Ultra-thin size switching power supply

Abstract

The utility model discloses a kind of ultra-thin size switching power supply, including power shell and built-in circuit module, the maximum thickness of the power shell is ≤15mm, the circuit module includes input rectifier module, power conversion module, centralized control interface module, series connection interface module and large-current output port, the input rectifier module is electrically connected with power conversion module, the centralized control interface module, series connection interface module are all with power conversion module signal connection, the large-current output port is electrically connected with the output end of power conversion module, the utility model, strong versatility: support 100-240V wide voltage input, adapt to different national power grid standard;Standardized input and output interface can be matched with various types of customized lamps, simultaneously have UL, CE, UKCA and the multi-country authentication of other countries, wide application range.

Description

Technical Field

[0001] This utility model relates to the field of switching power supply technology, and in particular to an ultra-thin switching power supply. Background Technology

[0002] Switching power supplies are core components of lighting control systems, responsible for converting mains power into the operating voltage and current suitable for the lighting fixtures. With the increasing sophistication of household lighting equipment such as cabinet lights, the market demand for miniaturized and ultra-thin switching power supplies is becoming increasingly urgent. Currently, conventional switching power supplies generally have a minimum thickness of over 17 mm, exhibiting the following significant drawbacks: Large installation space requirements: In confined installation environments such as cabinets, thick power supplies are difficult to embed, increasing construction difficulty; Significant aesthetic impact: After installation, they protrude into the cabinet, detracting from the overall aesthetics; Insufficient functional compatibility: They lack designs for high-current output of long light strips, requiring additional controllers for simultaneous control of multiple lights, resulting in complex wiring; Imbalanced overall performance: Some small power supplies suffer from high noise, poor heat dissipation, and low safety levels, making them unsuitable for household use. To address these issues, there is an urgent need to develop an ultra-thin, functionally integrated, and stable switching power supply to meet the installation and usage needs of cabinet lights and similar applications. Utility Model Content

[0003] The technical problem to be solved by this utility model is to provide an ultra-thin switching power supply that achieves the comprehensive effects of "ultra-thin installation, low-noise operation, safety and efficiency, and multi-lamp control" through structural optimization and functional integration, so as to meet the usage needs of cabinet lighting and other scenarios.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by this utility model is as follows: An ultra-thin switching power supply includes a power supply housing and a built-in circuit module. The maximum thickness of the power supply housing is ≤15mm. The circuit module includes an input rectifier module, a power conversion module, a centralized control interface module, a series interface module, and a high-current output port. The input rectifier module is electrically connected to the power conversion module. The centralized control interface module and the series interface module are both signal-connected to the power conversion module. The high-current output port is electrically connected to the output terminal of the power conversion module. The input rectifier module is used to convert mains power into high voltage DC power, and integrates filtering, overvoltage and overshoot protection and noise removal functions; the power conversion module is used to convert high voltage DC power into working voltage and current suitable for the lamp, integrates a high-precision intelligent loop feedback unit and overvoltage / undervoltage / overcurrent / overtemperature protection unit, and adopts a low EMC cost circuit design. The centralized control interface module is used to connect to the switch controller, dimmer, or sensor, supply power to them, and transmit control signals. The centralized control interface module includes a resistor group, transistors Q2 / Q5 / Q6, and MOSFETs. The control signal is transmitted to the transistors via the resistor group, and then the transistors control the MOSFETs to turn on and off, thereby realizing the switching and dimming of the lamps. The serial interface module is signal-coupled with the centralized control interface module, and multiple power supplies are cascaded through a dedicated serial line, so that a single centralized control signal can synchronously control all cascaded power supplies; the high-current output port is a high-current carrying terminal, which is adapted to the total power output requirements of long light strips.

[0005] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is as follows: the power supply shell is made of 94V0 flame retardant material and is filled with thermally conductive silicone. The thermally conductive silicone fills the gaps between components to achieve thermal balance of components and surface heat dissipation.

[0006] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is: the operating noise of the power conversion module is ≤18.9DBA, and the input rectifier module supports a wide voltage input of 100-240V.

[0007] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is as follows: the circuit composition of the centralized control interface module and the series interface module includes resistors R47 / R43 / R39 / R40 / R31 / R34 / R35, transistors Q4 / Q5, Zener diode ZD3 and interface CZ3 / CZ4, and the PIN2 / PIN3 terminals of the centralized control interface module are coupled to the series interface module through resistor R25.

[0008] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is as follows: the input rectifier module includes a bridge rectifier unit, an EMC protection unit and a filter capacitor unit, and the power conversion module includes an isolation transformer, an LC filter unit, an output diode, an optocoupler isolation unit and an output sampling unit.

[0009] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is as follows: the input end of the power supply casing is equipped with an international standard AC8 connector, the output end is equipped with a standard DuPont connector, and the terminal type of the high current output port is VH1.

[0010] To solve the above-mentioned technical problems, another technical solution adopted by this utility model is: the power conversion module has a conversion efficiency of 88-92%, which is suitable for 12V or 24V lamp power supply requirements.

[0011] The beneficial effects of this utility model are as follows: Ultra-thin design with strong adaptability: At a maximum thickness of 15mm, it is significantly thinner than conventional power supplies (17mm or more), allowing it to be embedded in narrow spaces such as cabinets. This facilitates installation without compromising aesthetics, addressing the space constraints of traditional power supplies. Excellent overall performance: Conversion efficiency reaches 88-92%, generating minimal heat; operating noise ≤18.9dBA, ensuring quiet operation; 94V0 flame-retardant shell + internal thermally conductive silicone potting provides both fire safety and efficient heat dissipation, meeting the safety requirements of home environments; High functional integration: Integrated control interface, series interface, and high-current output port, enabling simultaneous control of multiple lamps and power supply for long light strips without the need for additional controllers, simplifying system configuration and reducing user costs; Strong versatility: Supports a wide voltage input range of 100-240V, adapting to different national power grid standards; standardized input / output interfaces are compatible with various customized lamps, and it possesses multiple international certifications such as UL, CE, and UKCA, making it widely applicable. Attached Figure Description

[0012] Figure 1 This is a circuit diagram of an ultra-thin switching power supply according to an embodiment of the present invention. Detailed Implementation

[0013] To explain in detail the technical content, objectives, and effects of this utility model, the following description is provided in conjunction with the embodiments and accompanying drawings.

[0014] Before detailing the embodiments of this application, some related concepts will first be explained: Electromagnetic Compatibility (EMC) refers to the ability of a device or system to function properly in its electromagnetic environment without causing unacceptable electromagnetic interference to other devices in the environment. 94V0 flame retardant rating: The flame retardant rating in the UL standard requires that the material self-extinguish within 30 seconds after ignition in a vertical burning test, and that no molten droplets ignite the cotton below. UL / CE / UKCA certifications are product safety certifications for the United States, the European Union, and the United Kingdom, respectively, and are the entry requirements for products to enter the corresponding markets.

[0015] In existing technologies, the minimum thickness of conventional switching power supplies is generally over 17 mm, which has the following significant drawbacks: Large installation space requirements: In confined installation environments such as cabinets, thick power supplies are difficult to embed, increasing construction difficulty; Significant impact on appearance: After installation, they protrude into the cabinet, ruining the overall aesthetics; Insufficient functional compatibility: There is a lack of high-current output design for long light strips, requiring additional controllers for simultaneous control of multiple lights, resulting in complex wiring; Imbalanced overall performance: Some small power supplies suffer from problems such as high noise, poor heat dissipation, and low safety levels, making it difficult to meet the requirements of home use.

[0016] To at least solve the above problems, please refer to Figure 1 This utility model provides an ultra-thin switching power supply, including a power supply housing and a built-in circuit module. The maximum thickness of the power supply housing is ≤15mm. The circuit module includes an input rectifier module, a power conversion module, a central control interface module, a series interface module, and a high-current output port. The input rectifier module is electrically connected to the power conversion module. The central control interface module and the series interface module are both signal connected to the power conversion module. The high-current output port is electrically connected to the output terminal of the power conversion module. The input rectifier module is used to convert mains power into high voltage DC power, and integrates filtering, overvoltage and overshoot protection and noise removal functions; the power conversion module is used to convert high voltage DC power into working voltage and current suitable for the lamp, integrates a high-precision intelligent loop feedback unit and overvoltage / undervoltage / overcurrent / overtemperature protection unit, and adopts a low EMC cost circuit design. The centralized control interface module is used to connect to the switch controller, dimmer, or sensor, supply power to them, and transmit control signals. The centralized control interface module includes a resistor group, transistors Q2 / Q5 / Q6, and MOSFETs. The control signal is transmitted to the transistors via the resistor group, and then the transistors control the MOSFETs to turn on and off, thereby realizing the switching and dimming of the lamps. The serial interface module is signal-coupled with the centralized control interface module, and multiple power supplies are cascaded through a dedicated serial line, so that a single centralized control signal can synchronously control all cascaded power supplies; the high-current output port is a high-current carrying terminal, which is adapted to the total power output requirements of long light strips.

[0017] As described above, the beneficial effects of this utility model are as follows: Its maximum thickness of 15mm is far lower than the conventional power supply's 17mm or more, allowing it to be embedded in narrow spaces such as cabinets, making construction convenient and not affecting the aesthetics of the installation environment, thus solving the pain point of insufficient installation space in traditional power supplies; Excellent overall performance: conversion efficiency reaches 88-92%, with low heat generation; operating noise ≤18.9DBA, ensuring quiet operation; 94V0 flame-retardant shell + internal thermally conductive silicone potting, combining fire safety and efficient heat dissipation performance, meeting the safety requirements of household scenarios; High functional integration: integrating a central control interface, a series interface, and a high-current output port, enabling simultaneous control of multiple lamps and power supply for long light strips without the need for additional controller configuration, simplifying system configuration and reducing user costs; Strong versatility: supporting a wide voltage input of 100-240V, adapting to different national power grid standards; standardized input and output interfaces are compatible with various customized lamps, and it also possesses multiple international certifications such as UL, CE, and UKCA, making it widely applicable.

[0018] Furthermore, the power supply casing is made of 94V0 flame-retardant material and is internally encapsulated with thermally conductive silicone. The thermally conductive silicone fills the gaps between components to achieve thermal balance of components and surface heat dissipation.

[0019] As described above, thermally conductive silicone reduces the temperature of components through efficient heat dissipation, thereby reducing the risk of casing combustion caused by overheating from the source; the 94V0 casing, in the event of extreme failures such as thermally conductive silicone failure or component short circuits, blocks the spread of flames and the hazards of molten droplets. The two work together to meet the core requirements of cabinets that are "small space, safety first, and high appearance requirements", satisfying household safety standards while maintaining an ultra-thin size and long-term stable operation.

[0020] Furthermore, the operating noise of the power conversion module is ≤18.9 dBA, and the input rectifier module supports a wide voltage input of 100-240V.

[0021] As described above, the wide voltage design allows the power supply to work stably in different power grid environments around the world without requiring users to worry about voltage differences; the low noise design ensures that the power supply can "operate invisibly" in various quiet home environments. Together, they meet the core requirements of cabinet lighting fixtures to be "universal, quiet, and stable," which not only enhances the product's market competitiveness but also optimizes the user's actual experience.

[0022] Furthermore, the circuit composition of the centralized control interface module and the series interface module includes resistors R47 / R43 / R39 / R40 / R31 / R34 / R35, transistors Q4 / Q5, Zener diode ZD3, and interfaces CZ3 / CZ4. The PIN2 / PIN3 terminals of the centralized control interface module are coupled to the series interface module through resistor R25.

[0023] As described above, the wiring for multi-lamp control is simplified: only one dedicated serial cable is needed to connect the CZ4 interfaces of each power supply to achieve synchronous control of N power supplies. There is no need to lay control signal lines separately for each light strip, reducing the amount of wiring inside the cabinet and allowing it to be hidden in the gaps of the cabinet back panel without compromising aesthetics; the control signal synchronization is strong: the signal delay transmitted through R25 coupling is reduced, and the synchronization error of multiple light strips, such as three 1.5-meter light strips, on / off / dimming is reduced to a level that is completely imperceptible to the human eye, avoiding the stuttering feeling of "lights turning on one after another"; the circuit safety is high: the Zener diode ZD3 and the resistor group form double protection, even if the external controller fails and outputs a high voltage of 12V, it can limit the base voltage of the transistor to ≤3.3V, preventing the circuit from burning out; the electrical isolation design can avoid "grounding loop current" when multiple power supplies are cascaded, protecting the core components of the power supply.

[0024] Furthermore, the input rectifier module includes a bridge rectifier unit, an EMC protection unit, and a filter capacitor unit, and the power conversion module includes an isolation transformer, an LC filter unit, an output diode, an optocoupler isolation unit, and an output sampling unit.

[0025] As described above, the system boasts strong anti-interference capabilities: the EMC protection unit filters out most grid interference, ensuring that the cabinet light strip remains flicker-free even when the kitchen microwave is started, meeting the "unnoticeable operation" requirements for home use; stable and reliable conversion: when the input voltage fluctuates between 100-240V, the output voltage error is ≤±2%, and the light strip brightness remains unchanged; the output ripple is ≤50mVp-p, preventing LED lights from flickering due to voltage fluctuations, meeting the flicker-free requirements of GB / T24825-2019; and a high safety level: the dual isolation design of the isolation transformer and optocoupler ensures that the power output terminal resistance to ground is ≥100MΩ and the leakage current is ≤0.1mA. Even if the power supply casing is damaged, the cabinet body will not become electrified, meeting the household safety standard GB4943.1-2011.

[0026] Furthermore, the power supply housing is equipped with an international standard AC8 connector at the input end and a standard DuPont connector at the output end, and the high-current output port has a terminal type of VH1.

[0027] As described above, the installation is more convenient: the AC8 socket is plug-and-play, requiring no socket modification; the DuPont connector directly connects to the light fixture, avoiding the tedious cutting and wiring, improving installation efficiency, and allowing even non-professional users to replace the light fixture themselves; it has strong versatility: the standardized interface allows the power supply to be adapted to cabinet lights of different brands and regions, and users do not need to replace the power supply when replacing the light strip, reducing operating costs; it ensures stable operation of long light strips: the VH1 terminal can carry the large current of long light strips, such as a 6-meter 12V / 24W light strip with a current of 2A. During long-term operation, the terminal temperature is ≤40℃, eliminating the risk of overheating and burning out, and ensuring consistent brightness at both ends of the light strip, solving the pain point of "brightness decay of long light strips".

[0028] Furthermore, the power conversion module has a conversion efficiency of 88-92%, which is suitable for 12V or 24V lighting power supply requirements.

[0029] As described above, the power supply offers several advantages: First, it provides multi-voltage compatibility: one power supply can be used with cabinet lights on both 12V and 24V, eliminating the need for multiple power supplies for different light strips and reducing the number of power supplies required (e.g., an L-shaped cabinet only needs one power supply), saving internal installation space. Second, it offers low long-term operating costs: high efficiency reduces electricity expenses, multi-voltage compatibility reduces power supply procurement costs, and the power supply generates less heat, extending its lifespan and reducing replacement frequency.

[0030] Connection for single-power-supply independent control scenarios and single-segment short LED strip devices: Connect the AC mains power to the input rectifier module 2 via AC8 connector 7, connect the power supply line of the cabinet light fixture to the power output terminal via standard DuPont connector 8, and insert the dimmer 16 into the physical interface 15 of the centralized control interface module 4; Workflow: Power conversion: The input rectifier module 2 converts the 220V AC mains power into high-voltage DC power through a bridge rectifier unit. After the EMC protection unit filters electromagnetic interference and the filter capacitor unit smooths the waveform, it is transmitted to the power conversion module 3; The power conversion module 3 steps down the voltage through the isolation transformer 10, and the LC filter unit optimizes the waveform, outputting a stable 12V. Voltage is supplied to the lamp, and the output sampling unit monitors the output current and voltage in real time; Dimming control: The user sends a dimming signal through the dimmer 16. The signal is transmitted to the transistor 12 after being divided and current limited by the resistor group 13 of the centralized control interface module 4. The transistor controls the conduction degree of the MOSFET 11 according to the signal level change, thereby adjusting the output current of the power conversion module 3 to achieve stepless adjustment of the lamp brightness; Protection mechanism: When the output voltage is too high / low, the current is too large, or the internal temperature of the power supply exceeds 60℃, the intelligent loop feedback unit of the power conversion module 3 triggers the protection unit to immediately cut off the output. The power supply is automatically restored after the fault is cleared.

[0031] Multi-power supply cascade control scenario adaptation for multi-segment long LED strip device connection: Take 3 power supplies of this utility model, and connect the series interface modules 5 of each power supply in sequence through the dedicated series cable 18 to form a cascade network; insert the switch controller 16 into the central control interface module 4 of the first power supply, and connect the high current output ports 6 of the 3 power supplies to 3 long LED strips 17 with a length of 6 meters respectively; Work process: Signal synchronization: The switch signal sent by the switch controller 16 is processed by the central control interface module 4 of the first power supply, and coupled to the series interface module 5 through the PIN2 / PIN3 terminals and resistor R25, and then synchronized through the series cable 18. The control interface module 4 transmits the signal to the other two cascaded power supplies; synchronous control: the power conversion modules 3 of the three power supplies receive the control signal simultaneously and turn the output on or off synchronously, and the three long light strips 17 turn on and off synchronously; the VH1 terminal of the high current output port 6 has a strong carrying capacity, ensuring that the brightness at the end of the long light strip is consistent with that at the beginning, and there is no current attenuation; advantages: there is no need to configure an independent controller for each power supply, and the synchronous control of multiple long light strips can be achieved through only one switch controller, reducing the amount of wiring, significantly improving installation efficiency, and the number of power supply cascades can be flexibly expanded according to the length of the light strip, supporting up to 8 power supply cascades.

[0032] The above description is merely an embodiment of this utility model and does not limit the patent scope of this utility model. Any equivalent modifications made based on the content of this utility model specification and drawings, or direct or indirect applications in related technical fields, are similarly included within the patent protection scope of this utility model.

Claims

1. An ultra-thin switching power supply, characterized in that: The power supply includes a power supply housing and a built-in circuit module. The maximum thickness of the power supply housing is ≤15mm. The circuit module includes an input rectifier module, a power conversion module, a central control interface module, a series interface module, and a high-current output port. The input rectifier module is electrically connected to the power conversion module. The central control interface module and the series interface module are both signal connected to the power conversion module. The high-current output port is electrically connected to the output terminal of the power conversion module. The input rectifier module is used to convert mains power into high voltage DC power, and integrates filtering, overvoltage and overshoot protection and noise removal functions; the power conversion module is used to convert high voltage DC power into working voltage and current suitable for the lamp, integrates a high-precision intelligent loop feedback unit and overvoltage / undervoltage / overcurrent / overtemperature protection unit, and adopts a low EMC cost circuit design. The centralized control interface module is used to connect to the switch controller, dimmer, or sensor, supply power to them, and transmit control signals. The centralized control interface module includes a resistor group, transistors Q2 / Q5 / Q6, and MOSFETs. The control signal is transmitted to the transistors via the resistor group, and then the transistors control the MOSFETs to turn on and off, thereby realizing the switching and dimming of the lamps. The serial interface module is signal-coupled with the centralized control interface module, and multiple power supplies are cascaded through a dedicated serial line, so that a single centralized control signal can synchronously control all cascaded power supplies; the high-current output port is a high-current carrying terminal, which is adapted to the total power output requirements of long light strips.

2. The ultra-thin switching power supply according to claim 1, characterized in that: The power supply casing is made of 94V0 flame-retardant material and is internally encapsulated with thermally conductive silicone. The thermally conductive silicone fills the gaps between components to achieve thermal balance of components and surface heat dissipation.

3. The ultra-thin switching power supply according to claim 1, characterized in that: The power conversion module operates at a noise level of ≤18.9 dBA, and the input rectifier module supports a wide voltage input of 100-240V.

4. The ultra-thin switching power supply according to claim 1, characterized in that: The circuit composition of the centralized control interface module and the series interface module includes resistors R47 / R43 / R39 / R40 / R31 / R34 / R35, transistors Q4 / Q5, Zener diode ZD3, and interfaces CZ3 / CZ4. The PIN2 / PIN3 terminals of the centralized control interface module are coupled to the series interface module through resistor R25.

5. The ultra-thin switching power supply according to claim 1, characterized in that: The input rectifier module includes a bridge rectifier unit, an EMC protection unit, and a filter capacitor unit. The power conversion module includes an isolation transformer, an LC filter unit, an output diode, an optocoupler isolation unit, and an output sampling unit.

6. The ultra-thin switching power supply according to claim 1, characterized in that: The power supply housing has an input terminal equipped with an international standard AC8 connector and an output terminal equipped with a standard DuPont connector. The high-current output port has a terminal type of VH1.

7. The ultra-thin switching power supply according to claim 1, characterized in that: The power conversion module has a conversion efficiency of 88-92% and is compatible with 12V or 24V lighting power supply requirements.

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