Mechanical enclosure
A mechanical enclosure for a power converter is disclosed. In some embodiments, the mechanical enclosure comprises a base; a first compartment configured for receiving one or more electronic devices; and a second compartment configured for receiving a magnetic device, the second compartment formed by a cavity protruding from a bottom surface of the base.
1 . A mechanical enclosure for a power converter, the enclosure comprising:
a base comprising a level surface;
a first compartment configured for receiving one or more electronic devices above the level surface of the base;
a second compartment configured for receiving a magnetic device, the second compartment formed by a cavity recessed below the level surface of the base;
a cover in the first compartment configured to completely seal the magnetic device within the cavity; and
a first set of cooling fins and a second set of cooling fins, wherein the first set of cooling fins is perpendicular to the second set of fins.
2 . The mechanical enclosure of claim 1 , further comprising:
one or more cooling systems, the one or more cooling systems comprising:
a first cooling system, operatively connected to an outer surface of the first compartment, the first cooling system configured for cooling the first compartment; and
a second cooling system, operatively connected to an outer surface of the second compartment, the second cooling system configured for cooling the second compartment.
3 . The mechanical enclosure of claim 2 , wherein the one or more cooling systems comprise the first set of cooling fins and the second set of cooling fins.
4 . The mechanical enclosure of claim 2 , further comprising a fan configured to drive air through the one or more cooling systems.
5 . The mechanical enclosure of claim 1 , wherein the first set of cooling fins protrudes from an outer side of the level surface of the base.
6 . The mechanical enclosure of claim 1 , wherein the second set of cooling fins protrudes from an outer wall of the cavity.
7 . The mechanical enclosure of claim 6 , wherein the second set of cooling fins comprises two discrete sections disposed on opposite ends of an outer wall of the cavity.
8 . The mechanical enclosure of claim 1 , wherein the cavity is entirely recessed below the level surface of the base.
9 . A method for manufacturing a mechanical enclosure for a power converter, the method comprising:
providing a base comprising a level surface;
providing a first compartment for receiving one or more electronic devices above the level surface of the base;
providing a second compartment for receiving a magnetic device, the second compartment formed by a cavity recessed below the level surface of the base; and
a cover in the first compartment configured to completely seal the magnetic device within the cavity; and
a first set of cooling fins and a second set of cooling fins, wherein the first set of cooling fins is perpendicular to the second set of fins.
10 . The method of claim 9 , further comprising:
providing one or more cooling systems, the one or more cooling systems comprising:
a first cooling system, operatively connected to an outer surface of the first compartment, the first cooling system configured for cooling the first compartment; and
a second cooling system, operatively connected to an outer surface of the second compartment, the second cooling system configured for cooling the second compartment.
11 . The method of claim 10 , wherein the one or more cooling systems comprise the first set of cooling fins and the second set of cooling fins.
12 . The method of claim 10 , further comprising:
providing a fan for driving air through the one or more cooling systems.
13 . The method of claim 9 , wherein the first set of cooling fins protrudes from an outer side of the level surface of the base.
14 . The method of claim 9 , wherein the second set of cooling fins protrudes from an outer wall of the cavity.
15 . The method of claim 9 , wherein the magnetic device is pre-potted, and wherein providing the second compartment for receiving the magnetic device comprises providing the second compartment for receiving the pre-potted magnetic device within a housing, the housing having one or more pegs configured to support the pre-potted magnetic device within the cavity of the enclosure.
16 . A method for assembling a mechanical enclosure for a power converter, the method comprising:
providing a base comprising a level surface;
providing a first compartment for receiving one or more electronic devices above the level surface of the base;
providing a second compartment for receiving a magnetic device, the second compartment formed by a cavity recessed below the level surface of the base;
providing a cover in the first compartment configured to completely seal the magnetic device within the cavity;
providing a first set of cooling fins and a second set of cooling fins, wherein the first set of cooling fins is perpendicular to the second set of fins:
pre-potting the magnetic device;
placing the pre-potted magnetic device in the cavity;
filling the remaining gap of cavity with additional potting material; and
assembling the one or more or more electronic devices in the first compartment.