Modular power supply and method for manufacturing the same

• US 9,867,275 B2
• Filed: 03/01/2016
• Issued: 01/09/2018
• Est. Priority Date: 07/27/2015
• Status: Active Grant

• Current Assignee: Delta Electronics Shanghai Company Limited (Delta Electronics Incorporated)
• Original Assignee: Delta Electronics Shanghai Company Limited (Delta Electronics Incorporated)
• Inventors: Chen, Shijie, Deng, Yan, Wei, Zhihui
• Primary Examiner(s): SMITH, COURTNEY L
• Application Number:
  US15/058,133
• Publication Number:
  US 20170034899A1
• Time in Patent Office: 679 Days
• Field of Search: None
• CPC Class Codes: H01F 27/22 Cooling by heat conduction through solid or powdered fillings
• CPC Class Codes: H01F 27/24 Magnetic cores
• CPC Class Codes: H01F 27/2804 Printed windings
• CPC Class Codes: H01F 27/292 Surface mounted devices
• CPC Class Codes: H05K 1/0203 Cooling of mounted components H05K1/0272 takes precedence
• CPC Class Codes: H05K 1/0204 using means for thermal conduction connection in the thickness direction of the substrate H05K1/0207 takes precedence
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 3/30 Assembling printed circuits with electric components, e.g. with resistor
• CPC Class Codes: H05K 7/209 Heat transfer by conduction from internal heat source to heat radiating structure H05K7/20909 takes precedence

Abstract

A modular power supply and a method for manufacturing the same are disclosed. The modular power supply comprises a printed circuit board, power components, and a heat sink. The power components are mounted on the printed circuit board and disposed at a side opposite to the heat sink, a lower surface of the printed circuit board is engaged with an upper surface of the heat sink which is planar, and an insulating layer is disposed between the upper surface of the heat sink and the lower surface of the printed circuit board. A method for manufacturing the modular power supply is also disclosed. The modular power supply has excellent heat dissipation effect, and the production and assembly process thereof is simplified, so that the production efficiency is improved and the quality is guaranteed.

Claims

1. A modular power supply, comprising a printed circuit board, power components, and a heat sink, characterized in that, the heat sink comprises an upper surface which is planar, the power components are mounted on the printed circuit board and disposed at a side opposite to the heat sink, a lower surface of the printed circuit board is engaged with the upper surface of the heat sink, with an insulating layer being disposed between the upper surface of the heat sink and the lower surface of the printed circuit board,

wherein, the power components comprise a semiconductor device, the semiconductor device comprises a case having a bottom and a top, hot sources of the semiconductor device are located at the bottom, and the bottom is close to the printed circuit board.

2. The modular power supply of claim 1, characterized in that, the power components comprise a magnetic element, the magnetic element comprises a magnetic core, a lower surface of the magnetic core and the lower surface of the printed circuit board are disposed in a same plane, the lower surface of the magnetic core is engaged with the upper surface of the heat sink, and the insulating layer is disposed between the lower surface of the magnetic core and the upper surface of the heat sink.

3. The modular power supply of claim 2, characterized in that, the printed circuit board is provided with mounting grooves which ensures that the lower surface of the magnetic core is engaged with the upper surface of the heat sink.

4. The modular power supply of claim 3, characterized in that, the magnetic element further comprises a winding board, the magnetic core is mounted on the winding board and positioned in the mounting grooves, the lower surface of the magnetic core and the lower surface of the printed circuit board are disposed in the same plane, and the winding board is mounted on the printed circuit board though a support member.

5. The modular power supply of claim 4, characterized in that, at least one heat-conducting through hole is formed on the printed circuit board at the positions where the support member is connected to the printed circuit board.

6. The modular power supply of claim 1, characterized in that, the semiconductor device further comprises a heat dissipating plate which is disposed between the bottom and the printed circuit board.

7. The modular power supply of claim 6, characterized in that, a plurality of through holes are formed in the printed circuit board at the positions below the semiconductor device.

8. The modular power supply of claim 1, characterized by further comprising a control printed circuit board which is connected to the printed circuit board and disposed at a side opposite to the heat sink.

9. The modular power supply of claim 1, characterized in that, the insulating layer is an insulating sheet which is formed integrally as one unit.

10. A method for manufacturing the modular power supply as claimed by claim 1, characterized by comprising the following steps:

S100, mounting the power components on the printed circuit board by using a planar carrier as a baffle during assembling to make the lower surface of the magnetic core in the power components and the lower surface of the printed circuit board be in a same plane;

S200, disposing the insulating layer on the lower surface of the printed circuit board or the upper surface of the heat sink, so that the heat from the printed circuit board can be directly conducted to the heat sink;

S300, fixing the printed circuit board to the heat sink to make the lower surface of the printed circuit board be engaged with the upper surface of the heat sink, with the insulating layer being disposed between the upper surface of the heat sink and the lower surface of the printed circuit board, the printed circuit board is not provided with any power component at its surface contacting the heat sink, and the heat from the power components is conducted to the heat sink via the through holes.

11. The method of claim 10, characterized in that, the power components comprise a magnetic element which comprises a magnetic core and a winding board, and step S100 further comprises:

S101, connecting the winding board to the printed circuit board;

S102, assembling the magnetic core in the mounting grooves of the printed circuit board by using the planar carrier as the baffle to make the lower surface of the magnetic core and the lower surface of the printed circuit board be in the same plane, making the lower surface of the magnetic core be engaged with the upper surface of the heat sink, and thus minimizing thermal resistance between the magnetic element and the heat sink.

12. The method of claim 10, characterized in that, the power components comprise a magnetic element which comprises a magnetic core and a winding board, and step S100 further comprises:

S101, assembling the magnetic core and the winding board into one piece;

S102, assembling the magnetic core in the mounting grooves of the printed circuit board by using the planar carrier as the baffle to make the lower surface of the magnetic core and the lower surface of the printed circuit board be in the same plane, making the lower surface of the magnetic core be engaged with the upper surface of the heat sink, and thus minimizing thermal resistance between the magnetic element and the heat sink;

S103, connecting the winding board to the printed circuit board by using the support member.

13. The method of claim 10, characterized in that, the power components comprise a magnetic element which comprises a magnetic core and a winding board, and step S100 further comprises:

S101, assembling a lower portion of the magnetic core to the winding board;

S102, assembling the lower portion of the magnetic core into the mounting grooves of the printed circuit board by using the planar carrier as the baffle to make the lower surface of the magnetic core and the lower surface of the printed circuit board be in the same plane, making the lower surface of the magnetic core be engaged with the upper surface of the heat sink, and thus minimizing thermal resistance between the magnetic element and the heat sink;

S103, connecting the winding board to the printed circuit board;

S104, assembling an upper portion of the magnetic core to the lower portion of the magnetic core.

14. The method of claim 10, characterized in that, the insulating layer is an insulating sheet which is formed integrally as one unit.