Power Converter Having Multiple Layer Heat Sinks

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.

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.