts DC power.

15. The small form factor power supply of claim 14, further comprising:

a voltage and current sensing circuit coupled to the output of the rectifier; and

feedback means coupling the voltage and current sensing circuit to the driver circuit.

16. The small form factor power supply of claim 15, wherein the feedhack means includes an amplitude modulation circuit to amplitude modulate a signal based upon the sensed voltage and current flow;

and

a feedback transformer coupled to the amplitude modulation circuit.

17. The small form factor power supply of claim 16, wherein the feedback means includes a bias power supply to power the driver circuit.

18. The small form factor power supply of claim 14, for use in a volume having an ambient temperature, wherein during operation the maximum temperature on the surface of the case is less than about fifty degrees centigrade when the ambient temperature is operating is about twenty-two degrees centigrade.

19. The small form factor power supply of claim 14, wherein the primary coils include first and second primary coils electromagnetically coupled to the core to induce magnetic flux in the core;

wherein the secondary coil electromagnetically is coupled to the core to generate an electromotive force based upon the magnetic flux in the core, wherein the secondary coil is positioned relative to the primary coils such that the flux generated by the primary coils destructively interfere;

wherein the driver circuit is coupled to each of the primary coils to provide;

separate driving signal to each primary coil and each driving signal having a phase, a phase relationship existing between the driving signals;

wherein the rectifier is coupled to the secondary coil to provide a regulated DC signal; and

wherein a feedback circuit is coupled between the output of the rectifier circuit and the driver circuit to alter the phase relationship between the driving signals to regulate the DC signal.

20. The small form factor power supply of claim 14, wherein the primary coil includes first and second primary coils electromagnetically that are coupled to the core to induce magnetic flux in the core;

and

wherein the secondary coil electromagnetically is coupled to the core to generate an electromotive force based upon the magnetic flux in the core, and wherein the secondary coil is positioned relative to the primary coils such that the flux generated by the primary coils constructively interfere;

wherein the driver circuit is coupled to each of the primary coils to provide a separate driving signal to each primary coil and each driving signal having a phase, a phase relationship existing between the driving signals;

wherein the rectifier circuit is coupled to the secondary coil to provide a regulated DC signal; and

wherein a feedback circuit is coupled between the output of the rectifier circuit and the driver circuit to alter the phase relationship between the driving signals to regulate the DC signal.

21. The small form factor power supply of claim 20, wherein the feedback circuit includes:

a current sensing circuit coupled to the secondary coil to sense current flow through the secondary coil;

a voltage sensing circuit coupled to the regulated DC signal;

an amplitude modulation circuit to amplitude modulate a signal based upon the sensed voltage and current flow; and

a feedback transformer coupled to the amplitude modulation circuit.

22. The small form factor power supply of claim 21, wherein the magnetic core is an E block type and each primary coil is mounted on an outer leg of the core and the secondary coil is mounted on an inner leg.

23. The small form factor power supply of claim 14, wherein the thickness of the case is less than about 0.436 inches, the length is less than about 5.0 inches, and the width is less than about 2.85 inches.

24. The small form factor power supply of claim 14, further including at least one heat sink coupled to the various circuit components and the case to maintain the maximum temperature of the case at less than about one hundred forty degrees Fahrenheit.

25. The small form factor power supply of claim 14, wherein the case includes flat top and bottom surfaces.

26. The small form factor power supply of claim 14, wherein at least one surface of the case includes louvers to improve heat dissipation from the various components enclosed in the case.

30. The small factor power supply of claim 14, further including at least one heat sink thermally coupled to at least one of the various circuit components and the case, and wherein at least one surface of the case includes louvers defining openings to improve heat dissipation from the various components and the at least one heat sink enclosed in the case.

31. The small form factor power supply of claim 30, wherein the at least one heat sink is positioned in the case adjacent to the louvers of the at least one surface of the case.

32. The small form factor power supply of claim 30, wherein the at least one heat sink covers the openings defined by the louvers on the at least one surface of the case to resist penetration of liquids into the case.

47. The small form factor power supply of claim 14, wherein the small form factor power supply is programmable to provide different power and current characteristics to match particular devices utilizing power from the small form factor power supply.

48. The small form factor power supply of claim 47, wherein the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

49. The small form factor power supply of claim 47, wherein the small form factor power supply includes an output for connecting to various cables to deliver power to the different devices, wherein the cables are formed to effect the output of the small form factor power supply.

33. A small form factor power supply capable of providing between about zero and seventy five watts DC, the small form factor power supply comprising:

a low profile magnetic core for a transformer;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns including the wiring patterns for primary and secondary coils of the transformer that are magnetically coupled to the core;

a driver circuit coupled to the wiring pattern for the primary coil;

a rectifier circuit formed on the printed circuit board and coupled to the secondary coil to provide a DC power source capable of delivering between zero and seventy five watts of DC power;

at least one heat sink coupled to the various circuit components; and

a case including at least one surface and enclosing the printed circuit board, the core and the circuit components and at least one heat sink, wherein at least one surface of the case includes louvers defining openings to improve heat dissipation from the various components and the at least one heat sink enclosed in the case, and wherein the case reaches a maximum temperature of less than about one hundred forty degrees Fahrenheit when the rectifier circuit delivers seventy five watts DC power.

34. The small form factor power supply of claim 33, wherein the product of a length and a width of the case is less than approximately fourteen square inches.

35. The small form factor power supply of claim 33, further comprising:

a voltage and current sensing circuit coupled to the output of the rectifier; and

feedback means coupling the voltage and current sensing circuit to the driver circuit.

36. The small form factor power supply of claim 35, wherein the feedback means includes an amplitude modulation circuit to amplitude modulate a signal based upon the sensed voltage and current flow;

and

a feedback transformer coupled to the amplitude modulation circuit.

37. The small form factor power supply of claim 36, wherein the feedback means includes a bias power supply to power the driver circuit.

38. The small form factor power supply of claim 33, for use in a volume having an ambient temperature, wherein during operation the maximum temperature on the surface of the case is less than about fifty degrees centigrade when the ambient temperature is operating is about twenty-two degrees centigrade.

39. The small form factor power supply of claim 33, wherein the primary coils include first and second primary coils electromagnetically coupled to the core to induce magnetic flux in the core;

wherein the secondary coil electromagnetically is coupled to the core to generate an electromotive force based upon the magnetic flux in the core, wherein the secondary coil is positioned relative to the primary coils such that the flux generated by the primary coils destructively interfere;

wherein the driver circuit is coupled to each of the primary coils to provide a separate driving signal to each primary coil and each driving signal having a phase, a phase relationship existing between the driving signals;

wherein the rectifier is coupled to the secondary coil to provide a regulated DC signal; and

wherein a feedback circuit is coupled between the output of the rectifier circuit and the driver circuit to alter the phase relationship between the driving signals to regulate the DC signal.

40. The small form factor power supply of claim 33, wherein the case includes flat top and bottom surfaces.

41. The small form factor power supply of claim 33, wherein the at least one heat sink is positioned in the case adjacent to the louvers of the at least one surface of the case.

42. The small form factor power supply of claim 33, wherein the at least one heat sink covers the openings defined by the louvers on the at least one surface of the case to resist penetration of liquids into the case.

50. The small form factor power supply of claim 33, wherein the small form factor power supply is programmable to provide different power and current characteristics to match particular devices utilizing power from the small form factor power supply.

51. The small form factor power supply of claim 50, wherein the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

52. The small form factor power supply of claim 50, wherein the small form factor power supply includes an output for connecting to various cables to deliver power to the different devices, wherein the cables are formed to effect the output of the small form factor power supply.

43. A small form factor power supply capable of providing between about zero and seventy five watts DC, the small form factor power supply comprising:

a low profile magnetic core for a transformer;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns including the wiring patterns for primary and secondary coils of the transformer that are magnetically coupled to the core;

a driver circuit coupled to the wiring pattern for the primary coil;

a rectifier circuit formed on the printed circuit board and coupled to the secondary coil to provide a DC power source capable of delivering between zero and seventy five watts of DC power;

at least one heat sink coupled to the various circuit components; and

a case including at least one surface and enclosing the printed circuit board, the core and the circuit components and at least one heat sink, wherein at least one surface of the case includes louvers defining openings to improve heat dissipation from the various components and the at least one heat sink enclosed in the case, and wherein the at least one heat sink covers the openings defined by the louvers on the at least one surface of the case to resist penetration of liquids into the case.

53. The small form factor power supply of claim 43, wherein the small form factor power supply is programmable to provide different power and current characteristics to match particular devices utilizing power from the small form factor power supply.

54. The small form factor power supply of claim 53, wherein the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

55. The small form factor power supply of claim 53, wherein the small form factor power supply includes an output for connecting to various cables to deliver power to the different devices, wherein the cables are formed to effect the output of the small form factor power supply.