US20090237889A1 - Power Converter Having Multiple Layer Heat Sinks - Google Patents
Power Converter Having Multiple Layer Heat Sinks Download PDFInfo
- Publication number
- US20090237889A1 US20090237889A1 US12/411,225 US41122509A US2009237889A1 US 20090237889 A1 US20090237889 A1 US 20090237889A1 US 41122509 A US41122509 A US 41122509A US 2009237889 A1 US2009237889 A1 US 2009237889A1
- Authority
- US
- United States
- Prior art keywords
- power converter
- heat sink
- layer
- power
- heat
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
- H05K1/0203—Cooling of mounted components
- H05K1/0204—Cooling of mounted components using means for thermal conduction connection in the thickness direction of the substrate
- H05K1/0206—Cooling of mounted components using means for thermal conduction connection in the thickness direction of the substrate by printed thermal vias
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0201—Thermal arrangements, e.g. for cooling, heating or preventing overheating
- H05K1/0203—Cooling of mounted components
- H05K1/0209—External configuration of printed circuit board adapted for heat dissipation, e.g. lay-out of conductors, coatings
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0296—Conductive pattern lay-out details not covered by sub groups H05K1/02 - H05K1/0295
- H05K1/0298—Multilayer circuits
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09209—Shape and layout details of conductors
- H05K2201/0929—Conductive planes
- H05K2201/09363—Conductive planes wherein only contours around conductors are removed for insulation
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/09—Shape and layout
- H05K2201/09209—Shape and layout details of conductors
- H05K2201/09654—Shape and layout details of conductors covering at least two types of conductors provided for in H05K2201/09218 - H05K2201/095
- H05K2201/09781—Dummy conductors, i.e. not used for normal transport of current; Dummy electrodes of components
Definitions
- the present invention is generally related to power converters, and more particularly to power converters adapted to power portable electronic devices.
- Power converters are typically used to power and/or recharge the batteries of portable electronic devices including notebook computers, PDA's, MP3 players, digital cameras, and wireless phones just to name a few. Some of the portable electronic devices are configured to require a significant amount of power, with some notebook computers now consuming up to 140 watts.
- the present invention achieves technical advantages as a power converter including a printed circuit board (PCB) having a plurality of heat conductive layers configured to sink heat generated by the power converter electronics.
- PCB printed circuit board
- Each of these layers are comprised of thermally conductive material configured as planar sheets, each of these thermal layers being coupled to at least one wire to sink heat therefrom, such as via a wire of an input cable and/or output cable.
- a more compact power converter is realized having improved power output while operating within safety guidelines.
- FIG. 1 is an exploded perspective view of a power converter including a printed circuit board having multiple thermal planes;
- FIG. 2 is a top view of a circuit component layer
- FIGS. 3A-3B are top views of thermal material layers forming a second and third layer of the printed circuit board shown in FIG. 1 .
- FIG. 1 there is shown at 10 an exploded perspective view of a power converter having a multiple layer printed circuit board 11 including layers 12 , 14 , 16 and 18 .
- Top layer 12 includes electrical traces and electrical components forming the power converter circuitry 20 .
- Disposed thereunder is shown two thermally conductive layers 14 and 16 that are spatially separated from one another, and from the electronics layer 12 , each adapted to sink heat from the first layer during operation of the circuitry 20 .
- Lower layer 18 is also comprised of components forming another stage of the power converter, or adding to the power converter shown in 20 and serves to operate as a separate power stage altogether, or an adjoining power stage 20 .
- FIG. 2 there is shown a top view of the first layer, 14 , seen to include electrically conductive traces and pads for receiving suitable electronic components and interconnecting the same. Further shown are pluralities of vias shown at 22 , the vias are electrically and thermally coupled to the underlying second and third layers and to the first layer 14 with the common vias being shown at 22 .
- these second and third heat sink layers are comprised of a thermally conductive material, such as a metal, and preferably, a highly thermally conductive material such as copper, although other materials are suitable and within the scope of this invention.
- the pluralities of heat sink layers are provided in the common printed circuit board 11 as shown in FIG. 1 .
- each of these second and third layers are physically separated from each other, but electrically and thermally coupled to each other to sink heat from the first layer, and to efficiently balance and distribute heat therebetween.
- an input cable 30 and an output cable 40 each coupled to the circuitry 20 of first layer 12 to provide power thereto, and provide therefrom, respectively.
- At least two electrical conductors are provided in each cable 30 and 40 to provide the power thereto, which power may be an AC or DC power.
- at least one thermally conductive member 32 and 42 preferably a copper wire, is included in respective cable 30 and 40 to facilitate sinking heat from the second and third thermally conductive layers 14 and 16 away from power converter 10 .
- heat may be sunk via input cable 30 to the power source, and heat may also be sunk via output cable 40 to the portable electronic device to be powered.
- the power converter 10 can be disposed in a housing, (not shown) that has a very thin profile and small overall area. A significant amount of power can be converted using power converter 10 , with the generated heat being universally dispersed to the multiple heat sink layers 14 and 16 without generating a hot spot to the encompassing housing such that power converter 10 operates within safety guidelines, such as those established by UL Laboratories.
- power converter 10 may comprise a 90 watt power converter operating at 90% efficiency, whereby the dimensions of the printed circuit board may be 2.48 by 2.48 inches, disposed in a housing having a thickness of no greater than 0.55 inches and operating less than 85 degrees Celsius.
- the thermal distribution of the inner layer heat sinks and the heat sinking of the input and output cable allows the power supply to become more like the ideal thermal model in which all heat is uniformly distributed allowing the power supply to dissipate more heat to the environment, thus staying cooler.
- This design further achieves technical advantages in that the thermal heat sinking properties can be consistently replicated during 5 manufacturing, which provides improved quality control and fewer defective units during manufacturing.
Abstract
A power converter including a printed circuit board (PCB) having a plurality of heat conductive layers configured to sink heat generated by the power converter electronics. Each of these heat conductive layers are comprised of thermally conductive material configured as planar sheets, each of these heat conductive layers being coupled to at least one wire to sink heat therefrom, such as via a wire of an input cable and/or output cable. Advantageously, a more compact power converter is realized having improved power output while operating within safety guidelines.
Description
- This application is a continuation of, and claims priority to U.S. patent application Ser. No. 11/344,507 filed Jan. 31, 2006.
- The present invention is generally related to power converters, and more particularly to power converters adapted to power portable electronic devices.
- Power converters are typically used to power and/or recharge the batteries of portable electronic devices including notebook computers, PDA's, MP3 players, digital cameras, and wireless phones just to name a few. Some of the portable electronic devices are configured to require a significant amount of power, with some notebook computers now consuming up to 140 watts.
- At the same time, portable electronic device users are demanding that these power converters be smaller and smaller. The miniaturization of these power supplies is constrained by the amount of heat generated during the power conversion, such as in a DC/DC converter, AC/DC converter, DC/AC converter, and an AC/AC converter. Improved efficiency of the power conversion is one way to reduce the heat generated by the power converter. More efficient heat transfer devices are also being designed to better sink generated heat and release it to the ambient. Heat fans and cooling fins are just some types of cooling designs to keep the power converter operating within safe limits, such as established by numerous safety agencies including UL Laboratories.
- The present invention achieves technical advantages as a power converter including a printed circuit board (PCB) having a plurality of heat conductive layers configured to sink heat generated by the power converter electronics. Each of these layers are comprised of thermally conductive material configured as planar sheets, each of these thermal layers being coupled to at least one wire to sink heat therefrom, such as via a wire of an input cable and/or output cable. Advantageously, a more compact power converter is realized having improved power output while operating within safety guidelines.
-
FIG. 1 is an exploded perspective view of a power converter including a printed circuit board having multiple thermal planes; -
FIG. 2 is a top view of a circuit component layer; and -
FIGS. 3A-3B are top views of thermal material layers forming a second and third layer of the printed circuit board shown inFIG. 1 . - Referring now to
FIG. 1 there is shown at 10 an exploded perspective view of a power converter having a multiple layer printedcircuit board 11 includinglayers Top layer 12 includes electrical traces and electrical components forming thepower converter circuitry 20. Disposed thereunder is shown two thermallyconductive layers electronics layer 12, each adapted to sink heat from the first layer during operation of thecircuitry 20.Lower layer 18 is also comprised of components forming another stage of the power converter, or adding to the power converter shown in 20 and serves to operate as a separate power stage altogether, or anadjoining power stage 20. - Referring now to
FIG. 2 , there is shown a top view of the first layer, 14, seen to include electrically conductive traces and pads for receiving suitable electronic components and interconnecting the same. Further shown are pluralities of vias shown at 22, the vias are electrically and thermally coupled to the underlying second and third layers and to thefirst layer 14 with the common vias being shown at 22. Preferably, these second and third heat sink layers are comprised of a thermally conductive material, such as a metal, and preferably, a highly thermally conductive material such as copper, although other materials are suitable and within the scope of this invention. - Advantageously, the pluralities of heat sink layers are provided in the common printed
circuit board 11 as shown inFIG. 1 . In addition, each of these second and third layers are physically separated from each other, but electrically and thermally coupled to each other to sink heat from the first layer, and to efficiently balance and distribute heat therebetween. - Referring back to
FIG. 1 , there is shown aninput cable 30 and anoutput cable 40 each coupled to thecircuitry 20 offirst layer 12 to provide power thereto, and provide therefrom, respectively. At least two electrical conductors are provided in eachcable conductive member respective cable conductive layers power converter 10. Thus, heat may be sunk viainput cable 30 to the power source, and heat may also be sunk viaoutput cable 40 to the portable electronic device to be powered. - Advantageously, due to the multiple heat sink layers, the
power converter 10 can be disposed in a housing, (not shown) that has a very thin profile and small overall area. A significant amount of power can be converted usingpower converter 10, with the generated heat being universally dispersed to the multipleheat sink layers power converter 10 operates within safety guidelines, such as those established by UL Laboratories. - By way of example,
power converter 10 may comprise a 90 watt power converter operating at 90% efficiency, whereby the dimensions of the printed circuit board may be 2.48 by 2.48 inches, disposed in a housing having a thickness of no greater than 0.55 inches and operating less than 85 degrees Celsius. The thermal distribution of the inner layer heat sinks and the heat sinking of the input and output cable allows the power supply to become more like the ideal thermal model in which all heat is uniformly distributed allowing the power supply to dissipate more heat to the environment, thus staying cooler. - This design further achieves technical advantages in that the thermal heat sinking properties can be consistently replicated during 5 manufacturing, which provides improved quality control and fewer defective units during manufacturing.
- Though the invention has been described with respect to a specific preferred embodiment, many variations and modifications will become apparent to those skilled in the art upon reading the present application. It is therefore the intention that the appended claims be interpreted as broadly as possible in view of the prior art to include all such variations and modifications.
Claims (8)
1.-6. (canceled)
7. A power converter comprising:
a printed circuit board (PCB) forming a first layer of the power converter;
a second heat sink layer spaced apart from a third heat sink second layer, wherein the second heat sink layer and the third heat sink layer each comprise a thermally conductive material;
a thermally conductive member thermally coupled to each of the second and third heat sink layers and configured to draw heat from the PCB to the second and third heat sink layers;
wherein the second heat sink layer and the third heat sink layer are separated from each other by an electrically non-conductive material, and are each thermally coupled to the PCB by a plurality of vias extending through the electrically non-conductive material.
8. The power converter of claim 7 , wherein the thermally conductive member comprises a wire.
9. The power converter of claim 8 , wherein the electrical circuit has an input configured to receive power, further comprising an input cable coupled to the input and including the wire.
10. The power converter of claim 9 , wherein the electrical circuit has an output configured to provide output power, further comprising an output cable coupled to the output and further including a wire thermally coupled to each of the heat sink layers.
11. The power converter of claim 7 , wherein the thermally conductive material of the second heat sink layer and the third heat sink layer is metal.
12. The power converter of claim 11 , wherein the metal is copper.
13. The power converter of claim 7 , wherein the PCB comprises electrical traces and electrical components.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/411,225 US20090237889A1 (en) | 2006-01-31 | 2009-03-25 | Power Converter Having Multiple Layer Heat Sinks |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11/344,507 US7525803B2 (en) | 2006-01-31 | 2006-01-31 | Power converter having multiple layer heat sinks |
US12/411,225 US20090237889A1 (en) | 2006-01-31 | 2009-03-25 | Power Converter Having Multiple Layer Heat Sinks |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/344,507 Continuation US7525803B2 (en) | 2006-01-31 | 2006-01-31 | Power converter having multiple layer heat sinks |
Publications (1)
Publication Number | Publication Date |
---|---|
US20090237889A1 true US20090237889A1 (en) | 2009-09-24 |
Family
ID=38320904
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/344,507 Expired - Fee Related US7525803B2 (en) | 2006-01-31 | 2006-01-31 | Power converter having multiple layer heat sinks |
US12/411,225 Abandoned US20090237889A1 (en) | 2006-01-31 | 2009-03-25 | Power Converter Having Multiple Layer Heat Sinks |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/344,507 Expired - Fee Related US7525803B2 (en) | 2006-01-31 | 2006-01-31 | Power converter having multiple layer heat sinks |
Country Status (1)
Country | Link |
---|---|
US (2) | US7525803B2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180177038A1 (en) * | 2015-12-18 | 2018-06-21 | Lg Chem, Ltd. | Printed circuit board heat dissipation system using highly conductive heat dissipation pad |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7646107B2 (en) | 2004-09-30 | 2010-01-12 | Targus Group Internatnional, Inc. | Programmable power adaptor |
FI20125384L (en) * | 2012-04-04 | 2013-10-05 | Tellabs Oy | A system with a solder joint |
US9917224B2 (en) * | 2012-05-29 | 2018-03-13 | Essence Solar Solutions Ltd. | Photovoltaic module assembly |
US8821199B2 (en) | 2012-07-25 | 2014-09-02 | Targus Group International, Inc. | Multi-prong power tip adaptor |
US8550827B1 (en) | 2012-07-25 | 2013-10-08 | Targus Group International, Inc. | Multi-sleeve power tips |
Citations (6)
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US6129598A (en) * | 1997-06-23 | 2000-10-10 | Delta Electronic, Inc. | Printed-circuit-board (PCB) in a power supply system includes integrated cable connection terminals |
US20040144561A1 (en) * | 2002-12-27 | 2004-07-29 | Hideyo Osanai | Metal/ceramic bonding substrate and method for producing same |
US20040207989A1 (en) * | 2003-04-18 | 2004-10-21 | International Business Machines Corporation | System and method for improving power distribution current measurement on printed circuit boards |
US20060073664A1 (en) * | 2004-10-05 | 2006-04-06 | Masao Kondo | Semiconductor device and manufacturing method of the same |
US20060228825A1 (en) * | 2005-04-08 | 2006-10-12 | Micron Technology, Inc. | Method and system for fabricating semiconductor components with through wire interconnects |
US20070227761A1 (en) * | 2004-04-27 | 2007-10-04 | Imbera Electronics Oy | Heat Conduction From an Embedded Component |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6433274B1 (en) * | 2000-01-06 | 2002-08-13 | Mobility Electronic, Inc. | Power converter device |
EP1148547B8 (en) * | 2000-04-19 | 2016-01-06 | Denso Corporation | Coolant cooled type semiconductor device |
US6651322B1 (en) * | 2000-12-28 | 2003-11-25 | Unisys Corporation | Method of reworking a multilayer printed circuit board assembly |
JP2002359329A (en) * | 2001-05-30 | 2002-12-13 | Hitachi Ltd | Semiconductor device |
US6778405B2 (en) * | 2001-09-25 | 2004-08-17 | Innoveta Technologies | Power module adapter |
JP3932259B2 (en) * | 2001-12-12 | 2007-06-20 | 株式会社ルネサステクノロジ | High frequency power amplifier circuit and electronic component for wireless communication |
US6982873B2 (en) * | 2002-01-16 | 2006-01-03 | Rockwell Automation Technologies, Inc. | Compact vehicle drive module having improved thermal control |
US7292451B2 (en) * | 2003-12-17 | 2007-11-06 | Siemens Vdo Automotive Corporation | Architecture for power modules such as power inverters |
-
2006
- 2006-01-31 US US11/344,507 patent/US7525803B2/en not_active Expired - Fee Related
-
2009
- 2009-03-25 US US12/411,225 patent/US20090237889A1/en not_active Abandoned
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6129598A (en) * | 1997-06-23 | 2000-10-10 | Delta Electronic, Inc. | Printed-circuit-board (PCB) in a power supply system includes integrated cable connection terminals |
US20040144561A1 (en) * | 2002-12-27 | 2004-07-29 | Hideyo Osanai | Metal/ceramic bonding substrate and method for producing same |
US20040207989A1 (en) * | 2003-04-18 | 2004-10-21 | International Business Machines Corporation | System and method for improving power distribution current measurement on printed circuit boards |
US20070227761A1 (en) * | 2004-04-27 | 2007-10-04 | Imbera Electronics Oy | Heat Conduction From an Embedded Component |
US20060073664A1 (en) * | 2004-10-05 | 2006-04-06 | Masao Kondo | Semiconductor device and manufacturing method of the same |
US20060228825A1 (en) * | 2005-04-08 | 2006-10-12 | Micron Technology, Inc. | Method and system for fabricating semiconductor components with through wire interconnects |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20180177038A1 (en) * | 2015-12-18 | 2018-06-21 | Lg Chem, Ltd. | Printed circuit board heat dissipation system using highly conductive heat dissipation pad |
US10314159B2 (en) * | 2015-12-18 | 2019-06-04 | Lg Chem, Ltd. | Printed circuit board heat dissipation system using highly conductive heat dissipation pad |
Also Published As
Publication number | Publication date |
---|---|
US20070175655A1 (en) | 2007-08-02 |
US7525803B2 (en) | 2009-04-28 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |