Electrical Adapter Housing with Elastic Contacts

Solution Overview

Problem

Conventional electrical adapters face increased manufacturing costs and reduced yield due to the need for complex engagement mechanisms between the transformer unit and plug assembly, which complicates assembly and component replacement.

Innovation Solution

The adapter features a housing with compartments and slits, a PCB with elastically bent contacts and positioning grooves, and a damping section with channels, allowing for secure electrical connections without the need for soldered components, using bent contacts to reliably connect electrical terminals to the connecting surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If engaging members and posts are provided on transformer unit and plug assembly respectively, then connection between components is achieved, but manufacturing cost increases and yield decreases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the plug assembly with the housing by integrating the blade assembly directly into the housing structure. The housing serves dual functions as both structural enclosure and mounting platform for electrical components, eliminating the need for separate engaging members and reducing part count.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is designed to perform multiple functions: it provides structural protection, serves as mounting platform for transformer and PCB, contains damping sections for vibration absorption, and integrates blade assemblies for electrical connection. This multi-functionality reduces the need for separate specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If engaging members and posts are provided on transformer unit and plug assembly respectively, then connection between components is achieved, but assembly complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the plug assembly with the housing by integrating the blade assembly directly into the housing structure. The housing serves dual functions as both structural enclosure and mounting platform for electrical components, eliminating the need for separate engaging members and reducing part count.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing is divided into functional sections including front portion with blade assemblies, rear portion with damping sections, and bottom plate with mounting holes. This segmentation allows independent manufacturing and assembly of different functional modules while maintaining overall system simplicity.

Inventive Principle:

Principle #1Segmentation

3Reliability

If complex engagement mechanisms are used, then connection reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the plug assembly with the housing by integrating the blade assembly directly into the housing structure. The housing serves dual functions as both structural enclosure and mounting platform for electrical components, eliminating the need for separate engaging members and reducing part count.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The elastically bent contacts automatically engage with electrical terminals through spring pressure, providing self-aligning and self-locking connection without requiring complex engagement mechanisms or precise manual assembly. The elastic deformation of contacts accommodates dimensional variations and ensures reliable electrical connection.

Inventive Principle:

Principle #25Self-service

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 simplifies assembly and reduces manufacturing costs by eliminating the need for complex engagement mechanisms, ensuring reliable electrical connections and easy component replacement.

Implementation Method 1

two elastically bent contacts mounted on a rear end of the PCB

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS7563139B1Connecting arrangement of electrical adapter

Publication Date: 2009.07.21 WANG LIEN SHENG

AI summary

An electrical adapter includes a housing comprising a front portion including two compartments and two front slits, and a rear portion including longitudinal slots and a damping section including two side cavities, and bottom channels; two blades each having a rear portion fastened in the slit and the compartment; a PCB in the housing and having a transformer unit; two conductive seats on a front end of the PCB, each seat being fastened in the compartment; elastically bent contacts mounted on a rear end of the PCB, the contact including a connecting surface and an axial central positioning groove on the connecting surface; and an electrical wire having its rear portion bent to pass the channel to fasten an end electrical terminal of either conductor thereof on the groove in the cavity and electrically connect same to the connecting surfaces.