Power supply with separated airflows

• US 5,831,847 A
• Filed: 02/05/1997
• Issued: 11/03/1998
• Est. Priority Date: 02/05/1997
• Status: Expired due to Term

• Current Assignee: Jerome Industries Corp.
• Original Assignee: Jerome Industries Corp.
• Inventors: Love, David Ross
• Primary Examiner(s): Hecker, Stuart N.
• Application Number:
  US08/804,463
• Time in Patent Office: 636 Days
• Field of Search: 363/141, 361/687, 361/695, 361/697
• US Class Current: 363/141
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: H05K 5/0214 with means preventing penetration of rain water or dust semi-permeable membranes H05K5/0215, H05K5/0216
• CPC Class Codes: H05K 7/20909 Forced ventilation, e.g. on heat dissipaters coupled to components
• CPC Class Codes: H05K 7/20945 Thermal management, e.g. inverter temperature control

Abstract

A power supply adapted to be driven by a primary power source to produce an output voltage. The supply has a case with a bottom wall, an air inlet, an air outlet, and an enclosed chamber bordered by the bottom wall, the air inlet and the air outlet. The bottom is adapted to rest on a horizontal surface to define an upward direction within the case. The air inlet is operable to deliver air into the case along an incoming passageway having components directed inwardly and upwardly to prevent liquid that falls atop the case from intruding into the case. A power converter mounted in the case is adapted to be connected to the primary power source for producing the output voltage. The power supply also has a fan mounted in the case between the air inlet and the air outlet for providing a separated pair of airflows downstream and upstream of the fan. The pair of airflows pass across different portions of the power converter. The power supply also has a principal bulwark mounted in the case for (a) dividing the chamber, (b) supporting the fan, and (c) impeding bypassing of the fan.

Claims

1. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having an air inlet and an air outlet;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage;

a fan mounted in said case between said air inlet and said air outlet for providing a separated pair of airflows downstream and upstream of said fan, said pair of airflows passing across different portions of said converter means; and

a controller operatively coupled to said fan and said converter means for powering said fan in response to output from said converter means exceeding a predetermined amount.

2. A power supply according to claim 1 wherein said fan is remote from said air inlet and remote from said air outlet.

3. A power supply according to claim 1 wherein said converter means comprises:

a main power transformer;

a primary circuit for driving said transformer; and

a secondary circuit coupled to and driven by said transformer, a portion of said primary circuit being positioned to be cooled by one of said pair of airflows, the other one of said airflows being directed to cool a portion of said secondary circuit.

4. A power supply according to claim 3 wherein a portion of said primary circuit is positioned to be cooled by the upstream one of said pair of airflows.

5. A power supply according to claim 1 wherein said pair of airflows have unequal path lengths, the shorter one of said pair of airflows having a path length at least one quarter that of the longer one of said pair of airflows.

6. A power supply according to claim 1 wherein said controller is operable to power said fan in response to said output voltage being provided from said converter means at a current level exceeding a predetermined threshold.

7. A power supply according to claim 6 wherein said converter means has a serial output element, said controller being operable to power said fan in response to voltage across said serial output element exceeding an amount corresponding to current in excess of said predetermined threshold.

8. A power supply according to claim 1 wherein said controller comprises:

a control device coupled between said fan and said converter means for supplying power to said fan from said output voltage.

9. A power supply according to claim 1 wherein said controller comprises:

a auxiliary secondary winding coupled to said fan for supplying power to said fan from said primary power source without using power from the output voltage.

10. A power supply according to claim 9 wherein said auxiliary secondary winding conveys pulse width modulated power, said controller comprising:

a filter coupled to and driven by said auxiliary secondary winding for providing a control signal; and

a control device coupled to said filter and to said auxiliary secondary winding for providing power to said fan from said auxiliary secondary winding in response to said control signal.

11. A power supply according to claim 1 wherein said controller is operable to power said fan in response to output from said converter means with some hysteresis.

12. A power supply according to claim 1 wherein said case has a top and a bottom adapted to rest on a horizontal surface to define an upward direction within said case, said air inlet being operable to deliver air into said case along an incoming passageway having components directed inwardly and upwardly to prevent liquid that falls atop said case from intruding into said case.

13. A power supply according to claim 12 wherein said air inlet is directed at an acute angle to said top.

14. A power supply according to claim 12 wherein said air inlet is directed at an acute angle to the top in the range of 25°

to 50°

.

15. A power supply according to claim 12 wherein said air inlet is arranged to avoid intrusion of liquid spilled atop said case.

16. A power supply according to claim 12 wherein said air inlet is arranged to avoid intrusion of liquid dripped atop said case.

17. A power supply according to claim 12 wherein said air inlet provides at least one straight course of ingress.

18. A power supply according to claim 17 wherein said air inlet lacks a completely horizontal course of ingress.

19. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having an air inlet and an air outlet, said case having a top and a bottom adapted to rest on a horizontal surface to define an upward direction within said case, said air inlet being operable to deliver air into said case along an incoming passageway having components directed inwardly and upwardly to prevent liquid that falls atop said case from intruding into said case, said air outlet being operable to discharge air from said case along an outgoing passageway having components directed outwardly and downwardly to prevent liquid that falls atop said case from intruding into said case, said air inlet and air outlet each comprising a stacked plurality of slots;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage; and

a fan mounted in said case between said air inlet and said air outlet for providing a separated pair of airflows downstream and upstream of said fan, said pair of airflows passing across different portions of said converter means.

20. A power supply according to claim 19 wherein said air inlet and said air outlet are laterally positioned to provide an airflow across said converter means with transverse azimuths of ingress and egress.

21. A power supply according to claim 19 comprising:

a principal bulwark mounted in said case for supporting said fan and impeding bypassing of said fan.

22. A power supply according to claim 21 wherein said converter means comprises:

a main power transformer;

a primary circuit for driving said transformer; and

a secondary circuit coupled to and driven by said transformer, a portion of said primary circuit and a portion of said secondary circuit being on opposite sides of said principal bulwark.

23. A power supply according to claim 21 wherein said converter means comprises:

a component requiring conduction cooling mounted on said principal bulwark to conduct heat thereto, so that said principal bulwark acts as a heat sink.

24. A power supply according to claim 23 comprising:

a gasket peripherally mounted alongside said principal bulwark between said principal bulwark and said case.

25. A power supply according to claim 21 comprising:

an auxiliary bulwark mounted in said case, said principal bulwark and said auxiliary bulwark internally dividing said case into three air chambers.

26. A power supply according to claim 25 wherein said principal bulwark and said auxiliary bulwark are electrically isolated.

27. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having an air inlet and an air outlet;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage;

a fan mounted in said case between said air inlet and said air outlet for providing a separated pair of airflows downstream and upstream of said fan, said pair of airflows passing across different portions of said converter means;

a principal bulwark mounted in said case for supporting said fan and impeding bypassing of said fan, said converter means comprising;

a main power transformer;

a primary circuit for driving said transformer; and

a secondary circuit coupled to and driven by said transformer, a portion of said primary circuit and a portion of said secondary circuit being on opposite sides of said principal bulwark, airflow from said air inlet crosses most of said primary circuit before crossing most of said secondary circuit.

28. A power supply according to claim 27 wherein airflow from said air inlet crosses most of said primary circuit before crossing said transformer.

29. A power supply according to claim 28 wherein said secondary circuit comprises:

a component requiring conduction cooling mounted on said principal bulwark to conduct heat thereto, so that said principal bulwark acts as a heat sink.

30. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having an air inlet and an air outlet;

a fan mounted in said case between said air inlet and said air outlet for providing a separated pair of airflows downstream and upstream of said fan;

a principal bulwark mounted in said case for supporting said fan and impeding bypassing of said fan;

an auxiliary bulwark mounted in said case, said principal bulwark and said auxiliary bulwark internally dividing said case into three air chambers, said principal bulwark and said auxiliary bulwark being electrically isolated; and

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage, said pair of airflows passing across different portions of said converter means, said converter means comprising;

a main power transformer;

a primary circuit having a primary component for driving said transformer; and

a secondary circuit having a secondary component coupled to and driven by said transformer, said primary component and said secondary component being mounted on separate ones of said auxiliary bulwark and said principal bulwark for dissipating heat.

31. A power supply according to claim 30 wherein said transformer is mounted between said principal bulwark and said auxiliary bulwark.

32. A power supply according to claim 30 wherein said primary component comprises a power switch, said secondary component comprising a rectifier.

33. A power supply according to claim 30 wherein said primary component comprises a power switch mounted on said auxiliary bulwark, said secondary component comprising a rectifier mounted on said principal bulwark.

34. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having an air inlet, an air outlet, a top and a bottom adapted to rest on a horizontal surface to define an upward direction within said case, said air inlet being operable to deliver air into said case along an incoming passageway at an acute angle to horizontal having components directed inwardly and upwardly to prevent liquid that falls atop said case from intruding into said case, said air outlet being operable to discharge air from said case along an outgoing passageway having components directed outwardly and downwardly to prevent liquid that falls atop said case from intruding into said case, said air inlet and said air outlet each comprising a stacked plurality of slots;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage; and

a fan mounted in said case between said air inlet and said air outlet for providing a pair of airflows downstream and upstream of said fan.

35. A power supply according to claim 34 wherein said air inlet is directed at an acute angle to said top.

36. A power supply according to claim 34 wherein said air inlet is directed at an acute angle to the top in the range of 25°

to 50°

.

37. A power supply according to claim 34 wherein said air inlet provides at least one straight course of ingress.

38. A power supply according to claim 37 wherein said air inlet lacks a completely horizontal course of ingress.

39. A power supply according to claim 34 wherein said air inlet is arranged to avoid intrusion of liquid spilled atop said case.

40. A power supply according to claim 34 wherein said air inlet is arranged to avoid intrusion of liquid dripped atop said case.

41. A power supply according to claim 34 wherein said air inlet and said air outlet are laterally positioned to provide an airflow across said converter means with transverse azimuths of ingress and egress.

42. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having a lower wall, an air inlet, an air outlet, and an enclosed chamber bordered by said lower wall, said air inlet and said air outlet;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage;

a fan mounted in said case between said air inlet and said air outlet for providing a pair of airflows downstream and upstream of said fan; and

a principal bulwark mounted in said case for (a) dividing said chamber, (b) supporting said fan, and (c) impeding bypassing of said fan, said converter means comprising;

a main power transformer;

a primary circuit for driving said transformer; and

a secondary circuit coupled to and driven by said transformer, a portion of said primary circuit and a portion of said secondary circuit being on opposite sides of said principal bulwark, airflow from said air inlet crossing most of said primary circuit before crossing most of said secondary circuit.

43. A power supply according to claim 42 wherein said converter means comprises:

a component requiring conduction cooling mounted on said principal bulwark to conduct heat thereto, so that said principal bulwark acts as a heat sink.

44. A power supply according to claim 42 wherein airflow from said air inlet crosses most of said primary circuit before crossing said transformer.

45. A power supply according to claim 42 wherein said secondary circuit comprises:

a component requiring conduction cooling mounted on said principal bulwark to conduct heat thereto, so that said principal bulwark acts as a heat sink.

46. A power supply according to claim 42 comprising:

a gasket peripherally mounted alongside said principal bulwark between said principal bulwark and said case.

47. A power supply according to claim 42 comprising:

an auxiliary bulwark mounted in said case, said principal bulwark and said auxiliary bulwark internally dividing said case into three air chambers.

48. A power supply according to claim 47 wherein said principal bulwark and said auxiliary bulwark are electrically isolated.

49. A power supply according to claim 48 wherein said converter means comprises:

a main power transformer;

a primary circuit having a primary component for driving said transformer; and

a secondary circuit having a secondary component coupled to and driven by said transformer, said primary component and said secondary component being mounted on separate ones of said auxiliary bulwark and said principal bulwark for dissipating heat.

50. A power supply according to claim 49 wherein said primary component comprises a power switch, said secondary component comprising a rectifier.

51. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having a lower wall, an air inlet, an air outlet, and an enclosed chamber bordered by said lower wall, said air inlet and said air outlet;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage;

a fan mounted in said case between said air inlet and said air outlet for providing a pair of airflows downstream and upstream of said fan;

a principal bulwark mounted in said case for (a) dividing said chamber, (b) supporting said fan, and (c) impeding bypassing of said fan; and

an auxiliary bulwark mounted in said case, said principal bulwark and said auxiliary bulwark internally dividing said case into three air chambers, said principal bulwark and said auxiliary bulwark being electrically isolated, said converter means comprising;

a main power transformer mounted between said principal bulwark and said auxiliary bulwark;

a primary circuit having a primary component for driving said transformer; and

a secondary circuit having a secondary component coupled to and driven by said transformer, said primary component and said secondary component being mounted on separate ones of said auxiliary bulwark and said principal bulwark for dissipating heat.

52. A power supply adapted to be driven by a primary power source to produce an output voltage, comprising:

a case having a lower wall, an air inlet, an air outlet, and an enclosed chamber bordered by said lower wall, said air inlet and said air outlet;

converter means mounted in said case and adapted to be connected to said primary power source for producing said output voltage;

a fan mounted in said case between said air inlet and said air outlet for providing a pair of airflows downstream and upstream of said fan;

a principal bulwark mounted in said case for (a) dividing said chamber, (b) supporting said fan, and (c) impeding bypassing of said fan; and

an auxiliary bulwark mounted in said case, said principal bulwark and said auxiliary bulwark internally dividing said case into three air chambers, said principal bulwark and said auxiliary bulwark being electrically isolated, said converter means comprising;

a main power transformer;

a primary circuit having a primary component for driving said transformer; and

a secondary circuit having a secondary component coupled to and driven by said transformer, said primary component and said secondary component being mounted on separate ones of said auxiliary bulwark and said principal bulwark for dissipating heat, said primary component comprising a power switch mounted on said auxiliary bulwark, said secondary component comprising a rectifier mounted on said principal bulwark.