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Thermal INSULATOR Pad to Reduce Housing Temperature? (Desperate!)

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Mr. Scram:
Can you perhaps elaborate how you ended up in this situation with all kinds of parts tooled but before finalising the design? Perhaps we can learn from the situation.

German_EE:
Please see http://www.w6pql.com/images/2m/inside.jpg and http://www.w6pql.com/images/2m/leftside.jpg for examples. The active device is soldered to the copper heat spreader and then the whole assembly is bolted to a heatsink. Sure, it's a bit bigger than your power supply, but the principle of the heat spreader is the same.

TimNJ:

--- Quote from: Mr. Scram on August 18, 2019, 08:27:37 pm ---Can you perhaps elaborate how you ended up in this situation with all kinds of parts tooled but before finalising the design? Perhaps we can learn from the situation.

--- End quote ---

Ah, I thought I explained this earlier, but looks like not.

We have an existing product line (in production for about 2 years) which uses this housing and metal hardware. For this customer, we estimated that re-using the existing tooled hardware would be sufficient, since the power level is similar. However, it turns out that this power supply runs a little hotter on top of our customer being much more stringent (than most) on this specification

It was a gamble. Half the reason the customer chose us is because we hardly had any tooling costs in our quote. Unfortunately, did not have a say in that process. And now we are struggling to make this work.

SilverSolder:

It sounds like you are frustratingly close to making it work... 

Can power consumption be lowered somewhere else in the system to bring you over the goal line?  Usually you can always find a watt or two...

Mr. Scram:

--- Quote from: SilverSolder on August 19, 2019, 10:27:15 pm ---
It sounds like you are frustratingly close to making it work... 

Can power consumption be lowered somewhere else in the system to bring you over the goal line?  Usually you can always find a watt or two...

--- End quote ---
The opening post states efficiency has been maxed out for a while which suggests they've been looking.

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