Synchronous Rectifier PCB Heat Dissipation Module
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power supply devices with heat-dissipating power switching elements require complex and labor-intensive assembly methods, involving insulators and screws, which are costly and time-consuming, and do not efficiently manage heat dissipation.
Innovation Solution
A synchronous rectifier printed circuit board (PCB) with power switching elements and driving circuits, where the power switching elements are disposed on a separate PCB forming a power switching module that can be easily plugged or welded into a main unit, utilizing enlarged conductive tracks for efficient heat dissipation and simplifying assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power switching elements are fastened on opposite surfaces of a heat dissipating element using screws and nuts, then heat dissipation is achieved, but the assembly procedure becomes complicated and labor-consuming
Solution Approach 1:
The patent divides the power supply device into separate modules: a primary circuit board and a secondary circuit board (power switching module). The power switching elements are mounted on the secondary circuit board which serves as both the mounting substrate and heat dissipation structure, eliminating the need for separate heat dissipating elements and complex fastening procedures.
Solution Approach 2:
The patent combines the heat dissipation function with the circuit board structure itself. The secondary circuit board integrates both the electrical connection function and the heat dissipation function, merging what were previously separate components (circuit board + heat sink + fastening mechanism) into a single integrated structure.
2Reliability
If insulators are placed between the heat dissipating element and power switching elements, then electrical shorting is prevented, but the procedure becomes more complicated and costly
Solution Approach 1:
The patent uses the circuit board itself as the intermediary between the power switching elements and the heat dissipation structure. The circuit board provides both electrical insulation (preventing shorting) and thermal conduction (dissipating heat), eliminating the need for separate insulator components and their associated assembly steps.
Solution Approach 2:
The circuit board performs multiple functions simultaneously: it serves as the electrical connection substrate, the heat dissipation structure, and the electrical insulation barrier. This multi-functionality eliminates the need for separate dedicated insulator components.
3Reliability
If multiple insulators and fastening components are used, then electrical isolation is ensured, but manufacturing costs increase
Solution Approach 1:
The patent merges the insulation function into the circuit board material itself, eliminating the need for separate insulator components. This reduces both the number of parts and the assembly complexity, directly lowering manufacturing costs while maintaining electrical isolation reliability.
4Ease of operation
If power switching elements are mounted on a separate PCB forming a power switching module, then assembly and maintenance are simplified, but heat dissipation efficiency must be maintained
Solution Approach 1:
The patent segments the power supply into modular units (primary and secondary circuit boards) that can be independently manufactured, tested, and assembled. This modularization simplifies assembly and maintenance while the secondary circuit board's design ensures adequate heat dissipation through its integrated structure.
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 reduces manufacturing costs and simplifies maintenance by allowing easy replacement and efficient heat dissipation, preventing overheating and reducing the complexity of assembly procedures.
Implementation Method 1
dissipating the heat generated by the power switching elements 11, 12 through the heat dissipating element 15
Implementation Method 2
a transformer that includes a primary coil, a secondary coil
Data Source
AI summary
A power supply device includes a main unit and a power switching module. The main unit includes a primary circuit board, a transformer including a primary and a secondary coil, a primary-side circuit and a secondary-side circuit. The power switching module includes a separate PCB formed with at least two connection pads and two conductive tracks, and at least one power switching element disposed on the PCB and having two terminals respectively connected to the two connection pads through the two conductive tracks. The power switching module is in the form of a separate PCB that is electrically connected to the primary- or secondary-side circuits through the two connection pads.