Patent Description:
Power distribution units ("PDUs") distribute electric power to devices that are electrically connected to the PDU. The PDU includes a connection to a three-phase busway, and a plurality of components to provide, regulate, and monitor the current being distributed to the devices. Some examples of the components used in such a PDU include input modules, outlet modules, circuit breakers, and sensors. As electrical current passes through the PDU, one or more features of the PDU can increase in temperature. Exposure to increased temperatures can degrade or destroy some components within the PDU and can cause the PDU to be unsafe or ineffective for its intended purpose. Accordingly, for safe and effective distribution of electric power, structures for dissipating heat within a PDU are needed. <CIT>relates to a socket terminal heat-dissipating mechanism provided for use in an electronic device. The electronic device includes a frame and a casing. The Socket terminal heat-dissipating mechanism includes a Socket and an insulating layer. The socket is mounted in the frame of the electronic device, and includes a contact terminal. The insulating layer is arranged between the contact terminal and the casing of the electronic device, wherein heat energy is conducted from the contact terminal of the Socket to the casing through the insulating layer, and passively dissipated away.

In one embodiment, a PDU includes an input module. The PDU includes an electrical connector configured to be connected to an outlet of a power source to provide power to the input module. The PDU includes an outlet module, and the input module is configured to distribute the power from the electrical connector to the outlet module. The outlet module includes an outlet assembly including an outlet having a shroud protruding from a bottom side of the outlet and a pin extending from the shroud. The outlet assembly includes a heat dissipating structure having a wall with an inner surface facing an outer surface of the shroud. The outlet assembly includes a thermal pad positioned between the shroud and the wall, with a first side surface of the thermal pad abutting the outer surface of the shroud and a second side surface of the thermal pad abutting the inner surface of the wall of the heat dissipating structure.

In another embodiment, an outlet assembly includes a chassis including an opening. The outlet assembly includes an outlet positioned in the opening with a face defining a receptacle facing away from the outlet assembly. The outlet has a plurality of pins extending from a bottom side of the outlet. The outlet assembly includes a heat dissipating structure extending from the chassis in a direction toward the plurality of pins past the bottom side of the outlet. The heat dissipating structure includes a wall with an inner surface facing an outer surface of at least one pin of the plurality of pins. The outlet assembly includes a thermal pad positioned between the at least one pin and the wall.

In yet another embodiment, an outlet assembly includes an outlet having a pin extending from a bottom side of the outlet. The outlet assembly includes a heat dissipating structure having a wall with an inner surface facing an outer surface of the pin, and a thermal pad positioned between the pin and the wall. The heat dissipating structure applies a force to the thermal pad that presses the thermal pad toward the pin.

PDUs distribute electric power to devices in a variety of environments and for a variety of applications. For example, features of PDUs are described in <CIT>, "Power Distribution Unit With Interior Busbars," and <CIT>.

In data centers and other industrial environments, a power source is typically provided to information technology ("IT") equipment with a three-phase busway that carries current. Each phase can be provided separately to different types of IT equipment. In some instances, the three-phase busway provides power to a rack that holds electrical equipment such as servers. The IT equipment located in the rack receives power from the busway via a PDU mounted to the rack frame. The PDU includes a connection to the three-phase busway, and a plurality of components to provide, regulate, and monitor the current being distributed to the IT equipment in the rack. Some examples of the components used in such a PDU include outlet modules, communications modules, circuit breakers, and sensors. Although a PDU providing power to IT equipment in a data center is described, sensors. Although a PDU providing power to IT equipment in a data center is described, the present disclosure is not so limited. One or more features of the disclosed PDU can be provided, either alone or in combination, to define a PDU for distributing power to devices in a wide variety of applications.

<FIG> is a perspective view of an exemplary PDU <NUM> that includes an electrical connector <NUM>, an input module <NUM>, outlet modules <NUM>, a communications module <NUM> located between the two outlet modules <NUM>, and a housing <NUM>. The PDU <NUM> is configured to be mounted in a rack frame (not shown), and to provide power to equipment located in the rack. The rack may house IT equipment, such as servers, data storage, and other similar equipment. PDU <NUM> includes mounting features (not shown) that are used to fix PDU <NUM> to a rack frame. Exemplary mounting features include, without limitation, mechanical fasteners, locking mechanisms, protruding pins and corresponding slots, etc. (not shown).

Electrical connector <NUM> is configured to be connected to an outlet of a three-phase power source to provide power to the input module <NUM>. The electrical connector <NUM> can be provided as a plug (as shown) that connects to a power source by a removable connection or by hardwiring or other electrical connection between the electrical connector <NUM> and a power source. Input module <NUM> in turn distributes the power to the outlet modules <NUM> and communications module <NUM>. Plug <NUM> is configured to draw current from the three-phase current source outlet. The input module <NUM> can include circuit protection devices (not shown), that may include, without limitation, circuit breakers, fuses, residual-current devices, reclosers, polyswitches, and any combination of these and other protection devices. The current received from plug <NUM> first passes through a circuit protection device before being distributed to the outlet modules <NUM> or communications module <NUM>.

Outlet modules <NUM> provide power to equipment mounted in the rack, through the equipment plugs. Communications module <NUM> provides information related to PDU performance or operating characteristics. Examples of performance or operating characteristics include, without limitation, voltage, current, frequency, power, and energy. The communications module <NUM> can provide this information to a user using a variety of communications technologies, such as wireless internet (or intranet) transmitters, Bluetooth, a physical display, indicator lights etc..

<FIG> shows a perspective view of a section <NUM> of one outlet module <NUM>, with the outlets <NUM> facing downwards and the housing <NUM> removed for clarity. The components of outlet module section <NUM> are more easily seen in <FIG>, which depicts an exploded drawing of outlet module section <NUM> from the same perspective as in <FIG>. <FIG> shows the perspective view of the section <NUM> of <FIG>, with some additional features removed for clarity. The outlet module section <NUM> in this embodiment has six outlets <NUM>, although a lesser or greater number of outlets <NUM> can be provided in alternative embodiments. Each outlet <NUM> includes an outlet pin <NUM> extending in a direction opposite the outlet face. The components and functioning of each outlet module section <NUM> may be similar, so only outlet module section <NUM> is shown.

Referring to <FIG> and <FIG>, a set of busbars <NUM> runs the length of the entire outlet module <NUM> and delivers current to the outlets <NUM> in each outlet module section <NUM>. A busbar cap <NUM> receives the busbars <NUM> and maintains the distance between each busbar. Busbars <NUM> are made from a conductive material, such as phosphor bronze, copper, or an alloy. Each of the busbars <NUM> is connected via wiring to one of three circuit protection devices (not shown) in the input module <NUM>. Each circuit protection device receives power from one of the three current phases received by the plug <NUM> from an external source. Three of the busbars <NUM>, carry input current corresponding to their respective phases. The other three busbars <NUM> are neutral lines (electrically connected to either a different phase or an actual neutral) that each complete a circuit with the respective busbars carrying the input current. In an alternative embodiment (not shown) wires are employed instead of busbars.

Chassis <NUM> is a one-piece frame that extends the length of the outlet module <NUM> and receives each outlet module section <NUM>. Chassis <NUM> is made from a metal, such as aluminum or an aluminum alloy. A single chassis <NUM> includes a plurality of openings <NUM> (shown in <FIG>) each opening sized to receive outlets <NUM> of an outlet module section <NUM> in a snap-fit type interface. As shown in <FIG>, multiple outlets <NUM> are disposed in one molded plastic assembly that includes an integrated busbar <NUM> for grounding all of the outlets <NUM>. Grounding path provides grounding for equipment plugged into each outlet <NUM>. In alternative embodiments (not shown), an individual outlet is disposed in each assembly and may not include ground busbar <NUM>. Outlets <NUM> are also attached to outlet faceplate <NUM>. Outlets <NUM> can be fixed to faceplate <NUM> via a snap-fit type connection, through use of an adhesive, or with mechanical fasteners. Outlets <NUM> further include indentations <NUM> that align with protrusions <NUM> (shown in <FIG>) of chassis openings <NUM>, to provide an aligned and secure connection therewith.

The outlet module section <NUM> can include one or more additional components for distributing electric power. For example, as illustrated in <FIG> and <FIG>, printed circuit board assembly ("PCBA") <NUM> can include one or more microprocessors that communicate with communications module <NUM> and relay board <NUM>, other logic elements, and/or a microcontroller. PCBA includes a number of pins <NUM> that correspond to the number of outlets <NUM> in the outlet module section <NUM>. Relay board <NUM> includes relays <NUM>, light emitting diodes ("LEDs"), and communication ports. Each outlet <NUM> is further electrically connected to a relay <NUM> via mating electrical conductor elements located on relay <NUM> and outlet <NUM>, so that outlets <NUM> receive current through relays <NUM>.

Jumpers <NUM> connect the busbars <NUM> to the appropriate pins <NUM> of PCBA <NUM>, which are electrically connected to outlets <NUM>. Jumpers <NUM> are further connected to the pins <NUM> of outlets <NUM>. In other alternative embodiments (not shown), jumpers <NUM> could be soldered to busbars <NUM> and pins <NUM>, <NUM>, or jumpers <NUM> could be connected via any other permanent connection means. When a user plugs equipment in to the outlet <NUM>, the circuit including the circuit protection device, busbars <NUM>, outlet <NUM>, and user equipment is closed, thereby providing power to the user equipment.

<FIG> illustrate another embodiment of an outlet module section <NUM> that omits a PCBA and relay board. Outlet module section <NUM> in this embodiment is part of a simple PDU that does not include outlet switching or outlet metering, and may or may not include a communications module. The outlet module section <NUM> includes a plurality of outlets <NUM> fixed to a chassis <NUM>, and further includes a flat insulator sheet <NUM> resting on one side of outlets <NUM>. The flat insulator sheet <NUM> prevents short circuits.

As shown in <FIG>, each outlet <NUM> further includes two-outlet pins <NUM> extending from a back side of each outlet <NUM>. In this embodiment, the outlet module section <NUM> does not include relays, so the outlet pins <NUM> complete a circuit with busbars <NUM>. For example, busbars <NUM> provide power to the outlet module section <NUM> and jumpers <NUM> connect the busbars <NUM> to the outlet pins <NUM>.

<FIG> shows the outlet module section <NUM> in an exploded view. Flat insulator sheet <NUM> separates the outlet pins <NUM> from each other, and provides an insulating layer between the current-carrying busbars <NUM> and the outlets <NUM>. Flat insulator sheet <NUM> includes a plurality of slots sized and shaped to receive outlet pins <NUM>, and to permit an electrical connection between the outlets <NUM> and busbars <NUM> via outlet pins <NUM> only. The flat insulator sheet <NUM> thereby prevents any accidental contact between conductive elements to prevent short-circuiting. In alternative embodiments (not shown), the flat insulator sheet <NUM> can be omitted, or a plurality of insulator sheets can be included instead of a single flat insulator sheet.

Regardless of the specific configuration of various components, when an electrical current flows through the outlet module section <NUM>, <NUM> of the outlet module <NUM> of the PDU <NUM>, certain components may experience an increase in temperature. For example, when an electrical current flows through the electrically conductive pins <NUM>, <NUM> of the outlet <NUM>, <NUM>, the temperature of the pins <NUM>, <NUM> increases based on the electrical resistance of the pins <NUM>, <NUM> and the heating effect of the electrical current. Increased temperatures can create safety and operability problems for the PDU <NUM>. For example, safety codes may define a temperature below which components within the PDU <NUM> must be during operation. Additionally, increased temperatures can melt plastic components, and degrade the strength or other material characteristics of various metal or plastic components. Some PDUs that obtain a temperature during operation greater than a predetermined temperature may be identified as unsafe and unusable and may not function for their intended purpose.

Accordingly, to decrease or maintain a temperature of the PDU <NUM> below the predetermined temperature, structures to dissipate heat within the PDU <NUM> are desirable. For example, a heat dissipating structure provides the ability for relatively hotter components within the PDU <NUM> (e.g., pins <NUM>, <NUM>) to transfer heat to relatively cooler components (e.g., chassis <NUM>, <NUM>) or housing <NUM>. Heat dissipating structures for PDUs thus increase operational safety of the PDU <NUM>, prolong the lifetime of components within the PDU <NUM>, and provide a reliable efficient system for distributing electric power.

<FIG> provide exemplary embodiments of a first exemplary heat dissipating structure <NUM> (shown in <FIG>) and a second exemplary heat dissipating structure <NUM> (shown in <FIG> and <FIG>). The heat dissipating structure <NUM>, <NUM> is provided to dissipate heat within a PDU <NUM>. Heat dissipating structure <NUM> is described with reference to a schematic representation of an outlet assembly <NUM>, and heat dissipating structure <NUM> is described with reference to a schematic representation of an outlet assembly <NUM>. Outlet assembly <NUM>, <NUM> is configured to function with an outlet module section <NUM>, <NUM> of an outlet module <NUM> of a PDU <NUM>. For example, outlet assembly <NUM>, <NUM> can include one or more features of the PDU <NUM> discussed above. Thus, the outlet assembly <NUM>, <NUM> should not be interpreted as limiting the applicability of the present disclosure, as the heat dissipating structure <NUM>, <NUM> finds utility in a variety of applications with a variety of components for dissipating heat from outlets <NUM>, <NUM> of a PDU <NUM>.

The outlet assembly <NUM>, <NUM> includes outlet <NUM>, faceplate <NUM>, chassis <NUM>, and housing <NUM>. The chassis <NUM> includes an opening <NUM> providing access to the outlet <NUM>. The outlet <NUM> can be positioned in the opening <NUM> with a face <NUM> defining a receptacle facing away from the outlet assembly <NUM>, <NUM> to provide a user access to the receptacle. Additionally, in some embodiments, the outlet assembly <NUM>, <NUM> can include a board <NUM>. The board <NUM> may be a sheet, a panel, an instrument panel, a PCBA, a relay board, an insulating sheet, or a structure having a thin profile with a flat surface manufactured from a relatively stiff material.

As shown in <FIG> (with the housing <NUM> removed for clarity), the outlet <NUM> includes pins <NUM> extending from a bottom side <NUM> of the outlet <NUM>. The pins <NUM> are partially enclosed within a shroud <NUM> protruding from the bottom side <NUM> of the outlet <NUM>. As discussed above, one or more of the pins <NUM> electrically connects to an electrical current. As the current flows through the pins <NUM>, one or more pins <NUM> may increase in temperature, as described above. Under some operating conditions, the pins <NUM> may attain the highest temperature of any component of the outlet <NUM>, due to the flow of current. Features that are spatially located or positioned adjacent (e.g., in contact with or in close proximity to) the pins <NUM> can also increase in temperature based on conduction of the heat from the pins <NUM> to, for example, the shroud <NUM>, the bottom side <NUM> of the outlet <NUM>, the board <NUM>, and the outlet <NUM> generally. The transfer of heat to these components is limited by the material properties of the components, which can be poor conductors of heat. Thus, heat can accumulate and build up (e.g., continually increase) on the pins <NUM> during operation of the outlet <NUM>. As described above, the concentration of increased temperatures can create safety and operability problems for the PDU <NUM>.

As further shown in <FIG>, the outlet assembly <NUM> includes heat dissipating structure <NUM> and a thermal pad <NUM>. The thermal pad <NUM> and the heat dissipating structure <NUM> dissipate heat (e.g., increase the amount and rate of heat transfer) from the one or more pins <NUM> (or the components spatially adjacent to the pins <NUM>) to comparatively cooler components via conduction, or to the environment based on convection or radiation. The thermal pad <NUM> is a thermally conductive pad (e.g., thermal gap pad) that is rated for a particular rate of heat transfer. The specific thermal conductivity properties of the thermal pad <NUM> can be selected based on the operating conditions of the outlet assembly <NUM> including, but not limited to, the level of current flowing through the pins <NUM>, the length of time the current is expected to flow, the ambient temperature of the environment in which the outlet assembly <NUM> may be employed, particular safety standards and codes, and customer specifications. In some embodiments, the thermal conductivity of the thermal pad <NUM> can range from about <NUM> W/mK to about <NUM> W/mK, such as about <NUM> W/mK. The thermal pad <NUM> can be manufactured from silicone, or a filler material that provides thermal conductivity greater than the thermal conductivity of air. Thus, by providing the thermal pad <NUM>, the rate of heat transfer is increased.

The shape of the thermal pad <NUM> may be defined by the shroud <NUM> of the outlet <NUM>. For example, the thermal pad <NUM> can be manufactured, cut, formed, or otherwise fashioned to include a predetermined shape <NUM> corresponding to a profile of the shroud <NUM>. Providing the thermal pad <NUM> with a predetermined shape <NUM> corresponding to a profile of the shroud <NUM> can increase heat transfer to the thermal pad <NUM> from the pins <NUM> and the shroud <NUM> based on increased surface area contact between the corresponding profile of the shroud <NUM> and the mating predetermined shape <NUM> of the thermal pad <NUM>.

In the illustrated embodiment, the predetermined shape <NUM> of the thermal pad <NUM> includes a recess and protrusions defining a rectangular cut-out portion configured to abut one or more walls of the shroud <NUM>. In other words, the thermal pad <NUM> is substantially C-shaped. In other embodiments, the predetermined shape <NUM> may be a linear profile, an oval or circular profile, a polygonal profile, a curved or non-linear profile, or other shaped-profile corresponding to a structural profile of the shroud <NUM>, where the thermal pad <NUM> is configured to be positioned to abut (e.g., contact) the shroud <NUM>. The thermal pad <NUM> is shown in an unassembled, partially exploded, state in <FIG>. When assembled, the thermal pad <NUM> is held in place by the board <NUM> (shown in <FIG>), such that the thermal pad abuts the shroud <NUM> and a wall portion <NUM> of heat dissipating structure <NUM>.

In the illustrated embodiment, the wall <NUM> of the heat dissipating structure <NUM> is an integrally formed extension of the chassis <NUM>. The chassis <NUM> includes a vertical extension defining the wall <NUM> of the heat dissipating structure <NUM>. When provided as an integral feature with the chassis <NUM>, the heat dissipating structure <NUM> and the chassis <NUM> are manufactured from the same material (e.g., steel, aluminum, brass). The heat dissipating structure <NUM> and the chassis <NUM> can be manufactured from other materials selected based on one or more of cost of the material, strength of the material, thermal conductivity of the material, or other characteristics.

The heat dissipating structure <NUM> provides both a structural function by securing the thermal pad <NUM> against the shroud <NUM> and a heat transfer function by dissipating heat from the thermal pad <NUM>. Based on conduction heat transfer, heat from the pins <NUM> transfers from the pins <NUM> to the shroud <NUM>, from the shroud <NUM> to the thermal pad <NUM>, from the thermal pad <NUM> to the heat dissipating structure <NUM>, and from the heat dissipating structure <NUM> to the chassis <NUM>. Heat can further transfer from the chassis <NUM> to the housing <NUM> (shown in <FIG>) and to the environment. The thermal pad <NUM> and the heat dissipating structure <NUM> dissipate heat from the pins <NUM> to reduce or maintain a temperature of the pins <NUM>, thereby preventing or reduce an increase in temperature of the pins <NUM>. The reduced or maintained temperature of the pins <NUM> can define a safe and efficient operating temperature of the outlet <NUM> and of the PDU <NUM> in which the outlet <NUM> is incorporated.

<FIG> illustrates a top perspective view of outlet assembly <NUM>. Additionally, <FIG> is a partial front side view of the outlet assembly <NUM>. The outlet assembly <NUM> is substantially the same as the outlet assembly <NUM> shown in <FIG>, except for the differences discussed herein. Like reference numerals are used for like components. In the illustrated embodiment, the heat dissipating structure <NUM> is a separate piece that connects to the chassis <NUM> at interface <NUM> with the wall <NUM> of the heat dissipating structure <NUM> extending from the interface <NUM>. When provided as a separate structure, the heat dissipating structure <NUM> and the chassis <NUM> can be manufactured from the same material (e.g., steel/steel, aluminum/aluminum, brass/brass) or from different materials (e.g., steel/aluminum, steel/brass, aluminum/steel, aluminum/brass, brass/steel, brass/aluminum). The particular materials listed are exemplary and not intended to be limiting.

As shown in <FIG>, when assembled, the thermal pad <NUM> is positioned adjacent to and in abutting relationship with the shroud <NUM>. The thermal pad <NUM> is held in place with the wall portion <NUM> of the heat dissipating structure <NUM>. As shown in <FIG>, an inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM> faces the shroud <NUM>. With the thermal pad <NUM> positioned between the shroud <NUM> and the wall <NUM>, the wall <NUM> applies a force on the thermal pad <NUM> to maintain the thermal pad <NUM> in contact with the shroud <NUM>. By applying a force to hold the thermal pad <NUM> against the shroud <NUM>, the surface area of the thermal pad <NUM> in contact with the outer surface of the shroud <NUM> can increase (or be most efficiently provided) as compared to a thermal pad placed in position near the shroud without a force applied.

Additionally, when providing the heat dissipating structure <NUM> as a separate piece, the construction of the heat dissipating structure <NUM> can benefit from greater design flexibility that may otherwise be limited by the manufacturing limitations of an integral chassis <NUM> and heat dissipating structure <NUM>. For example, the heat dissipating structure <NUM> includes a flange <NUM> extending from the wall <NUM> on which a portion of the thermal pad <NUM> is positioned. In alternative embodiments, an integral chassis <NUM> and heat dissipating structure <NUM> can also include a flange feature, even if the manufacturing of such a flange in an integral component may be more challenging. Thus, whether the heat dissipating structure <NUM>, <NUM> is respectively formed as an integral part of the chassis <NUM> or as a separate piece connected to the chassis <NUM> at interface <NUM>, the flange <NUM> is an optional feature of the heat dissipating structure <NUM>, <NUM>. In the illustrated embodiment, the flange <NUM> supports the thermal pad <NUM> to increase the ability of the heat dissipating structure <NUM> to apply a force on the thermal pad <NUM> and hold or maintain the thermal pad <NUM> in contact with the shroud <NUM>.

Although <FIG> shows a single pin <NUM> and a portion of the shroud <NUM>, the thermal pad <NUM> can laterally circumscribe the shroud <NUM>, either partially or entirely, in other embodiments to dissipate heat from any one or more pins <NUM>. Similarly, the thermal pad <NUM> can be provided as a single piece having a predetermined shape <NUM> corresponding to a profile of the shroud <NUM> formed therein. Alternatively, the thermal pad <NUM> can be provided as a plurality of pieces that are assembled to define the predetermined shape <NUM> corresponding to a profile of the shroud <NUM>, where the plurality of pieces laterally circumscribe the shroud <NUM>, either partially or entirely.

The thermal pad <NUM> includes a first side surface <NUM> facing and abutting an outer surface <NUM> of the shroud <NUM> and a second side surface <NUM> facing and abutting inner surface <NUM> of wall <NUM> of the heat dissipating structure <NUM>. The first side surface <NUM> is opposite the second side surface <NUM> with lateral surfaces of the thermal pad <NUM> extending between the side surfaces <NUM>, <NUM>. For example, the thermal pad <NUM> includes a first lateral surface <NUM> facing and abutting an underneath surface <NUM> of the board <NUM> and a second lateral surface <NUM> facing and abutting an outer surface <NUM> of the bottom side <NUM> of the outlet <NUM>. When the heat dissipating structure <NUM> includes a flange <NUM>, the fourth lateral surface <NUM> also faces and abuts an inner lateral surface <NUM> of the flange <NUM>. The inner lateral surface <NUM> of the flange <NUM> meets the inner surface <NUM> of the wall <NUM>. In the illustrated embodiment, the inner lateral surface <NUM> and the inner surface <NUM> meet at a right angle, although other angles can be provided.

Relative to the face <NUM>, the wall <NUM> of the heat dissipating structure <NUM> extends away from the face <NUM>, defining a receptacle for receiving an electrical plug, in a direction toward the pins <NUM>. The wall <NUM> can extend past one or more of the bottom side <NUM> of the outlet <NUM>, past the board <NUM>, or past the shroud <NUM>. In some embodiments, the wall <NUM> extends past one or more of the bottom side <NUM> of the outlet <NUM>, past the board <NUM>, or past the shroud <NUM> and terminates prior to (e.g., short of) extending past an outermost end of the pins <NUM>. Thus, the wall <NUM> is positioned and structured to hold the thermal pad <NUM> relative to the outlet <NUM> with the predetermined shape <NUM> abutting the shroud <NUM>.

The flange <NUM> extends from the surface <NUM> of the wall <NUM> toward the outlet <NUM>. In some embodiments, the inner surface <NUM> can be coplanar with the surface <NUM> of the bottom side <NUM> of the outlet <NUM>, although the inner surface <NUM> can be offset relative to (e.g., above or below) the surface <NUM> of the bottom side <NUM> of the outlet <NUM>. A cantilevered end of the flange <NUM> can abut the outlet <NUM> or may be spaced a distance from the outlet defining a gap "g" between the flange <NUM> and the outlet <NUM>. The thermal pad <NUM> thus spans the gap "g" from the shroud <NUM> to the wall <NUM> of the heat dissipating structure <NUM>.

In an alternate embodiment shown in <FIG>, the first side surface <NUM> of the thermal pad <NUM> faces and abuts the outer surface <NUM> of the shroud <NUM> and an outer surface <NUM> of the pin <NUM>. In another alternate embodiment shown in <FIG>, the first side surface <NUM> of the thermal pad <NUM> faces and abuts the outer surface <NUM> of the pin <NUM>. For example, in some embodiments, the pin <NUM> can extend from the bottom side <NUM> of the outlet <NUM> without a shroud <NUM>. In either embodiment of <FIG> and <FIG>, the thermal pad <NUM> can be provided as a single piece having a predetermined shape <NUM> corresponding to a profile of the shroud <NUM> or the pin <NUM> formed therein. Alternatively, the thermal pad <NUM> can be provided as a plurality of pieces that are assembled to define the predetermined shape <NUM> corresponding to a profile of the shroud <NUM> or the pin <NUM>, where the plurality of pieces laterally circumscribe the shroud <NUM> or the pin <NUM>, either partially or entirely.

When assembled, the thermal pad <NUM> is positioned adjacent to and in abutting relationship with the shroud <NUM> or the pin <NUM>. The thermal pad <NUM> is held in place with the wall portion <NUM> of the heat dissipating structure <NUM>. As shown in <FIG> and <FIG>, the inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM> faces the shroud <NUM> or the pin <NUM> With the thermal pad <NUM> positioned between the shroud <NUM> or the pin <NUM> and the wall <NUM>, the wall <NUM> applies a force on the thermal pad <NUM> that presses the thermal pad <NUM> toward the shroud <NUM> or the pin <NUM>. The heat dissipating structure <NUM> maintains the thermal pad <NUM> in contact with the shroud <NUM> or the pin <NUM>. By applying a force to hold the thermal pad <NUM> against the shroud <NUM> or the pin <NUM>, the surface area of the thermal pad <NUM> in contact with the outer surface <NUM> of the shroud <NUM> and the outer surface <NUM> of the pin <NUM> can increase (or be most efficiently provided) as compared to a thermal pad placed in position near the shroud or the pin without a force applied.

A method of assembling the outlet assembly <NUM> includes positioning the thermal pad <NUM> relative to the outlet <NUM> with the first side surface <NUM> of the thermal pad <NUM> facing the outer surface <NUM> of the shroud <NUM> or the pin <NUM> This step can include positioning the predetermined shape <NUM> of the thermal pad <NUM> relative to the shroud <NUM> or the pin <NUM> with the first side surface <NUM> of the thermal pad <NUM> facing the outer surface <NUM> of the shroud <NUM> or the outer surface <NUM> of the pin <NUM>. The method also includes positioning the thermal pad <NUM> relative to the outlet <NUM> with the second lateral surface <NUM> of the thermal pad <NUM> facing the outer surface <NUM> of the bottom side <NUM> of the outlet <NUM>.

When the heat dissipating structure <NUM> is provided as an integral part of the chassis <NUM> (as shown in <FIG>), the method can include positioning the thermal pad <NUM> relative to the heat dissipating structure <NUM> with the second side surface <NUM> of the thermal pad <NUM> facing the inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM>. Alternatively, when the heat dissipating structure <NUM> is provided as a separate component (as shown in <FIG>), the method can include fastening the heat dissipating structure <NUM> to the chassis <NUM> at interface <NUM>. One or more fasteners, adhesives, or material bonding (e.g., weld) can fix the heat dissipating structure <NUM> to the chassis <NUM> at interface <NUM>. After fastening the heat dissipating structure <NUM> to the chassis <NUM>, the method can include positioning the thermal pad <NUM> relative to the heat dissipating structure <NUM> with the second side surface <NUM> of the thermal pad <NUM> facing the inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM>.

With reference to the outlet assembly <NUM> of <FIG>, in embodiments where the heat dissipating structure <NUM> includes a flange <NUM>, the method can include positioning the thermal pad <NUM> relative to the outlet <NUM> or the heat dissipating structure <NUM> with the second lateral surface <NUM> of the thermal pad <NUM> facing the inner surface <NUM> of the flange <NUM>. The method of assembling the outlet assembly <NUM> includes positioning the board <NUM> with its underneath surface <NUM> facing the first lateral surface <NUM> of the thermal pad <NUM>. The board <NUM> can be fixed in position based on its weight, other components apply a stabilizing force on the board, or with one or more fasteners, adhesives, or material bonding (e.g., weld). For example, in some embodiments, the one or more of the pins <NUM> can be welded or soldered to the board <NUM> to maintain the board <NUM> in position.

With reference to outlet assemblies <NUM>, <NUM> in addition to positioning the thermal pad <NUM> with its surfaces <NUM>, <NUM>, <NUM>, <NUM> facing respective surfaces of other components, any one or more of the steps of the method of assembling the outlet assembly <NUM>, <NUM> can include positioning the thermal pad <NUM> relative to the outlet <NUM> or the heat dissipating structure <NUM>, <NUM> with one or more of its surfaces <NUM>, <NUM>, <NUM>, <NUM> abutting respective surfaces of other components. In some embodiments, the thermal pad <NUM> can be sized and shaped to occupy the exact dimensions of the void defined by the relative placement of the pin <NUM>, the shroud <NUM>, the board <NUM>, and the heat dissipating structure <NUM>, <NUM>.

Alternatively, the thermal pad <NUM> can be oversized to occupy more than the dimensions of the void defined by the relative placement of the pin <NUM>, the shroud <NUM>, the board <NUM>, and the heat dissipating structure <NUM>, <NUM>. In such embodiments, the thermal pad <NUM> may be manufactured from a material having resilience. Thus, when the heat dissipating structure <NUM>, <NUM> and the board <NUM> are positioned in abutting relationship with the thermal pad <NUM>, the oversized thermal pad <NUM> undergoes compression to accommodate the size restrictions imposed by the placement of the heat dissipating structure <NUM>, <NUM> and the board <NUM>. The thermal pad <NUM> is thus pressed or forced against the shroud <NUM> or the pin <NUM> and the bottom side <NUM> of the outlet <NUM>. The pressing force maintains the surface area of the thermal pad <NUM> in contact with the shroud <NUM> or the pin <NUM> and the bottom side <NUM> of the outlet <NUM> and can increase heat transfer between abutting surfaces as compared to an undersized or exact-sized thermal pad <NUM> that is not pressed against the shroud <NUM> or the pin <NUM> or the bottom side <NUM> of the outlet <NUM>.

With reference to <FIG>, once assembled and operable (e.g., with current flowing), heat generated at the pin <NUM> transfers from the pin <NUM> to the shroud <NUM>, and from the outer surface <NUM> of the shroud <NUM> to the first side surface <NUM> of the thermal pad <NUM>. With reference to <FIG>, once assembled and operable (e.g., with current flowing), heat generated at the pin <NUM> transfers from the pin <NUM> to the shroud <NUM>, and from the outer surface <NUM> of the shroud <NUM> or the outer surface <NUM> of the pin <NUM> to the first side surface <NUM> of the thermal pad <NUM>. With reference to <FIG>, once assembled and operable (e.g., with current flowing), heat generated at the pin <NUM> transfers from the outer surface <NUM> of the pin <NUM> to the first side surface <NUM> of the thermal pad <NUM>.

The heat then transfers through the thermal pad <NUM> exiting the second side surface <NUM> of the thermal pad <NUM> into the inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM>. Heat within the heat dissipating structure <NUM> transfers to the chassis <NUM>. Such pattern of heat transfer thus dissipates heat from the pin <NUM> to the heat dissipating structure <NUM> based on conduction through the thermal pad <NUM>. Heat may transfer from the first lateral surface <NUM> of the thermal pad <NUM> into the underneath surface <NUM> of the board <NUM>, and from the second lateral surface <NUM> of the thermal pad <NUM> into the outer surface <NUM> of the bottom side <NUM> of the outlet <NUM> or into the inner surface <NUM> of the flange <NUM> of heat dissipating structure <NUM>. Alternatively, heat may transfer from the underneath surface <NUM> of the board <NUM> into the first lateral surface <NUM> of the thermal pad <NUM>, and from the outer surface <NUM> of the bottom side <NUM> of the outlet <NUM> into the second lateral surface <NUM> of the thermal pad <NUM>.

Heat within the thermal pad <NUM> transfers into the inner surface <NUM> of the flange <NUM> of the heat dissipating structure <NUM> and the inner surface <NUM> of the wall <NUM> of the heat dissipating structure <NUM>. The flange <NUM> or the wall <NUM> can extend along a portion of the width of the thermal pad <NUM> or along the entire width of the thermal pad <NUM>. With reference to <FIG>, the width of the thermal pad <NUM> extends in a direction into and out of the paper. The larger the surface area (e.g., surfaces <NUM>, <NUM>) in contact with the thermal pad <NUM>, the greater the rate of heat transfer from the thermal pad <NUM> into the heat dissipating structure <NUM>. Thus, providing the heat dissipating structure <NUM> with the flange <NUM> and the wall <NUM> extending along the entire length of the thermal pad <NUM> increases heat transfer from the thermal pad <NUM> into the heat dissipating structure <NUM> and can thus obtain a cooler temperature pin <NUM> in a shorter period of time.

The specific description of the path of transfer of heat is exemplary and not intended to be limiting or contradictory to the principles of heat transfer. Thus, in further embodiments, heat can transfer from hot to cold based on conduction heat transfer between abutting surfaces. Irrespective of the particular mode of heat transfer, heat at the pins <NUM> is reduced to or maintained at a predetermined temperature based on the thermal pad <NUM> and the heat dissipating structure <NUM>, <NUM>, thus providing a safe and effective outlet assembly <NUM>, <NUM> for a PDU <NUM>.

To the extent that the term "includes" or "including" is used in the specification or the claims, it is intended to be inclusive in a manner similar to the term "comprising" as that term is interpreted when employed as a transitional word in a claim. Furthermore, to the extent that the term "or" is employed (e.g., A or B) it is intended to mean "A or B or both. " When the applicants intend to indicate "only A or B but not both" then the term "only A or B but not both" will be employed. Thus, use of the term "or" herein is the inclusive, and not the exclusive use. See, <NPL>). Also, to the extent that the terms "in" or "into" are used in the specification or the claims, it is intended to additionally mean "on" or "onto. " Furthermore, to the extent the term "connect" is used in the specification or claims, it is intended to mean not only "directly connected to," but also "indirectly connected to" such as connected through another component or components.

Claim 1:
An outlet assembly (<NUM>, <NUM>) comprising:
a chassis (<NUM>, <NUM>, <NUM>) including an opening (<NUM>, <NUM>);
an outlet (<NUM>, <NUM>, <NUM>) positioned in the opening (<NUM>, <NUM>) with a face (<NUM>) defining a receptacle facing away from the outlet assembly (<NUM>, <NUM>), wherein the outlet (<NUM>, <NUM>, <NUM>) has a plurality of pins (<NUM>, <NUM>, <NUM>) extending from a bottom side (<NUM>) of the outlet (<NUM>, <NUM>, <NUM>);
a heat dissipating structure (<NUM>, <NUM>) extending from the chassis (<NUM>, <NUM>, <NUM>) in a direction toward the plurality of pins (<NUM>, <NUM>, <NUM>) past the bottom side of the outlet (<NUM>, <NUM>, <NUM>), wherein the heat dissipating structure (<NUM>, <NUM>) includes a wall (<NUM>, <NUM>) with an inner surface facing an outer surface of at least one pin of the plurality of pins (<NUM>, <NUM>, <NUM>); and
a thermal pad (<NUM>) positioned between the at least one pin and the wall (<NUM>, <NUM>); and
a printed circuit board (<NUM>, <NUM>) having an underneath surface (<NUM>) abutting a first lateral surface (<NUM>) of the thermal pad (<NUM>).