Power supply voltage range design cost

[Skaperen]

Today's switch mode power supplies for computers mostly have a nominal voltage range of 100 to 240 volts. Whatever the added cost of making them operate over that much of a range there is must be less than the cost of having separate products for the two major narrow voltage ranges used throughout the world (separate production lines, managing inventory, etc). I'm curious what would be the cost involved in making a switch mode power supply that works over an even wider range, such as 60 volts to 300 volts. Is it a matter of just different components, or is there a point where a design change would have to be made? And would it be easier if the DC output is a single voltage (say 12 volts) as opposed to the multiple voltages a computer power supply has?

Where the mains supply is 220-240 volts, these power supplies generally have protection against extreme brownouts, and basically can still work fine at half voltage. The 100-120 volt parts of the world don't get that protection unless wired up line-to-line to get 200-240 volts.

 

[Tom.G]

A few of the capacitors will have to be larger value and higher voltage. Maybe better insulation on one transformer. Extra manufacturing cost probably $1 or so. Figure 5 times that when on the retail shelf in a store. Extra sales due to wider voltage range, percentage wise not discernable from zero.