Bidirectional Snap-Fit Power Adapter Housing Assembly

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Solution Overview

Problem

Ultrasonic welding of power adapter housing parts can cause thermal damage, aesthetic issues, and potential harm to internal electronic components, and results in weaker welds with geometric stress concentrations, making it inefficient and unreliable.

Innovation Solution

The use of modified snaps and protrusions with rails that deflect and bend in multiple directions to secure housing parts together, eliminating the need for ultrasonic welding and providing a strong, tool-free assembly that resists disassembly, thus ensuring the integrity and safety of the power adapter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If ultrasonic welding is used to join housing parts, then the housing parts are securely joined, but thermal damage occurs to the housing and electronic components

Engineering Contradiction:

Improvejoint strengthVSAvoidthermal damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the ultrasonic welding process (thermal/mechanical system) with a mechanical snap-fit system. The snap feature mechanically engages with the recess to join housing parts without applying thermal energy, thereby eliminating thermal damage to the housing and electronic components while maintaining secure attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The snap feature acts as an intermediary mechanical element between the two housing parts. Instead of directly welding the housing parts together, the snap mediates the connection by engaging with both parts through its protrusion and recess geometry, providing a secure joint without thermal exposure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If ultrasonic welding is used to join housing parts, then the housing parts are securely joined, but aesthetic appearance deteriorates due to marks and scuffing

Engineering Contradiction:

Improvejoint strengthVSAvoidaesthetic appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent replaces the ultrasonic welding process with a mechanical snap-fit system that does not involve high-frequency vibration or friction. This eliminates the generation of marks and scuffing on the housing surfaces, preserving the aesthetic appearance while maintaining secure attachment through the snap feature's mechanical engagement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If ultrasonic welding is used to join housing parts, then the housing parts are securely joined, but internal electronic components may be damaged by high-frequency energy

Engineering Contradiction:

Improvejoint strengthVSAvoidelectronic component integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the ultrasonic welding process with a mechanical snap-fit system that operates without high-frequency vibration or thermal energy. This eliminates the risk of damaging sensitive electronic components on the circuit board while maintaining secure attachment of the housing parts, thereby preserving electronic component integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If ultrasonic welding is used to join housing parts, then the housing parts are joined, but the welds are weaker than the housing material and contain stress concentrations

Engineering Contradiction:

Improveassembly processVSAvoidweld strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent replaces the welding process with a mechanical snap-fit system where the snap feature's protrusion engages with a recess in the other housing part. This mechanical interlocking creates a joint strength that can exceed the housing material strength, eliminating the weak welds and geometric stress concentrations inherent in ultrasonic welding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution prevents damage to housing and electronic components, eliminates the need for high-frequency or high-heat applications, and provides a secure assembly that is less likely to disassemble, ensuring the power adapter's reliability and safety, especially when connected to high-voltage sources.

Implementation Method 1

The snaps are designed for significant flexibility, as they are designed to deflect/bend in multiple, different directions

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11516929B2Power adapter housing with snaps capable of bidirectional deflection

Publication Date: 2022.11.29 APPLE INC

AI summary

A power adapter is disclosed. The power adapter includes housing parts that carries electronic components. To secure the housing parts together, one housing part includes snaps and another housing part includes protrusions and rails. During assembly, the protrusions slide under the snap, causing the snap to deflect in one direction, while the rails slide over the snap, which keeps the snap partially flat but also causes the snap to deflect in another direction. The engagement (during assembly) of the rails and the protrusions to opposing surfaces of the snap cause bi-directional deflection/bending of the snap. When each protrusion is positioned into an opening of the snap, the snap returns to a flat, non-deflected state, and the housing parts are secured together by the snap, protrusions, and rails. The rails support the snaps by limiting or preventing additional deflection of the snap, which subsequently promotes the housing remaining together.