DC Conversion Module Layout for High-Density Power Supplies

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Solution Overview

Problem

Existing power supplies have bulky designs due to the lack of efficient circuit structure, resulting in poor power density, as the front-end AC-to-DC converter, main converter, and auxiliary converter are typically designed on a single motherboard or stacked circuit boards with flying wires, leading to increased size and reduced power density.

Innovation Solution

A direct-current (DC) conversion module is designed with interleaved or delta-connected circuit boards and transformers, integrated into a main circuit board, utilizing a phase difference in control signals and delta connections to reduce circuit volume and enhance power density, incorporating a power factor corrector, DC conversion module, and isolated conversion module to optimize space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the front-end AC-to-DC converter, main converter, and auxiliary converter are designed on a single motherboard or stacked circuit boards with flying wires, then the power supply can be assembled using conventional methods, but the circuit size increases and power density deteriorates

Engineering Contradiction:

Improveconventional assembly methodVSAvoidcircuit size

Core Design Contradiction:

Ease of manufactureVSVolume of moving object

Solution Approach 1:

The patent merges the front-end AC-to-DC converter, main converter, and auxiliary converter into a single integrated circuit board structure. The circuit board includes a first board and a second board that are integrated together, eliminating the need for separate stacked boards and flying wire connections. This merging of previously separate converter modules into one unified board directly reduces circuit size while maintaining conventional assembly ease.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

Engineering Contradiction:

Improveconventional assembly methodVSAvoidpower density

Core Design Contradiction:

Ease of manufactureVSPower

Solution Approach 1:

The integration of multiple converter modules into a single circuit board reduces the overall volume occupied by these components. By combining the front-end AC-to-DC converter, main converter, and auxiliary converter on one board with integrated magnetic components, the patent achieves higher power density while preserving conventional assembly methods.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes three-dimensional space utilization by stacking circuit boards and integrating magnetic components vertically. The first and second circuit boards are arranged in a stacked configuration with magnetic components positioned between them, effectively using the vertical dimension to reduce the horizontal footprint and increase power density.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If multiple circuit boards are stacked and connected by flying wires, then each converter module can be independently designed, but the circuit size increases and power density is reduced

Engineering Contradiction:

Improveindependent module designVSAvoidcircuit size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent merges multiple independently designed converter modules into a single integrated circuit board structure. The first and second circuit boards are integrated with specific functional areas for the front-end AC-to-DC converter, main converter, and auxiliary converter, maintaining design independence while eliminating the need for separate stacked boards and flying wire connections, thus reducing overall circuit size.

Inventive Principle:

Principle #5Merging (Combining)

4Adaptability or versatility

If multiple circuit boards are stacked and connected by flying wires, then each converter module can be independently designed, but the power density becomes poor

Engineering Contradiction:

Improveindependent module designVSAvoidpower density

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The integration of independently designed converter modules into a single circuit board reduces the volume occupied by inter-board connections and spacing. The patent maintains the adaptability of independent module design while achieving higher power density through the merged board structure that eliminates flying wires and reduces overall circuit footprint.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4369586A1Power supply unit and DC conversion module

Publication Date: 2024.05.15 DELTA ELECTRONICS INC(CN)

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Figure 3A

AI summary

A power supply unit (PSU) supplies power to a load, and the power supply unit (PSU) includes a power factor corrector (PFC), a DC conversion module (CR_DC), and an isolated conversion module (CR_M). The power factor corrector (PFC) is plugged into a first main circuit board (CB_M1) and converts an AC power into a DC power. The DC conversion module (CR_DC) is plugged into the first main circuit board (CB_M1) and converts the DC power into a main power. The isolated conversion module (CR_M) includes a bus capacitor (Cbus), the bus capacitor (Cbus) is coupled to the DC conversion module (CR_DC) through a first power copper bar (BR_P1), and coupled to the power factor corrector (PFC) through a second power copper bar (BR_P2). The first power copper bar (BR_P1) and the second power copper bar (BR_P2) are arranged on a side opposite to the first main circuit board (CB_M1), and are arranged in parallel with the first main circuit board (CB_M1).