AC Adapter Foldable Prongs Spring Terminal Assembly

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Solution Overview

Problem

Portable Information Handling Systems (IHSs) face challenges in portability due to the bulkiness and complexity of existing AC adapters, which often require frequent transportation and retraction of prongs, leading to potential damage and inconvenience.

Innovation Solution

The design of an AC plug with foldable prongs that can be extended for power insertion into an outlet and retracted for compact storage, eliminating the need for wires between prongs and the power circuit, utilizing a printed circuit board with contact pads and spring-mounted terminals secured by a cap for efficient power transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If prongs are made extendable for compact storage, then portability is improved, but reliability of electrical contact deteriorates

Engineering Contradiction:

ImproveportabilityVSAvoidelectrical contact reliability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The prongs are nested within slots in the cover when retracted, with the spring-mounted terminals positioned within the same cover structure. The prongs extend outward when needed for electrical contact, and retract into the cover body when not in use, creating a compact portable form while maintaining reliable electrical connection through the spring mechanism.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The prongs are designed to be dynamically extendable and retractable rather than fixed. The spring-mounted terminals provide dynamic electrical contact that maintains reliability whether the prongs are extended for power insertion or retracted for compact storage, adapting to both portable and operational states.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If wire harnesses are eliminated for simpler assembly, then manufacturing complexity is reduced, but electrical connection reliability may deteriorate

Engineering Contradiction:

Improveassembly simplicityVSAvoidelectrical connection reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the mechanical wire harness connection system with a direct spring-mounted terminal-to-prong contact system. The spring terminals are mounted directly to the PCB and make electrical contact with the prongs through mechanical pressure, eliminating the need for wire harnesses while maintaining reliable electrical connection through the spring force.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The electrical connection function is merged directly into the structural components. The spring-mounted terminals are integrated with the PCB and directly contact the prongs, combining the electrical connection function with the mechanical structure rather than using separate wire harnesses, thus simplifying assembly while maintaining reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Volume of moving object

If prongs are made foldable for compact storage, then device bulkiness is reduced, but susceptibility to damage during retraction increases

Engineering Contradiction:

Improvedevice bulkinessVSAvoidprong damage during retraction

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The spring-mounted terminals provide beforehand cushioning for the prongs during retraction. The spring mechanism absorbs mechanical shocks and stresses that occur when the prongs are retracted into the cover, protecting the prongs from damage while enabling compact foldable storage.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The prongs are nested within protected slots in the cover when retracted, with the spring-mounted terminals positioned within the same cover structure. This nesting arrangement protects the prongs from external damage during retraction and storage while maintaining compact form factor.

Inventive Principle:

Principle #7Nested doll (Nesting)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This design enhances the portability and reliability of AC adapters by simplifying assembly, reducing bulkiness, and preventing damage during transport, while maintaining efficient power transfer without the need for wire harnesses or soldering.

Implementation Method 1

each of the plurality of prongs contacts a respective spring mounted terminal coupled to the power circuit

Methodology Applied

Scientific EffectSpring contact: Spring

Data Source

PatentUS10770854B2High integration assembly process for AC adapter with foldable prongs

Publication Date: 2020.09.08 DELL PROD LP

AI summary

Methods of assembly are provided for an AC plug supporting foldable prongs. The AC plug includes: a cover including slots and prongs. In an extended position, the prongs are insertable in AC outlet receptacles and each prong contacts a spring mounted terminal that is coupled to a power circuit. In a retracted position, each prong is recessed in a slot of the cover and does not contact a spring mounted terminal. In the extended position, the coupling between each prong and the power circuit does not utilize wires. A first end of each spring mounted terminal is positioned on a contact pad of a printed circuit board (PCB) that connects the AC plug to the power circuit. A cap is fastened to the cover and secures the spring mounted terminals to the respective contact pads and secures the PCB and spring mounted terminal to the cover.