Why Choose a Modular Power Converter?

1. Preface

2. Miniaturization of size saves a lot of system space

3. Easy power upgrade

4. Optimizing overall electrical performance

5. Optimizing overall electrical performance

6. Wide operating temperature range and sturdy mechanism tolerance

7. Save additional costs

8. Summary

Preface

Whether to use discrete or modular power converters is a common issue faced by engineers, and the most easily confused problem lies in the PCB space occupied and power density provided by the power converter. If there are differences in these requirements, the cost will vary greatly correspondingly.

However, nowadays most companies do not plan resources or establish teams to develop power converters for specific needs. Instead, they may assign component engineers responsible for the project to find power converters suitable for their applications. Therefore, how to solve urgent problems in limited time and resources is even more important for engineers and power supply manufacturers.

With more and more application scenarios and the trend towards miniaturization, power converters are often required to provide better overall electrical performance and higher power in smaller sizes. In response to this demand, modular power converters have become the first choice for many engineers. However, we must also admit that if we strictly examine the BOM, modular power supplies are usually much more expensive than discrete ones. If this development team needs to handle many different application scenarios at the same time, it will result in huge design costs.

In a word, using modular power converters usually comes with higher costs, but also more benefits. MINMAX's products all adopt modular design and have over 30 years of experience and technology, making us experts in the field of power modularization. We provide isolated DC-DC power converters ranging from 1 to 150 watts and isolated AC-DC power supplies ranging from 3 to 60 watts. MINMAX always adheres to the concept of "pursuing miniaturization" and continues to create maximum benefits for customers in the field of modular power supply. Next, let us explain to you what benefits can power modularization bring to you

Miniaturization of size saves a lot of system space

MINMAX is committed to the miniaturization design of power modules, achieving high integration through continuous improvement in wiring design and the selection of high-performance miniaturized components. After years of specialized research, MINMAX's power module has reduced the product area by up to 75% compared to the past, while maintaining the same output power. The power density has also been increased to 150W/in3. In the case of limited PCB design space for customers, we believe that MINMAX's modular power supply is the preferred solution.

Figure 1- Adopting modular power supply can significantly save design space in the system

Easy power upgrade

The power modules of MINMAX are all assembled in industry standard form. If customers have a need to upgrade the system power in the future, they can replace it with higher or lower output power without rewiring, and quickly complete the upgrade. And MINMAX's rich product line allows customers to have a variety of output power options to choose from within the same packaging size.

Figure 2- Easily upgrade system power without rewiring, saving time and effort

Optimizing overall electrical performance

In order to reduce the complexity and uncertainty for the system designers, MINMAX takes factors such as low/high line, empty/full load, low/high temperature into consideration when designing modular power supplies, and utilizes advanced technologies such as active clamping, synchronous rectification, and energy-saving circuit technology, etc., so that the power module can maintain excellent electrical performance under drastic changes, thereby achieving overall efficiency and thermal performance optimization, no need for minimum load, low power consumption, low ripple and noise, etc.

Figure 3- The power module designed by MINMAX can provide overall optimized electrical performance

Optimization of Thermal Design

The power module of MINMAX uses high thermal conductivity adhesive and high thermal conductivity metal shell in raw materials, coupled with advanced electronic circuit design and optimized circuit board distribution design, which can quickly transfer thermal energy during operation, improve overall power module efficiency and thermal performance, and provide the best solution for customers considering harsh working environments.

Figure 4- Optimized thermal structure design can improve overall power module efficiency and thermal performance

Wide operating temperature range and sturdy mechanism tolerance

The power module of MINMAX can achieve a wider working environment temperature range and maintain long-term operation through optimized thermal design, as well as to maintain efficient electrical performance. MINMAX's railway power module must undergo more than 500 temperature cycling tests (TCT) to simulate the working environment of the product under extreme temperature conditions, with a high and low temperature difference of up to 165 ℃. This is the best solution for customers considering firmness, reliability, and durability.

Figure 5.1- Optimized thermal structure design that provides a wider operating temperature range and wider applications

Figure 5.2- Ensuring product reliability and durability through over 500 temperature cycle tests (TCT)

Save additional costs

The power modules of MINMAX have passed international safety certification and relevant product reliability testing, so customers do not need to spend extra time and cost on the tedious process. In addition, by adopting modular power supplies, customers no longer need to spend a huge amount of money to cultivate a power development team, allowing the company's R&D units to focus more on their business, and also eliminating delivery time and material preparation troubles for customers. MINMAX's power solutions can solve all your pain points at once.

Summary

Design	Modular power supply	Discrete power supply
Save costs for more benefits	High	Low
Saved PCB space	More	Low
Fast upgrade compatibility	High	Low
Optimization of thermal performance design	Good	Poor
Operating environment temperature range	Wider	Narrow
Overall design considerations	Good	Poor
Overall electrical performance	Good	Poor