Dual-Input PCB Power Supply Layout for 3 kW Heat Isolation
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Solution Overview
Problem
Existing power supply devices for network servers require changes in input connectors and power distribution architecture when upgrading from 1.5 kW to 3 kW, leading to increased infrastructure costs and challenges in insulation and heat dissipation.
Innovation Solution
A power supply device with double input ports and isolated power supplies, each comprising a module with a printed circuit board, magnetic elements, and switching devices, optimized for heat dissipation and insulation, allowing integration of two 1.5 kW modules into a single chassis without changing the input connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If two 1.5 kW power supply modules are integrated into one power supply chassis to achieve 3 kW output, then the rated power is improved, but the heat dissipation difficulty increases
Solution Approach 1:
The power supply device is divided into two isolated power supply modules (first and second isolated power supplies), each handling 1.5 kW, with separate primary circuits and secondary circuits. This segmentation allows independent heat management for each module, reducing the overall heat dissipation difficulty while maintaining 3 kW total output power.
Solution Approach 2:
The patent introduces spatial separation between the two power supply modules by positioning them at different locations within the chassis with sufficient insulating distance. Heat dissipation is optimized by creating separate air channels and using fans positioned to efficiently cool each module independently, transforming a single-point heat problem into a distributed thermal management system.
2Power
If two isolated power supply modules are integrated into one chassis, then the power output is improved, but the insulation difficulty increases
Solution Approach 1:
The power supply device is divided into two completely isolated power supply modules, each with separate primary circuits, secondary circuits, and control systems. This segmentation ensures that electrical insulation requirements are met while achieving 3 kW total output power through parallel operation of the two modules.
Solution Approach 2:
The patent introduces an insulating barrier structure between the two isolated power supply modules to maintain sufficient insulating distance. This intermediary insulation structure allows the modules to be positioned closer together within the chassis while still meeting electrical insulation requirements, thus facilitating compact integration without compromising safety.
3Power
If the components are doubled to achieve 3 kW output, then the power capacity is improved, but the device complexity increases
Solution Approach 1:
The power supply device uses two identical isolated power supply modules, each with standardized primary circuits, secondary circuits, and control systems. This modular segmentation allows the system to achieve 3 kW capacity while maintaining manageable complexity through replication of proven designs rather than creating a completely new complex architecture.
Solution Approach 2:
Both isolated power supply modules use the same standardized connector type (C14 or C20) for input, allowing universal compatibility with existing power distribution infrastructure. This universality simplifies the overall system complexity by eliminating the need for different connector types and reducing the complexity of power distribution architecture modifications.
4Ease of manufacture
If standard connectors are used without replacement, then the infrastructure cost is reduced, but the current withstand capability is insufficient
Solution Approach 1:
The input current is segmented into two separate paths, each handled by an isolated power supply module. Each module processes half of the total current (1.5 kW equivalent), allowing the use of standard connectors with lower individual current ratings while still supporting the total 3 kW power capacity through parallel operation of the two modules.
Solution Approach 2:
The patent merges two separate power supply modules with identical connector types into a single chassis, combining their current handling capabilities. This merging allows the system to achieve high current withstand capability through parallel current paths while maintaining compatibility with standard connectors and existing power distribution architecture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution maintains the original input connectors, reduces infrastructure costs, and enhances heat dissipation and insulation, enabling efficient power supply without altering the existing power distribution architecture.
Implementation Method 1
at least one fan disposed behind the two input ports... the at least one fan is configured for heat dissipation of the at least one module
Implementation Method 2
an isolated circuit module comprising a transformer having windings formed by laying copper in the PCB and a magnetic core fixed on the PCB
Data Source
AI summary
The application provides a power supply device comprising two input ports disposed at a front end of the power supply device; at least one fan disposed behind the two input ports and two isolated power supplies connected respectively to the corresponding one of the two input ports and disposed behind the two input ports and the at least one fan. Each of the isolated power supplies comprises a main power circuit having at least one module, and each module comprises a PCB and a magnetic element and/or switching devices. The at least one module includes an isolated circuit module comprises a transformer having windings formed by laying copper in the PCB and the magnetic core fixed on the PCB. And at least one fan is configured for heat dissipation of the at least one module.