Power supply full-brick module with internal inrush current limit circuit
A power converter comprises a power conversion circuit and a housing. The power conversion circuit comprises a voltage input, a voltage output, a first DC-DC voltage converter, and a second DC-DC voltage converter coupled to the first DC-DC voltage converter via a converter output bus. A first capacitor terminal is coupled to a first rail of the converter output bus and an inrush circuit coupled to a second rail of the converter output bus and coupled to a second capacitor terminal. The housing comprises a length no greater than 117.3 mm. The second capacitor terminal is coupled to the second rail only via the inrush circuit.
1 . A power converter comprising:
a power conversion circuit comprising:
a voltage input comprising a first input terminal and a second input terminal;
a voltage output comprising a first output terminal and a second output terminal;
a first DC-DC voltage converter coupled between the voltage input and the voltage output;
a second DC-DC voltage converter coupled to the first DC-DC voltage converter via a converter output bus and coupled to the voltage output;
a first capacitor terminal coupled to a first rail of the converter output bus;
an inrush circuit coupled to a second rail of the converter output bus and coupled to a second capacitor terminal; and
a housing within which the power conversion circuit is positioned;
wherein the housing comprises a length no greater than 117.3 mm.; and
wherein the second capacitor terminal is coupled to the second rail only via the inrush circuit.
2 . The power converter of claim 1 , wherein the housing further comprises:
a width no greater than 61.5 mm.; and
a height no greater than 14.5 mm.
3 . The power converter of claim 2 , wherein:
the length is no greater than 116.8 mm.+/−0.5 mm.;
the width is no greater than 61 mm.+/−0.5 mm.; and
the height is no greater than 14 mm.+/−0.5 mm.
4 . The power converter of claim 1 , wherein the inrush circuit comprises:
a controllable switch coupled between the second capacitor terminal and the second rail; and
a resistor bank comprising at least one resistor coupled between the second capacitor terminal and the second rail.
5 . The power converter of claim 4 , wherein the power conversion circuit further comprises a control system comprising a controller coupled to the controllable switch and configured to control the controllable switch into a conduction mode and into a non-conduction mode;
wherein, in the conduction mode, current flowing through the inrush circuit bypasses the resistor bank; and
wherein, in the non-conduction mode, current flowing through the inrush circuit flows through the resistor bank.
6 . The power converter of claim 5 , wherein the controller is further configured to control the controllable switch from the non-conduction mode to the conduction mode after a delay period, the delay period beginning in response to a voltage introduced at the voltage input.
7 . The power converter of claim 4 , wherein the at least one resistor comprises:
a first resistor having a first terminal coupled with the second capacitor terminal and a second terminal; and
a second resistor having a first terminal coupled with the second terminal of the first resistor and a second terminal coupled with the second rail.
8 . The power converter of claim 1 , wherein the first DC-DC voltage converter comprises a power factor correction (PFC) circuit.
9 . The power converter of claim 1 , wherein the housing comprises a full-brick form factor.
10 . The power converter of claim 1 , wherein the housing comprises:
a pair of input pins coupled to the first and second input terminals;
a pair of capacitor pins coupled to the first and second capacitor terminals; and
a pair of output pins coupled to the first and second output terminals.
11 . The power converter of claim 10 , wherein the housing further comprises:
a case; and
a baseplate;
wherein the pair of input pins, the pair of capacitor pins, and the pair of output pins extend from the baseplate and through the case.
12 . A power supply comprising:
a power supply chassis having an interior volume;
a power conversion system housed within the interior volume and comprising:
a voltage input configured to receive an input voltage from a voltage source;
a power factor correction (PFC) circuit configured to generate a first DC voltage based on the input voltage;
a resonant converter configured to generate a second DC voltage based on the first DC voltage;
a voltage output configured to supply the second DC voltage to a load;
a voltage bus coupled between the PFC circuit and the resonant converter;
a capacitor coupler coupled in series with an inrush circuit, wherein the capacitor coupler comprises a pair of capacitor connection terminals and wherein the series-coupled capacitor coupler and inrush circuit are coupled between first and second rails of the voltage bus;
a control system coupled to the inrush circuit and configured to control an inrush current via the inrush circuit; and
a bulk capacitor coupled to the capacitor connection terminals;
wherein a length of the power supply chassis is no greater than 117.3 mm.
13 . The power supply of claim 12 , wherein a width of the power supply chassis is no greater than 61.5 mm.; and
wherein a height of the power supply chassis is no greater than 14.5 mm.
14 . The power supply of claim 12 , wherein the power supply chassis further houses a bridge rectifier coupled between the voltage input and the PFC circuit and configured to convert an AC voltage into a third DC voltage.
15 . The power supply of claim 14 , wherein the control system comprises at least one controller coupled to the PFC circuit and configured to control a switch of the PFC circuit to convert the third DC voltage into the first DC voltage; and
wherein the first DC voltage is greater than the third DC voltage.
16 . The power supply of claim 15 , wherein the control system comprises at least one controller coupled to the resonant converter and configured to control a switch of the resonant converter to convert the first DC voltage into the second DC voltage; and
wherein the second DC voltage is lower than the first DC voltage.
17 . The power supply of claim 12 , wherein power supply chassis comprises:
a case defining the interior volume;
one or more control boards enclosed within the interior volume; and
a baseplate coupleable to the case to enclose the interior volume.
18 . The power supply of claim 17 , wherein power supply chassis comprises:
a pair of input pins extending from the baseplate and electrically coupled to the voltage input;
a pair of capacitor pins extending from the baseplate and electrically coupled to the capacitor coupler; and
a pair of output pins extending from the baseplate and electrically coupled to the voltage output.
19 . The power supply of claim 12 , wherein the inrush circuit comprises:
a controllable switch coupled between the capacitor coupler and the second rail of the voltage bus; and
a resistor bank coupled in parallel with the controllable switch and comprising at least one resistor.
20 . The power supply of claim 19 , wherein the control system comprises a controller configured to control the controllable switch between a non-conduction mode and a conduction mode to restrict inrush current flow through the bulk capacitor.