# US 7,613,021 B2 · Small form factor power supply > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,613,021 B2 - Document ID: US7613021B2 - Status: Granted - Kind: B2 - Application number: 12/074,212 - Filed: 2008-02-29 - Published: 2008-06-26 - Granted: 2009-11-03 - Earliest claimed: 1994-04-26 - Assignees: Comarco Wireless Technologies, Inc. - Inventors: Thomas W. Lanni - Web page: https://patentgrep.com/patent/US7613021B2 ## CPC - H02M 1/4258: {using a single converter stage both for correction of AC input power factor and generation of a regulated and galvanically isolated DC output voltage (H02M1/4241 takes precedence)} - G06F 1/26: Power supply means, e.g. regulation thereof (for memories G11C) - H01R 13/6675: {with built-in power supply} - H02J 7/02: for charging batteries from AC mains by converters - H02J 7/445: {in response to measured battery parameters, e.g. voltage, current or temperature profile} - H02J 7/485: {with provisions for charging different types of batteries} - H02J 7/865: {Battery or charger load switching, e.g. concurrent charging and load supply (H02J7/50 takes precedence)} - H02M 3/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections} - H02M 3/156: with automatic control of output voltage or current, e.g. switching regulators - H02M 3/28: using discharge tubes with control electrode or semiconductor devices with control electrode to produce the intermediate AC - H02M 3/33507: {with automatic control of the output voltage or current, e.g. flyback converters (H02M3/33561, H02M3/33569 take precedence)} - H02M 3/33523: {with galvanic isolation between input and output of both the power stage and the feedback loop} - H02M 3/3372: {of the parallel type} - H02M 3/3378: {in a push-pull configuration of the parallel type (H02M3/3374 takes precedence)} - H02M 3/3382: {in a push-pull circuit arrangement} - H02M 3/3387: {in a push-pull configuration} - H02M 7/003: {Constructional details, e.g. physical layout, assembly, wiring or busbar connections} - H05K 1/165: {incorporating printed inductors} - H01F 27/2819: {Planar transformers with printed windings, e.g. surrounded by two cores and to be mounted on printed circuit} - H01R 13/24: resilient; resiliently-mounted - H01R 2201/16: for telephony - H01R 2201/24: for radio transmission - H02J 2207/20: Charging or discharging characterised by the power electronics converter - H05K 1/0203: {Cooling of mounted components (H05K1/0272 takes precedence)} - H05K 1/0262: {Arrangements for regulating voltages or for using plural voltages} - H05K 1/029: {having a programmable lay-out, i.e. adapted for choosing between a few possibilities} - H05K 1/16: incorporating printed electric components, e.g. printed resistors, capacitors or inductors - H05K 2201/086: for inductive purposes, e.g. printed inductor with ferrite core - H05K 2201/09063: Holes or slots in insulating substrate not used for electrical connections - Y02B 40/00: Technologies aiming at improving the efficiency of home appliances, e.g. induction cooking or efficient technologies for refrigerators, freezers or dish washers - Y02B 70/10: Technologies improving the efficiency by using switched-mode power supplies [SMPS], i.e. efficient power electronics conversion e.g. power factor correction or reduction of losses in power supplies or efficient standby modes - H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P) - G06F: ELECTRIC DIGITAL DATA PROCESSING (computer systems based on specific computational models G06N) - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - H02J: ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY - H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS - H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES - Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS ## Abstract A small form factor power supply includes a switching transformer, control circuitry and rectifier circuitry, each contained within a housing. The switching transformer has a planar core and windings which surround at least a portion of the planar core. The control circuitry includes at least one surface mounted component, to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency. The rectifier circuitry is coupled to a secondary of the switching transformer to provide a DC voltage. The housing contains the switching transformer, the control circuitry and the rectifier circuitry, wherein a height of the housing is not greater than 0.75 inches. ## Claims ### Claim 1 A small form factor power supply comprising: a switching transformer having a planar core and windings which surround at least a portion of the planar core; control circuitry, including at least one surface mounted component, to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, wherein a thickness of the housing is not greater than 0.436 inches. ### Claim 2 (depends on 1) The small form factor power supply of claim 1, wherein the planar core is an “E” type core. ### Claim 3 (depends on 1) The small form factor power supply of claim 1, wherein the rectifier circuitry includes at least one surface mounted component. ### Claim 4 (depends on 1) The small form factor power supply of claim 1 further including a circuit board having a cutout through which the planar core extends. ### Claim 5 (depends on 4) The small form factor power supply of claim 4, wherein the windings are formed by wiring traces on the printed circuit board. ### Claim 6 (depends on 5) The small form factor power supply of claim 5, wherein the at least one surface mounted component is mounted to the printed circuit board. ### Claim 7 A small form factor power supply comprising: a switching transformer having a low profile core and windings which surround at least a portion of the low profile core; control circuitry, including at least one surface mounted component, to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, wherein a thickness of the housing is not greater than about 0.436 inches. ### Claim 8 (depends on 7) The small form factor power supply of claim 7, wherein the low profile core is an “E” type core. ### Claim 9 (depends on 7) The small form factor power supply of claim 7, wherein the rectifier circuitry includes at least one surface mounted component. ### Claim 10 (depends on 7) The small form factor power supply of claim 7 further including a circuit board having a cutout through which the low profile core extends. ### Claim 11 (depends on 10) The small form factor power supply of claim 10, wherein the windings are formed by wiring traces on the printed circuit board. ### Claim 12 (depends on 11) The small form factor power supply of claim 11, wherein the at least one surface mounted component is mounted to the printed circuit board. ### Claim 13 A small form factor power supply comprising: a switching transformer having a planar core and windings which surround at least a portion of the planar core; control circuitry, including at least one surface mounted component, to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, wherein a thickness of the housing is not greater than about 0.436 inches and a volume of the housing is not greater than about 5.4 cubic inches. ### Claim 14 (depends on 13) The small form factor power supply of claim 13, wherein the planar core is an “E” type core. ### Claim 15 (depends on 13) The small form factor power supply of claim 13, wherein the rectifier circuitry includes at least one surface mounted component. ### Claim 16 (depends on 13) The small form factor power supply of claim 13 further including a circuit board having a cutout through which the planar core extends. ### Claim 17 (depends on 16) The small form factor power supply of claim 16, wherein the windings are formed by wiring traces on the printed circuit board. ### Claim 18 (depends on 17) The small form factor power supply of claim 17, wherein the at least one surface mounted component is mounted to the printed circuit board. ### Claim 19 A small form factor power supply comprising: a switching transformer having a low profile core and windings which surround at least a portion of the low profile core; control circuitry, including at least one surface mounted component, to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, wherein a thickness of the housing is not greater than 0.436 inches and a volume of the housing is not greater than about 5.4 cubic inches. ### Claim 20 (depends on 19) The small form factor power supply of claim 19, wherein the low profile core is an “E” type core. ### Claim 21 (depends on 19) The small form factor power supply of claim 19, wherein the rectifier circuitry includes at least one surface mounted component. ### Claim 22 (depends on 19) The small form factor power supply of claim 19 further including a circuit board having a cutout through which the low profile core extends. ### Claim 23 (depends on 22) The small form factor power supply of claim 22, wherein the windings are formed by wiring traces on the printed circuit board. ### Claim 24 (depends on 23) The small form factor power supply of claim 23, wherein the at least one surface mounted component is mounted to the printed circuit board. ### Claim 25 A small form factor power supply comprising: a switching transformer having a planar core and windings which surround at least a portion of the planar core; control circuitry to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, the housing having a thickness and top and bottom surface areas, wherein a ratio of the top and bottom surface area to the thickness is at least about 56:1. ### Claim 26 A small form factor power supply comprising: a switching transformer having a planar core and windings which surround at least a portion of the planar core; control circuitry to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, the housing having a thickness and top and bottom surface areas, wherein a ratio of the top or bottom surface area to the thickness is at least about 28:1. ### Claim 27 A small form factor power supply comprising: a switching transformer having a planar core and windings which surround at least a portion of the planar core; control circuitry to control a switching device to couple a source of DC power to a primary of the switching transformer at a switching frequency; rectifier circuitry coupled to a secondary of the switching transformer to provide a DC voltage; and a housing containing the switching transformer, the control circuitry and the rectifier circuitry, the housing having a thickness and top and bottom surface areas, wherein the thickness of the housing is not greater than about 0.436 inches and a ratio of the top or bottom surface area to the thickness is at least about 28:1. ### Claim 28 A small form factor power supply comprising: a switching transformer having a low profile core and primary and secondary coils; a printed circuit board adapted to have circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns that are coupled to the primary and secondary coils of the switching transformer that are magnetically coupled to the low profile core; a rectifier circuit that is coupled to the secondary coil to provide a DC power source capable of delivering at least seventy five watts; and a housing enclosing the switching transformer, the printed circuit board, the rectifier circuit, and the circuit components, wherein the product of the length and width of the housing is less than approximately fourteen square inches. ### Claim 29 A small form factor power supply comprising: a switching transformer having a low profile core and primary and secondary coils; a printed circuit board adapted to have circuit components mounted thereon, wherein the printed circuit board defines certain wiring patterns that are coupled to the primary and secondary coils of the switching transformer that are magnetically coupled to the low profile core; a rectifier circuit that is coupled to the secondary coil to provide a DC power source capable of delivering at least seventy five watts; and a housing enclosing the switching transformer, the printed circuit board, the rectifier circuit, and the circuit components, wherein a volume of the housing is not greater than about 6.1 cubic inches.