An assembling method of a fast charging charger

Abstract

The application provides a quick charging charger assembling method, which comprises the following steps: (1) putting a PCB circuit board into a shell main body, wherein the PCB circuit board comprises a circuit board main body part and a circuit board connecting part; the shell main body is internally provided with a partition layer, so that the shell main body is divided into an upper cavity and a lower cavity, a through hole only allowing the circuit board connecting part to pass through is formed in the partition layer; the circuit board main body part is arranged in the lower cavity, the circuit board connecting part passes through the through hole of the partition layer and enters the upper cavity, the circuit board connecting part is connected with an alternating current plug arranged in the upper cavity; the upper cover plate is ultrasonically welded with the shell main body; (2) pouring silica gel into the lower cavity of the shell main body by inverting the shell main body, and waiting for the silica gel to solidify; and (3) ultrasonically welding the lower cover plate with the shell main body. The quick charging charger assembling method provided by the application greatly reduces packaging process steps, greatly simplifies the production process, and improves the assembling efficiency.

Description

Technical Field

[0001] This invention belongs to the field of electronic device technology, and specifically relates to a fast charger assembly method. Background Technology

[0002] A charger is a device that converts alternating current (AC) into low-voltage direct current (DC). Chargers are widely used in various fields, especially in daily life for common appliances such as mobile phones and cameras. They are static converters that use power electronic semiconductor devices to transform AC power with a fixed voltage and frequency into DC power. They are indispensable devices used everywhere in daily life. However, common chargers on the market have a series of shortcomings. For example, chargers tend to overheat during charging; ordinary chargers cannot dissipate heat effectively, resulting in low heat dissipation efficiency, and the heat dissipation problem is particularly serious for fast chargers.

[0003] To address the insufficient heat dissipation of the charger, improvements are primarily made in the following ways: First, by adding a heat dissipation structure. This requires more space and increases the charger's size, making the assembly process more complex and increasing costs. Second, by applying adhesive to specific components on the circuit board for localized heat dissipation, but the heat dissipation efficiency remains limited. The reason for not applying adhesive to the entire charger is that the existing charger structure cannot achieve complete sealing. Before the adhesive solidifies, it will leak out from unsealed openings (USB port, foldable plug), making it impossible to achieve complete adhesive application during assembly.

[0004] The existing assembly method of foldable fast chargers mainly includes the following steps: (1) Assembly of the foldable head of the top cover plate, using the spring plate to fix the conductive spring and AC plug on the bottom surface of the top cover plate; (2) Installation of the circuit board, including fixing the components with glue, adding thermal conductive film, applying safety tape, wrapping insulation film, installing heat sink, etc.; (3) Soldering the conductive spring to the circuit board with wires, and ultrasonically welding the top cover plate to the outer shell to complete the assembly of the charger.

[0005] Therefore, in order to effectively solve the heat dissipation problem of chargers, the structure and assembly process of existing chargers need to be further improved. Summary of the Invention

[0006] The purpose of this invention is to provide a fast charger that solves the problem of low heat dissipation efficiency in existing fast chargers.

[0007] Another objective of this invention is to provide a fast charger assembly method that addresses the shortcomings of existing fast charger assembly methods, which involve numerous steps and low assembly efficiency.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0009] A fast charger includes an upper cover, a lower cover, and a housing body. The upper cover is connected to the top of the housing body, and the lower cover is connected to the bottom of the housing body. It also includes a PCB circuit board disposed within the housing body. The PCB circuit board comprises a circuit board main body and a circuit board connecting part. A partition is provided inside the housing body, dividing the housing body into an upper cavity and a lower cavity. A through-hole is provided on the partition to accommodate only the circuit board connecting part. The circuit board main body is disposed within the lower cavity, and the lower cavity is filled with silicone. The circuit board connecting part passes through the through-hole in the partition and connects to an AC plug disposed within the upper cavity.

[0010] A fast charger assembly method, the fast charger includes an upper cover plate, a lower cover plate and a housing body, the upper cover plate is connected to the top of the housing body, the lower cover plate is connected to the bottom of the housing body, and the assembly method includes the following steps: (1) installing the PCB circuit board into the housing body, the PCB circuit board including a circuit board body part and a circuit board connection part; the housing body is provided with a partition, so that the housing body is divided into an upper cavity and a lower cavity, and the partition is provided with a through hole that only accommodates the circuit board connection part; so that the circuit board body part is located in the lower cavity, the circuit board connection part passes through the through hole of the partition and enters the upper cavity, and the circuit board connection part is connected to the AC plug located in the upper cavity; the upper cover plate and the housing body are ultrasonically welded.

[0011] (2) Invert the outer shell and pour silicone into the lower cavity of the outer shell, and wait for the silicone to cure;

[0012] (3) The lower cover plate is ultrasonically welded to the outer shell body.

[0013] In this invention, the process of connecting the circuit board connection part to the AC plug located in the upper cavity specifically includes: fixing the conductive spring on the top surface of the partition, fixing and welding the conductive spring to the circuit board connection part, and fixing the AC plug on the partition and making contact with the conductive spring.

[0014] In this invention, the AC plug includes two metal prongs and a plastic body connecting the two metal prongs.

[0015] Furthermore, the plastic body is cylindrical.

[0016] In this invention, the top surface of the partition is provided with a plug holder with a support hole, and the AC plug is fixed to the support hole of the plug holder by a plastic body, so that the AC plug can rotate on the plug holder.

[0017] In this invention, the conductive spring includes an elastic part, a fixing part, and a spring connecting part.

[0018] Furthermore, the top surface of the partition is provided with a spring support, and the conductive spring is fixed to the spring support by a fixing part.

[0019] The conductive spring is fixed to the circuit board connection part through the spring connection part and is soldered to the circuit board connection part to achieve circuit conduction.

[0020] The conductive spring is connected to the metal prong end of the AC plug through the elastic part.

[0021] In this invention, the upper cover plate has two slots that match the AC plug. This design allows the AC plug to be exposed and retracted during rotation via these slots.

[0022] Furthermore, plastic rivets are provided on the bottom surface of the upper cover plate, and correspondingly, a mounting bracket is provided on the top surface of the partition, the mounting bracket having fixing holes that match the rivets.

[0023] The present invention has the following beneficial effects:

[0024] (1) The fast charger of the present invention improves the internal structure of the charger by adding a partition layer, so that the main body of the circuit board is located in the lower cavity, thereby filling the entire space of the lower cavity with silicone material and improving the heat dissipation efficiency of the charger.

[0025] (2) The fast charger assembly method of the present invention reduces the amount of related materials such as heat sink, fixing glue, insulating sheet and insulating tape by potting the fast charger with silicone with good thermal conductivity and insulation properties. Correspondingly, the installation and fixing process of heat sink, fixing glue, insulating sheet and insulating tape is reduced, the packaging process steps of the charger are greatly reduced, the production process is greatly simplified and the assembly efficiency is improved.

[0026] (3) The present invention adopts a packaging process corresponding to the specific fast charger structure, which reduces the overall material cost, simplifies the assembly process, is easy to automate production, and is suitable for mass production. Attached Figure Description

[0027] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0028] Figure 1 This is a schematic diagram of the overall structure of the fast charger of the present invention;

[0029] Figure 2 This is an exploded view of the fast charger of the present invention;

[0030] Figure 3 This is a schematic diagram of the top structure of the fast charger of the present invention;

[0031] Figure 4This is a schematic diagram of the bottom structure of the fast charger of the present invention;

[0032] Figure 5 This is a cross-sectional view of the outer casing of the fast charger of the present invention;

[0033] Figure 6 This is a schematic diagram of the fast charger of the present invention with the top cover removed;

[0034] Figure 7 This is a schematic diagram of the top surface structure of the internal partition of the fast charger of the present invention;

[0035] Figure 8 This is a schematic diagram of the structure of the top cover of the fast charger of the present invention;

[0036] Figure 9 This is a schematic diagram of the PCB circuit board of the fast charger of the present invention;

[0037] Figure 10 This is a schematic diagram of the AC plug for the fast charger of the present invention;

[0038] Figure 11 This is a schematic diagram of the structure of the conductive spring of the fast charger of the present invention;

[0039] The following are the markings in the attached diagram: 1. Outer shell body; 2. Upper cover plate; 3. Lower cover plate; 4. AC plug; 5. Conductive spring; 6. PCB circuit board; 7. Partition; 8. Plug support; 9. Spring support; 10. Mounting support; 11. Through hole; 12. Slot; 13. Rivet; 14. USB hole; 501. Elastic part; 502. Fixing part; 503. Spring connecting part; 601. Circuit board body; 602. Circuit board connecting part. Detailed Implementation

[0040] like Figure 1-11 The fast charger shown includes an upper cover plate 2, a lower cover plate 3, an AC plug 4, a conductive spring 5, a PCB circuit board 6, and a housing body 1.

[0041] The main body 1 has an internal partition 7, which divides the main body 1 into an upper cavity and a lower cavity. The partition 7 has a through hole 11. The PCB circuit board 6 includes a circuit board main body 601 and a circuit board connecting part 602. The circuit board main body 601 is located in the lower cavity of the main body 1. The remaining space of the lower cavity is filled with silicone material (not shown in the figure). The silicone material achieves good heat dissipation and also plays a role in fixing the circuit board and its electrical components. The circuit board connecting part 602 is set through the through hole 11 of the partition 7, and the size and thickness of the circuit board connecting part 602 are similar to the size of the through hole 11. In this way, the silicone will not flow out of the through hole 11 during the silicone filling process.

[0042] A plug support 8 is provided on the top surface of the partition 7, and the plug support 8 has two support holes. A mounting bracket 10 is provided at the front and rear of the plug support 8, and the mounting bracket 10 has a fixing hole. A spring support 9 is provided on the left and right sides of the plug support 8. The AC plug 4 includes two metal prongs and a cylindrical plastic body connecting the two metal prongs. The AC plug 4 is fixed to the support holes of the plug support 8 by the plastic body, allowing the AC plug 4 to rotate on the plug support 8. The conductive spring 5 includes an elastic part 501, a fixing part 502, and a spring connecting part 503. Two conductive springs 5 ​​are provided, each conductive spring 5 is fixed to the spring support 9 by the fixing part 502; the spring connecting part 503 of the conductive spring 5 is fixedly connected to the circuit board connecting part 602, and the elastic part 501 is in contact with the metal prongs of the AC plug 4.

[0043] The top cover 2 is connected to the top of the main body 1. The top cover 2 has two slots 12 that match the AC plug 4, allowing the AC plug 4 to rotate out of the main body 1 for use and to be stored inside the main body 1 to reduce space occupation. The bottom surface of the top cover 2 has two plastic rivets 13, each rivet 13 matching a fixing hole in a mounting bracket 10. The rivets 13 and fixing holes ensure a more secure connection between the top cover 2 and the main body 1. The bottom cover 3 is connected to the bottom of the main body 1. The bottom cover 3 has three USB ports 14 for mounting USB connectors on the circuit board. External devices are powered via a USB cable connected to these USB connectors.

[0044] A method for assembling the above-mentioned fast charger includes the following steps:

[0045] (1) Install the PCB circuit board into the main body of the outer shell, so that the main body of the circuit board is located in the lower cavity, and the circuit board connection part enters the upper cavity through the through hole of the partition. Fix the spring connection part of the conductive spring to the circuit board connection part and solder it to the circuit board circuit to realize the circuit conduction. Then fix the fixing part of the conductive spring to the spring support. Then install the AC plug on the plug support so that the metal plug end of the AC plug contacts and connects with the elastic part of the conductive spring. Finally, use ultrasonic welding to connect the upper cover plate to the top of the main body of the outer shell.

[0046] (2) Invert the outer shell and pour silicone into the lower cavity of the outer shell, and wait for the silicone to cure;

[0047] (3) Use ultrasonic welding to connect the lower cover plate to the bottom of the outer shell body.

[0048] The above embodiments of the present invention are not intended to limit the scope of protection of the present invention. The implementation of the present invention is not limited thereto. All other modifications, substitutions or alterations made to the above structure of the present invention based on the above content of the present invention, in accordance with ordinary technical knowledge and common practice in the field, without departing from the basic technical idea of ​​the present invention, shall fall within the scope of protection of the present invention.

Claims

1. A method for assembling a fast charger, the fast charger comprising an upper cover plate, a lower cover plate, and a housing body, wherein the upper cover plate... The cover plate is connected to the top of the outer casing, and the lower cover plate is connected to the bottom of the outer casing; it also includes a PCB circuit board disposed within the outer casing; characterized in that... The assembly method includes the following steps: (1) The PCB circuit board is installed into the housing body. The PCB circuit board includes a circuit board body and a circuit board connection part. The housing body is provided with a partition, which divides the housing body into an upper cavity and a lower cavity. The partition is provided with a through hole that can only accommodate the circuit board connection part. The size and thickness of the circuit board connection part are equivalent to the size of the through hole. The circuit board body is located in the lower cavity. The circuit board connection part passes through the through hole of the partition and enters the upper cavity. The circuit board connection part is connected to the AC plug located in the upper cavity. The upper cover plate is ultrasonically welded to the housing body. (2) Invert the outer shell and pour silicone into the lower cavity of the outer shell, and wait for the silicone to cure; (3) Ultrasonic welding is performed between the lower cover plate and the outer shell body; The top cover plate has two slots that match the AC plug; plastic rivets are provided on the bottom surface of the top cover plate, and correspondingly, a mounting bracket is provided on the top surface of the partition, the mounting bracket having fixing holes that match the rivets; The top surface of the partition is provided with a plug holder with a support hole. The AC plug is fixed to the support hole of the plug holder by a plastic body, so that the AC plug can rotate on the plug holder. The top surface of the partition is provided with a spring support, and the conductive spring is fixed to the spring support by a fixing part.

2. The fast charger assembly method according to claim 1, characterized in that, The process of connecting the circuit board connection part to the AC plug located in the upper cavity specifically includes: fixing the conductive spring to the top surface of the partition, fixing and soldering the conductive spring to the circuit board connection part, and fixing the AC plug to the partition and making contact with the conductive spring.

3. The fast charger assembly method according to claim 2, characterized in that, The AC plug includes two metal prongs and a plastic body connecting the two metal prongs.

4. The fast charger assembly method according to claim 3, characterized in that, The plastic body is cylindrical.

5. The fast charger assembly method according to any one of claims 2-4, characterized in that, The conductive spring includes an elastic part, a fixing part, and a spring connecting part.

6. The fast charger assembly method according to claim 5, characterized in that, The conductive spring is fixed to the circuit board connection part through the spring connection part and is soldered to the circuit board connection part to achieve circuit conduction.

7. The fast charger assembly method according to claim 6, characterized in that, The conductive spring is connected to the metal prong end of the AC plug through the elastic part.

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