AC Adapter Assembly with Spring-Mounted Terminals and Foldable Prongs
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Solution Overview
Problem
Existing AC adapters for portable Information Handling Systems (IHSs) face challenges in portability due to varying AC plug configurations worldwide, and the assembly of both foldable and fixed prong plugs requires complex wiring connections to the power circuit.
Innovation Solution
A method for assembling AC plugs that uses a common assembly process for both foldable and fixed prong configurations, eliminating the need for wires by securing spring-mounted terminals and prongs directly to a printed circuit board via a cap, allowing for easy adaptation to different geographic outlet types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring connections are used to connect prongs to the power circuit, then reliable electrical connections are achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent extracts and eliminates the wiring connections from the assembly, directly connecting the spring-mounted terminals and prongs to the PCB through the cap structure without intermediate wires, thereby simplifying the assembly while maintaining electrical connectivity
Solution Approach 2:
The cap serves as a multi-functional component that combines the functions of structural support, electrical connection, and mechanical fastening, merging multiple components into one to reduce assembly complexity while ensuring reliable electrical connections
2Adaptability or versatility
If separate assembly processes are used for foldable and fixed prong configurations, then each configuration can be optimized, but manufacturing complexity and costs increase
Solution Approach 1:
The cap is designed as a universal component that can accommodate both foldable and fixed prong configurations through the same assembly process, making the assembly system multi-functional and adaptable to different prong types without requiring separate assembly procedures
Solution Approach 2:
The assembly system incorporates dynamic adaptability by allowing the same cap and spring-mounted terminal structure to work with both foldable and fixed prongs, enabling the manufacturing process to dynamically adjust to different configurations without changing the fundamental assembly method
3Ease of operation
If foldable prongs are implemented to enhance portability, then the AC adapter becomes more portable, but the assembly requires complex wiring connections
Solution Approach 1:
The patent removes the complex wiring connections from the foldable prong assembly, directly integrating the electrical connection function into the cap and spring-mounted terminal structure, thereby maintaining portability benefits while eliminating wiring complexity
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 approach simplifies the assembly process, reduces costs, and enhances the portability of AC adapters by enabling reliable connections without wires, supporting both foldable and fixed prong configurations using common components.
Implementation Method 1
each spring mounted terminal is loaded and exerts a force against a prong of the plurality of prongs
Data Source
AI summary
An AC (Alternating Current) plug for providing power via a power circuit is assembled by: selecting a cover that includes prongs and structures on an inner side; positioning a PCB (printed circuit board) that includes contact pads connecting the PCB to the power circuit on structures of the inner side of the cover; positioning the spring mounted terminals on structures on the inner side of the cover such that a first end of each spring mounted terminal is positioned on a contact pad of the PCB; positioning a cap on the spring mounted terminals, the PCB and the cover, such that assembly holes of the cap, the PCB and the cover are aligned; and fastening the cap to the cover, such that the first end of each spring mounted terminal is secured against a respective contact pad and each spring mounted terminal is loaded and exerts a force against a prong.