Why is it necessary to design power bricks to get too hot to handle?

Power bricks for consumer electronics often run very hot due to design trade-offs involving size, cost, and reliability. Manufacturers may prioritize minimizing production costs, sometimes resulting in power supplies that operate near their maximum allowable temperature limits. Safety standards such as UL60950 and EN60950 specify maximum surface temperatures for external plastic and rubber parts, typically up to 95°C, which is close to scalding temperatures. Some brands, like Dell with their 90W power bricks, demonstrate that supplies can endure high temperatures without failure over extended periods, though the heat generated can be uncomfortable or potentially damaging to surfaces. The design approach balances thermal performance with cost efficiency and warranty considerations, occasionally leading to power supplies that run hotter than ideal. Historical examples include older Commodore 64 power supplies, which required aftermarket cooling modifications to reduce heat. Users concerned about excessive heat may consider measuring surface temperatures and replacing power supplies that exceed safe or comfortable thermal thresholds.
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