Power Converter Capacitor Layout for Low-Height High-Density Modules
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Solution Overview
Problem
Conventional power converter modules with single-stage converters face challenges in achieving low module height and high power density, particularly in data centers, due to the height limitations imposed by capacitors.
Innovation Solution
The power converter design addresses this by separating at least part of the capacitors from the power module, connecting them in series or parallel configurations, and integrating them on a separate substrate to reduce the overall height and enhance power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If capacitors are integrated within the power module, then the power module can be completed as a single unit, but the height of the power converter increases and power density decreases
Solution Approach 1:
The power converter is divided into separate modules: a power module containing the converter circuit and a separate capacitor assembly. This segmentation allows the power module to be compact and low-height while capacitors are positioned externally, resolving the contradiction between integration and height reduction.
Solution Approach 2:
The capacitor assembly is positioned in a different spatial dimension relative to the power module, connected via flexible printed circuit boards that extend vertically. This dimensional arrangement allows capacitors to be electrically connected without increasing the horizontal footprint or requiring high vertical stacking within the power module itself.
2Length of stationary object
If capacitors are disposed separately from the power module, then the height of the power converter is reduced and power density is improved, but the electrical connection complexity increases
Solution Approach 1:
Multiple electrical connections between the power module and capacitor assembly are merged into integrated flexible printed circuit board assemblies. The FPCBs combine power signal traces, control signal traces, and grounding paths into unified connection structures, reducing the complexity of individual connection management while maintaining separate physical positioning.
Solution Approach 2:
Flexible printed circuit boards serve as intermediary elements between the power module and capacitor assembly. These FPCBs provide structured, flexible connection paths that simplify the electrical interface while allowing physical separation, thus reducing connection complexity compared to direct rigid wiring.
3Length of stationary object
If the module height is reduced to meet low module height requirements, then the power density is improved, but the capacitor height becomes a limiting factor
Solution Approach 1:
The capacitor function is segmented from the power module and positioned externally. This allows the power module to achieve low height while capacitor capacity is maintained through external capacitor assemblies that are not constrained by the power module's height limitations.
Solution Approach 2:
Multiple capacitors are arranged in parallel configurations on the capacitor assembly, effectively copying the capacitance function across multiple components. This parallel arrangement achieves high total capacitance without requiring individual capacitors to be tall, thus maintaining low overall height while satisfying capacitance requirements.
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 configuration effectively decreases the height of the power converter while improving power density, meeting the stringent requirements of high power density and low module height in data center applications.
Implementation Method 1
A primary winding and a secondary winding of the magnetic component are electrically connected to the primary switch circuit and the secondary circuit respectively
Data Source
AI summary
The present disclosure provides a power converter including a first capacitor, a second capacitor, and a power module. The first capacitor and the second capacitor are connected in series. The power module is electrically connected to the first capacitor and the second capacitor and includes a circuit board, an absorption capacitor, a primary switch circuit, a magnetic component, and a secondary circuit. The absorption capacitor, the primary switch circuit, the magnetic component and the secondary circuit are disposed on the circuit board. A primary winding and a secondary winding of the magnetic component are electrically connected to the primary switch circuit and the secondary circuit respectively.