A switching power supply module structure

Abstract

The utility model discloses a switching power module structure, including circuit board and the transformer of being located on it, the pin of circuit board is golden finger structure, the transformer is two, and the same surface on circuit board is arranged and distributed to left and right, the pin of circuit board is by first input pin group, second input pin group and output pin group constitutes, and the left, middle, right three group arrangement and distribution of circuit board one side, and each group pin is two, wherein left side a group is first input pin group for as a circuit input end pin, and right side a group is second input pin group for as another circuit input end pin, and middle a group is output pin group for as two circuits parallel output pin. Compared with prior art, the golden finger pin structure of left, middle, right three group arrangement and distribution of the utility model switching power module structure can optimize the original secondary side isolation safety distance.

Description

Technical Field

[0001] This utility model relates to the field of AC / DC switching power supplies, and in particular to a small-volume AC / DC switching power supply module structure with dual inputs and parallel outputs. Background Technology

[0002] In automotive charging gun applications, the power input differs between charging and discharging states. To ensure safety, two independent AC / DC conversion modules with isolated inputs and outputs are typically used: one for charging and the other for discharging. However, charging guns are usually small in size and cost-effective. Using two separate modules results in a large size and high cost, which no longer meets the needs of practical applications.

[0003] A detailed analysis of the power module used in car charging guns reveals that, as a highly integrated power conversion device, its core characteristics include: I. Basic Definitions and Core Features Structural characteristics: Employs direct soldering technology using gold fingers or pin headers; typical thickness range 5-11mm; supports direct PCB soldering. Input range: Dual isolated inputs, meeting a wide voltage input range of 85 - 418VAC / 100 - 591VDC. Output range: Two modules connected in parallel output, typical voltage is 12V. Conversion efficiency: Modern products can achieve over 80-90%. Thermal management design: Achieves stable operation in an 85℃ environment through thermal equilibrium design. II. Differences in Technology Classification and Evolution Topology: Flyback circuit standardization Power density: 5W / in³ for standard solutions AC / DC technology bottlenecks: Size requirements: The primary and secondary side safety distances for dual-input parallel output must be met. Current conventional single-board structures increase size by 30%, and high-voltage power devices need to be integrated. Safety certifications: UL / IEC / EN standards require redundant electrical isolation design between primary and secondary sides. Process limitations: The mounting accuracy of high-voltage MOSFETs requires ±25μm, hindering the advancement of automation. III. Industry Pain Points and Innovation Directions For example, in a car charging gun that integrates charging and discharging, a dual-input parallel output solution is required: generally, two power modules are used, and their outputs are connected in parallel, which results in a large overall volume.

[0004] Size conflict: Dual-channel isolated input requires two independent modules, which are twice the size of a single module. As analyzed above, single-input AC / DC power modules currently on the market cannot balance size, performance, and price. Conventional stacked structures often use pin header connectors for connection and fixation, resulting in low production efficiency, difficulty in achieving fully automated production, poor stability, insufficient strength, and easy deformation. Utility Model Content

[0005] In view of the above problems, the present invention aims to overcome the bottleneck problem of product miniaturization design in the prior art and provide a new type of switching power supply module structure that can achieve all existing electrical performance and further improve the power density of the package structure, making the product more miniaturized.

[0006] To achieve the above objectives, this utility model provides the following technical solution: A switching power supply module structure is disclosed, suitable for the module structure design of two flyback circuits with dual inputs and parallel outputs. The module includes a circuit board and a transformer mounted thereon. The circuit board has gold finger pins. Two transformers are arranged side-by-side on the same surface of the circuit board. The circuit board's pins consist of a first input pin group, a second input pin group, and an output pin group, arranged in three groups (left, center, and right) on one side of the circuit board. Each group has two pins. The left group is the first input pin group, used as the input pin of one circuit; the right group is the second input pin group, used as the input pin of the other circuit; and the center group is the output pin group, used as the parallel output pin of the two circuits.

[0007] Preferably, the first input pin group and the output pin group are separated by a safety distance equal to the primary and secondary sides; the second input pin group and the output pin group are separated by a safety distance equal to the primary and secondary sides.

[0008] Preferably, the widths of the first input pin group and the second input pin group of the circuit board are not equal, and the width of the first input pin group is greater than the width of the second input pin group; or the widths of the first input pin group and the second input pin group are equal.

[0009] Preferably, a groove or recess is formed between the first input pin group and the output pin group; a groove or recess is formed between the second input pin group and the output pin group.

[0010] Preferably, the output pin groups are a first output pin and a second output pin, the first output pin is used as a -Vo pin and the second output pin is used as a +Vo pin; and / or the total width of the pin distribution of the circuit board is less than or equal to the total width of the pin distribution of the two transformers.

[0011] Preferably, the adjacent pins of the two transformers are arranged opposite each other and cross each other.

[0012] Preferably, one side of the transformer has a pin seat that extends outward, and the outwardly extending pin seat has a retaining wall or a recess.

[0013] Preferably, the two transformers cover an area of ​​70% or more on the circuit board; and / or the lengths of the two transformers are substantially equal to the length of the circuit board.

[0014] Preferably, the gold finger structure pins of the circuit board have through holes, and the number of through holes is one or two; and / or each group of pins on the circuit board consists of two main function pins and two auxiliary function pins.

[0015] Preferably, there are two control IC modules on the circuit board, and the control IC modules have built-in power MOS; and / or there are two output rectifier modules on the circuit board for rectifying the output voltage of the transformer.

[0016] Preferably, the first input pin group and the first transformer are used to form a first flyback circuit; the second input pin group and the second transformer are used to form a second flyback circuit.

[0017] Compared with the prior art, the beneficial effects of the switching power supply module structure of this utility model are as follows: The transformer output pins extend outwards and are arranged in a relatively crossed configuration, making full use of the PCB layout space. The three sets of gold finger pins arranged on the left, center, and right optimize the primary and secondary side isolation safety distance, reducing the length of this new type of switching power supply to 4.2cm. Compared to existing switching power supplies that require two modules with a total length of 52.8mm, this new type of switching power supply saves customers 10.8mm of board space, reducing the length by over 40% compared to a single existing switching power supply. From an overall structural perspective, this new type of switching power supply achieves a power density of 6.22W / in³, which is more than 25% higher than the 4.95W / in³ power density of existing products. Attached Figure Description

[0018] Figure 1 This is a perspective view of the switching power supply module structure of this utility model; Figure 2 This is a perspective view of the switching power supply module structure of this utility model. Figure 3 This is a front view of the switching power supply module structure of this utility model; Figure 4 This is a rear view of the switching power supply module structure of this utility model; Figure 5 This is a circuit diagram of the switching power supply module structure of this utility model.

[0019] The reference numerals in the above figures are explained as follows: the directional terms in parentheses are only for numbering purposes to facilitate quick understanding and number lookup, and can be omitted when the overall directional description is already provided in the specific embodiment description.

[0020] 2. Circuit board, 21 (left) first input pin group, 22 (right) second input pin group, 23 (middle) output pin group, 211 (left) first groove, 212 (right) second groove, 213 through hole, 231 first output pin, 232 second output pin, 41 (left) first transformer, 42 (right) second transformer, 411 primary winding pin of the first transformer, 412 output winding pin of the first transformer, 421 primary winding pin of the first transformer, 422 output winding pin of the second transformer, 413 pin socket of the first transformer, 423 pin socket of the second transformer, 414 retainer of the first transformer, 424 retainer of the second transformer, 51 (left) first control IC module, 52 (right) second control IC module, 61 (left) first output rectifier module, 62 (right) second output rectifier module; A. Width of the first input pin group; B is the width of the second input pin group. Detailed Implementation

[0021] To make the above-mentioned objectives, features, and advantages of this utility model more apparent and understandable, the utility model and its beneficial effects will be further described in detail below with reference to specific embodiments and accompanying drawings. However, the specific embodiments of this utility model are not limited thereto. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this application.

[0022] The spatial relative terms used herein, such as “up,” “down,” “left,” and “right,” are for the convenience of describing the relationship between one element or feature and another shown in the figures. It will be understood that, in addition to the directions described in the figures, the spatial relative terms are intended to include different orientations of the device in conventional use. For example, if the device in the figure is reversed, the relationships between other elements or features in the technical description may also be reversed accordingly. Therefore, directional terms such as “upper” and “left” may include other orientations that may occur with conventional substitution. The device may also be oriented (rotated 90 degrees or in other orientations), and the spatial relative description used herein will be interpreted accordingly.

[0023] Please see Figures 1 to 5The accompanying drawings illustrate the structure of a switching power supply module of this utility model. This module structure is suitable for a dual-input parallel output module design with two flyback circuits. It includes a circuit board 2 and a transformer mounted on it. The pins of the circuit board 2 have a gold finger structure. Two transformers are arranged side-by-side on the same surface of the circuit board. The pins of the circuit board 2 consist of a first input pin group 21, a second input pin group 22, and an output pin group 23, arranged in three groups (left, center, and right) on one side of the circuit board. Each group has two pins. The left group of pins (the first input pin group 21) serves as the input pins for one circuit; the right group of pins (the second input pin group 22) serves as the input pins for the other circuit; and the center group of pins (the output pin group 23) serves as the parallel output pins for the two circuits, thus realizing a dual-input, parallel output switching power supply module structure. When meeting safety regulations for dual-output circuits, existing conventional single-board structures require a 30% increase in volume and integration of high-voltage power devices. The improved circuit board layout of this utility model offers significant advantages and can substantially reduce product size.

[0024] The first input pin group 21 and the output pin group 23 are separated by a safety distance between the primary and secondary sides, and the second input pin group 22 and the output pin group 23 are also separated by a safety distance between the primary and secondary sides. This effectively optimizes the safety distance between the primary and secondary sides and reduces the power supply size. Whether or not a safety distance between the primary and secondary sides is maintained can be determined by whether the power supply product meets the relevant safety certification requirements or has obtained the relevant safety certification. Because the safety distance varies depending on the product performance according to relevant standards, using measurement methods to determine it is limited by inconsistent measurement standards, and the interpretation of the measured safety distance may differ among parties. However, power supply products generally need to meet the relevant safety certification requirements, and power supply products that meet safety certification generally have a safety distance separation between the primary and secondary sides that meets the safety distance requirements, or in other words, a safety distance between the primary and secondary sides is maintained. To set an effective safety distance within the limited circuit board space while reducing the power supply size requires system optimization of the overall product structure, which is difficult to achieve simply through a single safety distance size design. In other words, while the requirements of electromagnetic compatibility (EMC) standards for products are uniform, the structural designs of products that meet EMC standards are diverse and cannot be achieved by simple, conventional methods. Instead, a systematic optimization design of the overall product structure is required.

[0025] Preferably, the width A of the first input pin group 21 and the width B of the second input pin group 22 are not equal, and the width of the first input pin group 21 is greater than the width of the second input pin group 22. In other embodiments, the widths of the first input pin group and the second input pin group may also be equal to adapt to the overall structural design requirements of different power supply products.

[0026] Two transformers, a first transformer 41 and a second transformer 42, are mounted on circuit board 2, arranged side-by-side on the same surface of circuit board 2. The first transformer 41 has its primary winding pin 411 on the left and its output winding pin 412 on the right. The second transformer 42 has its output winding pin 422 on the left and its primary winding pin 421 on the right. The output winding pins 412 of the first transformer 41 and 422 of the second transformer 42 are arranged adjacent to each other and interleaved, making full use of the PCB layout space, resulting in a more compact PCB layout and effectively reducing the power supply size. Although the power supply product adopts an optimized system structure design, the two transformers are still the decisive factor in the power supply size, occupying at least 70% of the area on circuit board 2. That is, the ratio of the projected area of ​​the two transformers to the area of ​​one surface of circuit board 2 is at least 70%, where the projected area of ​​the two transformers is the area enclosed by their bodies and pins. The lengths of the two transformers are approximately equal to the length of circuit board 2. In other words, the lengths of the two transformers differ from the length of circuit board 2 by less than 20%. Taking a product size as an example, the total length of its two transformers is 40.4mm, and the circuit board length is 42mm. The ratio of the total transformer length to the circuit board length is 96%, meaning the length difference is within 20%, indicating they are essentially equal. This 20% size difference primarily depends on the circuit board's edge structure, specifically the blank edge between the outer pins of the two transformers and the circuit board edge, as shown in the diagram. According to industry practice, this blank edge area is the PCB edge, specifically the process edge that prevents component placement on the PCB, typically 3-10mm, with 5mm being the most common. One side of the first transformer 41 has an outwardly extending first pin seat 413, and this outwardly extending pin seat has a first retaining wall 414 or a recess. The second transformer 42 has one side of an outwardly extending second pin seat 423, and this outwardly extending pin seat has a second retaining wall 424 or a recess.

[0027] A first groove 211 is formed between the first input pin group 21 and the output pin group 23 on the circuit board, and a second groove 212 is formed between the second input pin group 22 and the output pin group 23. The first groove 211 and the second groove 212 can form the safety spacing between the primary and secondary sides, so as to achieve a primary-secondary isolation voltage of 3000VAC between the two circuits on the circuit board. In other embodiments, in addition to the groove being formed at the edge of the circuit board between the primary and secondary sides, a recessed hole (not shown in the figure) can also be formed in the middle of the circuit board to increase the creepage distance within the same area and achieve the same or similar safety spacing design effect between the primary and secondary sides.

[0028] Each of the first input pin group 21, the second input pin group 22, and the output pin group 23 has a through-hole 213. The through-hole 213 allows the metal layer on the inner wall of the hole to connect to the top and bottom copper foil of the gold finger structure pins, and the empty space within the through-hole increases the solder accommodating space at the gold finger pins, thereby increasing the reliability of gold finger soldering. Each group of pins on the circuit board 2 consists of two main function pins. For example, the first input pin group 21 includes a first input first pin as the positive terminal +V1 of the first circuit input and a first input second pin as the negative terminal -V1 of the first circuit input; the second input pin group 22 includes a second input first pin as the positive terminal +V1 of the second circuit input and a second input second pin as the negative terminal -V1 of the second circuit input. In other embodiments, additional auxiliary function pins derived from the main function pins, or non-functional auxiliary function pins, may be included to form a group of pins.

[0029] Two control IC modules are mounted on circuit board 2: a first control IC module 51 and a second control IC module 52. Both are power conversion control modules, and each control IC module incorporates a power MOSFET to reduce the space required for circuit board layout. Two output rectifier modules are also mounted on circuit board 2: a first output rectifier module 61 and a second output rectifier module 62, used for rectifying the output voltage of the transformer. The first input pin group 21, the first control IC module 51, the first transformer 41, and the first output rectifier module 61 on circuit board 2 together form a first flyback circuit; the second input pin group 22, the second control IC module 52, the second transformer 42, and the second output rectifier module 62 on circuit board 2 together form a second flyback circuit; the output terminals of the first and second flyback circuits are connected in parallel to form an output pin group 23 connected to circuit board 2. The parallel output pin group 23 of the two circuits on circuit board 2 includes two pins, namely the first output pin 231 and the second output pin 232. The first output pin 231 is used as the -Vo pin, and the second output pin 232 is used as the +Vo pin. Thus, through the optimized system layout design of the pins on the circuit board, the integrated layout of the functional pins of the two circuits (i.e., two single-circuit power modules) is simplified. Compared to the existing conventional single-board structure, which increases the volume by 30% and requires the integration of high-voltage power devices, the improved circuit board layout structure of this utility model for switching power supplies has significant advantages and can greatly reduce the product size, while still meeting safety regulations for dual-output at both high and low voltage levels.

[0030] This utility model discloses a switching power supply module structure. The circuit board uses a three-group arrangement of gold finger pins (left, center, and right), optimizing the layout of the primary and secondary side isolation safety distances. Through systematic pin layout optimization, it simplifies the design by integrating the functional pins of two circuits (i.e., two single-circuit power modules). This facilitates fully automated production, resulting in stable product quality, high mechanical strength, and resistance to deformation. The electronic components are arranged in three zones on one surface of the circuit board, allowing for detailed optimization of the overall high-power-density layout. The transformer output pins extend outwards, and adjacent output pins of the two transformers are arranged with relative overlap, further maximizing PCB space utilization. Measurements comparing this utility model sample with existing products of equivalent power performance show that the power density of this utility model sample reaches 6.22 W / in³, which is more than 25% higher than the existing product's 4.95 W / in³.

[0031] From the product application perspective, existing solutions minimize transformer size while meeting the minimum safety distance between the primary and secondary sides, with the transformer length being approximately equal to the circuit board length. This maximizes the utilization of the circuit board's layout space, resulting in a single-circuit switching power supply length of only 26.4mm, and a total length of 52.8mm for two switching power supplies. The transformer output pins of this new switching power supply extend outwards and are arranged in a relatively crossed configuration, fully utilizing the PCB's layout space. The three sets of gold finger pins arranged on the left, center, and right optimize the primary and secondary side isolation safety distance, eliminating one output pin compared to existing applications using two switching power supplies. Measurements and calculations comparing existing products with equivalent power performance with this new sample show that the length of a single module in this new switching power supply is reduced to 42mm. Compared to existing applications requiring two modules with a total length of 52.8mm, this new switching power supply saves customers 10.8mm of board space, a reduction of over 40% compared to a single existing switching power supply—equivalent to saving nearly half the board space of an existing switching power supply.

[0032] The embodiments of this utility model are not limited thereto. Based on the above content of this utility model, using common technical knowledge and conventional means in the field, without departing from the basic inventive concept of this utility model, the specific implementation circuit of this utility model can be modified, replaced or changed in various other forms, all of which fall within the protection scope of this utility model.

Claims

1. A switching power supply module structure, suitable for the module structure design of two flyback circuits with dual inputs and parallel outputs, comprising a circuit board and a transformer mounted thereon, wherein the pins of the circuit board have a gold finger structure, characterized in that: There are two transformers, arranged side-by-side on the same surface of the circuit board; The pins of the circuit board consist of a first input pin group, a second input pin group, and an output pin group, arranged in three groups on one side of the circuit board: left, middle, and right. Each group has two pins. The left group is the first input pin group, used as the input pin of one circuit. The right group is the second input pin group, used as the input pin of another circuit. The middle group is the output pin group, used as the parallel output pin of the two circuits.

2. The switching power supply module structure according to claim 1, characterized in that: The first input pin group and the output pin group are separated by a primary and secondary safety distance; the second input pin group and the output pin group are separated by a primary and secondary safety distance.

3. The switching power supply module structure according to claim 1, characterized in that: The widths of the first input pin group and the second input pin group of the circuit board are not equal, and the width of the first input pin group is greater than the width of the second input pin group; or the widths of the first input pin group and the second input pin group are equal.

4. The switching power supply module structure according to claim 1, characterized in that: A groove or recess is provided between the first input pin group and the output pin group; a groove or recess is provided between the second input pin group and the output pin group.

5. The switching power supply module structure according to claim 1, characterized in that: The output pin groups are a first output pin and a second output pin, the first output pin is used as a -Vo pin and the second output pin is used as a +Vo pin; and / or the total width of the pin distribution of the circuit board is less than or equal to the total width of the pin distribution of the two transformers.

6. The switching power supply module structure according to claim 1, characterized in that: The adjacent pins of the two transformers are opposite each other and are arranged crosswise.

7. The switching power supply module structure according to claim 1, characterized in that: One side of the transformer has a pin seat that extends outward, and the outwardly extending pin seat has a retaining wall or a recess.

8. The switching power supply module structure according to claim 1, characterized in that: The two transformers cover an area of ​​70% or more on the circuit board; and / or the lengths of the two transformers are substantially equal to the length of the circuit board.

9. The switching power supply module structure according to claim 1, characterized in that: The gold finger structure pins of the circuit board have through holes, and the number of through holes is one or two; and / or each group of pins on the circuit board consists of two main function pins and two auxiliary function pins.

10. The switching power supply module structure according to claim 1, characterized in that: There are two control IC modules on the circuit board, and each control IC module has a built-in power MOS; and / or there are two output rectifier modules on the circuit board, which are used for rectifying the output voltage of the transformer.

11. The switching power supply module structure according to claim 1, characterized in that: The first input pin group and the first transformer are used to form a first flyback circuit; the second input pin group and the second transformer are used to form a second flyback circuit.

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