Synchronous Rectification Module Heat Dissipation
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Solution Overview
Problem
Conventional synchronous rectification modules suffer from low heat dissipating efficiency and high power loss, particularly in datacenter power supply applications, due to concentrated heat and high AC impedance, which limits power density and efficiency.
Innovation Solution
The synchronous rectification module design includes protruded outlet ends of secondary winding assemblies connected to circuit boards and a conducting member, increasing the heat transfer area and eliminating the need for large-area copper bus bars, thereby enhancing heat dissipation and reducing power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a heat sink is attached on the synchronous rectification unit to dissipate heat, then heat dissipating efficiency is improved, but device complexity and installation difficulty increase
Solution Approach 1:
The patent integrates the heat dissipation function directly into the transformer structure by designing protruding portions on the transformer body that serve as heat dissipation surfaces. This merges the transformer and heat sink into a single integrated component, eliminating the need for separate heat sink attachment while improving heat dissipation efficiency.
Solution Approach 2:
The protruding portions of the transformer act as intermediary heat dissipation structures that bridge the heat generation source (synchronous rectification unit) and the surrounding environment. These protrusions increase the heat transfer area without requiring additional heat sink components, thus serving as an intermediary solution between the rectification unit and external cooling.
2Loss of energy
If a large-area copper bus bar is used to connect the transformer with the synchronous rectification unit to reduce AC impedance, then power loss is reduced, but space utilization and power density decrease
Solution Approach 1:
The patent transitions from using planar copper bus bars to three-dimensional protruding structural connections. The protruding portions extend in multiple directions from the transformer body, creating spatially distributed connection points that reduce AC impedance without requiring large planar areas, thus improving power density.
Solution Approach 2:
The connection structure is segmented into multiple protruding portions distributed around the transformer body rather than using a single large copper bus bar. This segmentation allows for distributed current paths that reduce AC impedance while minimizing the overall space occupied by connection elements.
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 design improves heat dissipation efficiency and minimizes power loss by dispersing heat across increased surface areas and shortening the AC path, leading to increased power density and efficiency.
Implementation Method 1
The transformer includes plural secondary winding assemblies. Each of the secondary winding assemblies includes plural outlet ends. The outlet ends of portion of the secondary winding assemblies are protruded out from a first lateral region of the transformer, and the outlet ends of the other portion of the secondary winding assemblies are protruded out from a second lateral region of the transformer.
Implementation Method 2
a first conducting member is located at a third lateral region of the transformer and connected with a synchronous rectification unit. The first circuit board is connected with the first conducting member and located at the first lateral region. The second circuit board is connected with the first conducting member and located at the second lateral region.
Data Source
AI summary
A synchronous rectification module includes a transformer, a first conducting member and a synchronous rectification unit. The transformer includes plural secondary winding assemblies. The outlet ends of the secondary winding assemblies are protruded out from a first lateral region and a second lateral region of the transformer. The first conducting member is located at a third lateral region of the transformer. The synchronous rectification unit includes a first circuit board and a second circuit board. The first circuit board is connected with the first conducting member and located at the first lateral region. The second circuit board is connected with the first conducting member and located at the second lateral region. The outlet ends of the secondary winding assemblies are penetrated through corresponding first insertion holes of the first circuit board and corresponding second insertion holes of the second circuit board.