Small form factor power supply

• US 5,838,554 A
• Filed: 12/19/1997
• Issued: 11/17/1998
• 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): BERHANE, ADOLF D
• Application Number:
  US08/994,905
• Time in Patent Office: 333 Days
• Field of Search: 363/17, 363/20, 363/21, 363/24, 363/25, 363/78, 363/79, 363/80, 363/97, 363/98, 363/132, 363/141, 363/144, 323/212
• US Class Current: 363/141
• 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 1/4258 using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage H02M1/4241 takes precedence
• CPC Class Codes: H02M 3/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• 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
• CPC Class Codes: Y02B 40/00 Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers
• CPC Class Codes: Y02B 70/10 Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes

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 transformer having a core and primary and secondary coils;

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

a rectifier circuit that is coupled to 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;

a regulator coupled to coupled to one of either the primary coil and the secondary coil to regulate an output of the transformer; and

a case having louvers and depressions enclosing the printed circuit board, the core and the circuit components such that the louvers prevent a user from contacting the depressions receiving heat from the printed circuit board, the core and the circuit components, 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 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.

3. 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.

4. The small form factor power supply of claim 1, wherein the case and louvers are formed from a plastic material.

5. The small form factor power supply of claim 1, further including at least one heat sink in thermal contact with the depressions, wherein the at least one heat sink is positioned between the louvers, the depressions and the components to prevent leaks.

6. The small form factor power supply of claim 5, wherein the louvers are raised ridges that form an air gap between the raised ridges and the at least one heat sink.

7. The small form factor power supply of claim 1, where the louvers are spaced close together to prevent contact with a bottom of the depressions while still maintaining sufficient spacing to permit convective cooling of the components contained in the case.

8. The small form factor power supply of claim 1, wherein the regulator of 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.

9. The small form factor power supply of claim 8, wherein the small form factor power supply includes an output coupled to the regulator that is adapted 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.

10. The small form factor power supply of claim 1, wherein the small form factor power supply includes a thin film coupled to the louvers to substantially prevent entry of liquids into the case.

11. 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 transformer having a core and primary and secondary coils;

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

a rectifier circuit that is coupled to 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;

a regulator coupled to coupled to one of either the primary coil and the secondary coil to regulate an output of the transformer; and

a case enclosing the printed circuit board, the core and the circuit components such that 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, wherein the regulator of 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.

12. The small form factor power supply of claim 11, wherein the regulator of the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

13. The small form factor power supply of claim 11, wherein the small form factor power supply includes an output coupled to the regulator and adapted 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. The small form factor power supply of claim 13, wherein the cables are adapted to couple to different types of electronic devices selected from a group consisting of computers, peripheral computer devices, audio and video electronics and portable telephone equipment.

15. The small form factor power supply of claim 14, wherein the cables include a clip on adapter to charge and power the portable telephone equipment.

16. The small form factor power supply of claim 11, further including an interface that couples to the regulator to provide one or more power outputs to support one or more devices.

17. The small form factor power supply of claim 11, wherein 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.

18. The small form factor power supply of claim 11, wherein the product of the length and width of the case is less than approximately fourteen square inches.

19. A small form factor power supply capable of providing between about zero and seventy five watts DC to charge and power a portable telephone device, the small form factor power supply comprising:

a transformer having a core and primary and secondary coils;

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

a rectifier circuit that is coupled to 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;

a regulator coupled to coupled to one of either the primary coil and the secondary coil to regulate an output of the transformer; and

a case enclosing the printed circuit board, the core and the circuit components such that 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, wherein the regulator of the small form factor power supply is adapted to provide charging and power to the portable telephone.

20. The small form factor power supply of claim 19, wherein the regulator of the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

21. The small form factor power supply of claim 19, wherein the regulator of the small form factor power supply is programmable to provide different power and current characteristics to match different potable telephones, and wherein the small form factor power supply includes an output coupled to the regulator and adapted 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.

22. The small form factor power supply of claim 21, further including an interface that couples to the regulator to provide one or more power outputs to support one or more portable telephones.

23. The small form factor power supply of claim 21, wherein the cables include a clip on adapter to charge and power the portable telephone equipment.

24. The small form factor power supply of claim 19, wherein 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.

25. The small form factor power supply of claim 19, wherein the product of the length and width of the case is less than approximately fourteen square inches.

26. A small form factor power supply capable of providing power in a range between about zero to seventy five watts DC, the small form factor power supply comprising:

a transformer having a core and primary and secondary coils;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board is coupled to the primary and secondary coils of the transformer that are magnetically coupled to the core;

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

a regulator coupled to coupled to one of either the primary coil and the secondary coil to regulate an output of the transformer; and

a case enclosing the printed circuit board, the core and the circuit components such that the case reaches a maximum temperature of less than about one hundred forty degrees Fahrenheit when the rectifier circuit delivers power, wherein the regulator of 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.

27. The small form factor power supply of claim 26, wherein the regulator of the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

28. The small form factor power supply of claim 26, wherein the small form factor power supply includes an output coupled to the regulator and adapted 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.

29. The small form factor power supply of claim 26, wherein the cables are adapted to couple to different types of electronic devices selected from a group consisting of computers, peripheral computer devices, audio and video electronics and portable telephone equipment.

30. The small form factor power supply of claim 29, wherein the cables include a clip on adapter to charge and power the portable telephone equipment.

31. The small form factor power supply of claim 26, further including an interface that couples to the regulator to provide one or more power outputs to support one or more devices.

32. A small form factor power supply capable of providing power in a range between about zero and seventy five watts DC to charge and power a portable telephone device, the small form factor power supply comprising:

a transformer having a core and primary and secondary coils;

a printed circuit board adapted to have various circuit components mounted thereon, wherein the printed circuit board is coupled to the primary and secondary coils of the transformer that are magnetically coupled to the core;

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

a regulator coupled to coupled to one of either the primary coil and the secondary coil to regulate an output of the transformer; and

a case enclosing the printed circuit board, the core and the circuit components such that the case reaches a maximum temperature of less than about one hundred forty degrees Fahrenheit when the rectifier circuit delivers power, wherein the regulator of the small form factor power supply is adapted to provide charging and power to the portable telephone.

33. The small form factor power supply of claim 32, wherein the regulator of the small form factor power supply is programmable by utilizing additional resistors coupled to ground.

34. The small form factor power supply of claim 32, wherein the regulator of the small form factor power supply is programmable to provide different power and current characteristics to match different potable telephones, and wherein the small form factor power supply includes an output coupled to the regulator and adapted 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.

35. The small form factor power supply of claim 34, further including an interface that couples to the regulator to provide one or more power outputs to support one or more portable telephones.

36. The small form factor power supply of claim 37, wherein the cables include a clip on adapter to charge and power the portable telephone equipment.