Modular power supply

• US 6,046,921 A
• Filed: 05/30/1997
• Issued: 04/04/2000
• Est. Priority Date: 08/27/1996
• Status: Expired due to Fees

• Current Assignee: Larry L. Tracewell, Matthew S. Tracewell
• Original Assignee: Larry L. Tracewell, Matthew S. Tracewell
• Inventors: Tracewell, Matthew S., Tracewell, Larry L.
• Primary Examiner(s): BERHANE, ADOLF D
• Application Number:
  US08/866,434
• Time in Patent Office: 1,040 Days
• Field of Search: 363/141, 363/144, 363/146, 363/147, 361/687, 361/688, 361/694, 361/695, 361/696, 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 7/20918 the components being isolated from air flow, e.g. hollow heat sinks, wind tunnels or funnels

Abstract

Modular power supply apparatus wherein a plurality of d.c.-to-d.c. converters are coupled to an internally structured heat exchange channel through which fan driven air is passed in an unobstructed manner along a flow axis. Each of the converter modules is combined with a dedicated module circuit board which provides regulated output terminals in an orientation or direction arranged transversely to the flow axis. The opposite end of the module circuit boards are plugged into a main interconnect circuit board positioned along one side of the heat exchange channel. A support channel is provided outwardly of the main interconnect circuit board within which principal components of supporting circuitry are contained.

Claims

1. Power supply apparatus connectable with an external power input for deriving a regulated D.C. source, comprising:

a heat exchange channel extending along a flow axis between first and second openings and having at least one outwardly disposed heat transfer surface defining assembly;

at least one power converter module having a heat sink surface, an input connector assembly and regulated output connectors extending outwardly in a given direction therefrom, said heat sink surface being coupled in thermal exchange relationship with a said channel heat transfer surface and arranged thereon to position said regulated output connectors in an orientation wherein said given direction is transverse to said flow axis; and

a fan assembly mounted in air flow establishing relationship with said heat exchange channel first opening and directing air flow along said axis from said first opening through said second opening.

2. The power supply apparatus of claim 1 in which said heat exchange channel is formed having two substantially parallel oppositely disposed said heat transfer surfaces.

3. The power supply apparatus of claim 1 in which said heat exchange channel includes a multiple channel heat exchanger assembly, each said channel of which is aligned in parallel with said flow axis.

4. The power supply apparatus of claim 1 in which:

said heat exchange channel is formed having two substantially parallel oppositely disposed spaced apart said heat transfer surfaces extending between first and second channel side regions; and

including an interconnect circuit mounted upon an interconnect circuit board extending along said first side region in substantially parallel relationship with said flow axis, said interconnect circuit board being removably connectable with said power converter module input connector assembly.

5. The power supply apparatus of claim 4 including:

a support circuit connectable with said external power input and deriving a conditioned input therefrom; and

said interconnect circuit is coupled intermediate said support circuit and said power converter module input connector assembly for applying said conditioned input thereto.

6. The power supply apparatus of claim 5 in which:

said heat exchange channel, said power converter module, said interconnect circuit, said support circuit, and said fan assembly are mounted within a housing;

said input treatment circuit being mounted adjacent said interconnect circuit board outwardly from said heat exchange channel first side region.

7. The power supply apparatus of claim 5 including:

a housing assembly positioned about said heat exchange channel and spaced outwardly from said first side region to define a support channel aligned substantially in parallel relationshp with said flow axis; and

said interconnect circuit and at least a portion of said support circuit are mounted within said support channel.

8. The power supply apparatus of claim 7 in which said fan assembly comprises two axial flow fans each directing air flow toward said heat exchange channel first opening and one thereof additionally directing air into said support channel.

9. The power supply apparatus of claim 5 in which said fan assembly is a cross-flow fan having an output positioned at said heat exchange channel first opening and extending substantially between said first and second side regions.

10. The power supply apparatus of claim 5 in which:

said power converter module includes a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regulated output connectors, including a monitor function output connector mounted upon said module circuit board adjacent said regulated output connectors and electrically coupled with monitor function terminals located upon said power converter, said monitor function output connector and said regulated output connectors being located for external user access adjacent said second channel side region when said module input connector assembly is connected with said interconnect circuit board.

11. Power supply apparatus connectable with an A.C. source for deriving a regulated D.C. output, comprising:

a heat exchange channel extending along a flow axis between first and second openings and having oppositely disposed spaced apart first and second heat sinks with respective flat, first and second outwardly disposed heat transfer surfaces and first and second side regions extending along in parallel adjacency with said flow axis;

first and second power converter modules having respective first and second heat sink surfaces, respective first and second input connector assemblies and respective first and second regulated output connectors extending outtwardly in a given direction, said first and second heat sink surfaces being coupled in intimate thermal exchange relationship with said first heat transfer surface and arranged thereon to position said first and second regulated output connectors adjacent said second side region in an orientation wherein said given direction is transverse to said flow axis;

third and fourth power converter modules having respective third and fourth heat sink surfaces, respective third and fourth input connector assemblies and respective third and fourth regulated output connectors extending outwardly in a given direction, said third and fourth heat sink surfaces being coupled in intimate thermal exchange relationship with said second heat transfer surface and arranged thereon to position said third and fourth regulated output connectors in an orientation wherein said given direction is transverse to said flow axis;

a fan assembly mounted in air flow establishing relationship with said heat exchange channel first opening and directing air flow along said axis from said first opening through said second opening;

a support circuit connectable with said A.C. source and deriving a conditioned D.C. input therefrom; and

an interconnect circuit electrically coupled with said support circuit and each said first, second, third, and fourth input connector assemblies for conveying said conditioned D.C. input thereto.

12. The power supply apparatus of claim 11 in which:

each said first, second, third, and fourth power connector assemblies include a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regulated output connectors, including an inter-module parallel coupling circuit extending to said input connector assembly and having a module share circuit connected with a current share terminal of said switching power converter;

said interconnect circuit includes an interconnect share circuit coupled with each said inter-module parallel coupling circuit at said input connector assemblies; and

selector means for interconnecting the said inter-module parallel coupling circuits of said first, second, third, and fourth power converter modules to derive a select circuit configuration.

13. The power supply apparatus of claim 12 in which:

each said inter-module parallel coupling circuit further includes an adjacency connecting circuit coupled with said input connector assembly, and a vertical connecting circuit coupled with said input connector assembly; and

said interconnect circuit share circuit is electrically connectable with said adjacency circuits of said first and third power converter modules through respective said first and third input connectors, and is electrically connectable with said vertical connecting circuits of said first and second power converter modules through respective said first and second input connectors.

14. The power supply apparatus of claim 13 in which said selector means comprises:

a first share connector mounted upon each said module circuit board and electrically coupled with said module share circuit;

a second share connector mounted upon each said module circuit board in adjacency with said first connector and electrically connected with said adjacency connecting circuit;

a third share connector mounted upon each said module circuit board in adjacency with said first share connector and electrically connected with said vertical connecting circuit; and

connection means for selectively electrically connecting said first share connector with said second share connector and for selectively electrically connecting said first share connector with said third share connector.

15. The power supply apparatus of claim 14 in which said first, second and third share connectors are electrically conducting pads located in closely spaced adjacency upon said module circuit board.

16. The power supply apparatus of claim 11 in which:

said first heat sink includes a first multi-channel form heat exchanger assembly coupled in heat exchange relationship with said first heat transfer surface, each said channel of which is aligned in parallel with said flow axis; and

said second heat sink includes a second multi-channel form heat exchanger assembly coupled in heat exchange relationship with said second heat transfer surface, each said channel of which is aligned in parallel with said flow axis.

17. The power supply apparatus of claim 15 in which said first and second multi-channel heat exchanger assemblies are configured as metal sheets with an undulating cross-sectional pattern defining said multi-channel form.

18. The power supply apparatus of claim 17 in which said first and second multi-channel heat exchanger assemblies are mutually internested.

19. The power supply apparatus of claim 11 in which each said first and second power converter module includes a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regulated output connectors, including a monitor function output connector mounted upon said module circuit board adjacent said regulated output connector and electrically coupled with a monitor function terminal located upon said power converter, said monitor function output connector and said regulated output connectors being located for external user access adjacent said second channel side region.

20. The power supply apparatus of claim 11 in which each said first and second power converter module includes a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and two said regulated output connectors, each said regulated output connector comprising a pin insertion connector mounted upon said module circuit board at a location for power supply coupling with a load-defining circuit board.

21. The power supply apparatus of claim 11 in which:

said interconnect circuit is supported by an interconnect circuit board extending along said heat exchange channel first side region, said interconnect circuit board supporting first, second, third, and fourth interconnect plug-in connectors for receiving respective said first, second, third and fourth input connector assemblies in electrical communication with said interconnect circuit;

each said first, second, third and fourth power converter module includes a respective first, second, third and fourth module circuit board and a respective first, second, third and fourth D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regualted output connectors, said input connector assembly comprising respectively first, second, third and fourth module plug-in connectors removably insertable into electrical communication with respective said first, second, third and fourth interconnect plug-in connectors.

22. The power supply apparatus of claim 21 including:

a housing assembly positioned about said heat exchange channel and spaced outwardly from said first side region to define a support channel aligned substantially in parallel relationship with said flow axis; and

at least a portion of said interconnect circuit and said support circuit are mounted within said support channel.

23. The power supply apparatus of claim 22 in which said fan assembly comprises two axial flow fans each directing air flow toward said heat exchange channel first opening and one thereof additionally directing air into said support channel.

24. The power supply apparatus of claim 22 in which said fan assembly is a cross-flow fan having an output positioned at said heat exchange channel first opening and extending substantially between said first and second side regions.

25. Power supply apparatus connectable with an A.C. source for deriving a regulated D.C. output, comprising:

a heat exchange channel extending along a flow axis between first and second openings and having oppositedly disposed first and second heat sinks with respective flat first and second outwardly disposed heat transfer surfaces and first and second side regions extending along in parallel adjacency with said flow axis;

first and second power converter modules having respective first and second heat sink surfaces, respective first and second input connector assemblies and respective first and second regulated output connectors extending outwardly in a given direction, said first and second heat sink surfaces being coupled in intimate thermal exchange relationship with said first heat transfer surface and arranged thereon to position said first and second regulated output connectors adjacent said second side region in an orienation wherein said given direction is transverse to said flow axis;

third and fourth power converter modules having respective third and fourth heat sink surfaces, respective third and fourth input connector assemblies and respective third and fourth regulated output connectors extending outwardly in a given direction, said third and fourth heat sink surfaces being coupled in intimate thermal exchange relationship with said second heat transfer surface and arranged thereon to position said third and fourth regulated output connectors in an orientation wherein said given direction is transverse to said flow axis;

a fan assembly mounted in air flow establishing relationship with said heat exchange channel first opening and directing air flow along said axis from said first opening through said second opening;

a housing assembly including a U-shaped support housing extending in parallel adjacency with said flow axis and extending outwardly from said second side region to define a support channel,

a cover assembly extending about said heat exchange channel, said first, second, third and fourth power converter modules, and at least a portion of said fan assembly, having openings at said second side region for accessing said first, second, third and fourth regulated output connectors and being connected with said support housing at said first side region,

an air inlet end assembly coupled with said cover assembly and said support housing outwardly from said fan assembly, and

an air outlet assembly coupled with said cover assembly and said support housing adjacent said second opening;

an interconnect circuit board extending along said first side region;

a support circuit connectable with said A.C. source and deriving a conditioned D.C. input therefrom; and

an interconnect circuit supported by said interconnect circuit board, electrically coupled with said support circuit and each said first, second, third, and fourth input connector assemblies for conveying said conditioned D.C. input thereto.

26. The power supply apparatus of claim 25 in which:

said first heat sink includes a first multi-channel form heat exchanger assembly coupled in heat exchange relationship with said first heat transfer surface, each said channel of which is aligned in parallel with said flow axis; and

said second heat sink includes a second multi-channel form heat exchanger assembly coupled in heat exchange relationship with said second heat transfer surface, each said channel of which is aligned in parallel with said flow axis.

27. The power supply apparatus of claim 26 in which said first and second multi-channel heat exchanger assemblies are configured as metal sheets with an undulating cross-sectional pattern defining said multi-channel form.

28. The power supply apparatus of claim 25 in which said first and second multi-channel heat exchanger assemblies are mutually internested.

29. The power supply apapratus of claim 25 in which each said first and second power converter module includes a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regulated output connectors, including a monitor function output connector mounted upon said module circuit board adjacent said regulated output connector and electrically coupled with monitor function terminal located upon said power converter, said monitor function output connector and said regulated output connectors being located for external user access adjacent said second channel side region.

30. The power supply apparatus of claim 25 in which each said first and second power converter module includes a module circuit board and a D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and two said regulated output connectors, each said regulated output connector comprising a pin insertion connector mounted upon said module circuit board at a location for power supply coupling with a load-defining circuit board.

31. The power supply apparatus of claim 25 in which at least a portion of said interconnect circuit and said support circuit are located within said support channel.

32. The power supply apparatus of claim 25 in which:

said interconnect circuit includes first, second, third and fourth plug-in connectors for receiving respective first, second, third and fourth input connector assemblies; and

each said first, second, third and fourth power converter module includes a respective first, second, third and fourth module circuit board and a respective first, second, third and fourth D.C.-to-D.C. switching power converter mounted thereon at a mounting region intermediate said input connector assembly and said regualted output connectors, said input connector assembly comprising respectively first, second, third and fourth module plug-in connectors removably insertable into electrical communication with respective said first, second, third and fourth interconnect plug-in connectors.