Compact Multi-Port Power Adapter Assembly With Flexible Interposer
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Solution Overview
Problem
Existing power adapters face challenges in achieving a small form factor while delivering a large amount of power, charging multiple devices simultaneously, and efficiently allocating power among them, often requiring complex assembly and being prone to physical shocks.
Innovation Solution
The power adapter incorporates a flexible interposer with angled contacts and additional alignment features, a hoop-and-snap enclosure design, and space-efficient components like a toroid-shaped inductor to simplify assembly, absorb shocks, and optimize power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the power adapter uses conventional wired connections and rigid structures, then assembly is complex and components are vulnerable to physical shocks, but simplifying the structure may compromise alignment precision and connection reliability
Solution Approach 1:
The patent employs flexible printed circuit boards (FPC) instead of conventional rigid wired connections. The FPC allows for simplified assembly while maintaining connection reliability through its flexibility and strain relief capabilities, directly resolving the contradiction between ease of manufacture and connection reliability
Solution Approach 2:
The patent incorporates pre-designed strain relief features and flexible connection elements that cushion against physical shocks before they can damage critical components. This beforehand cushioning approach maintains connection reliability while allowing for simpler, more shock-resistant structures
2Adaptability or versatility
If the power adapter includes multiple connector receptacles and alignment features, then it can charge multiple devices simultaneously, but the internal space consumption increases
Solution Approach 1:
The patent implements a nested arrangement where connector receptacles and alignment features are positioned to utilize vertical and lateral spaces efficiently. The FPC is routed through existing structural cavities and channels, nesting the connection pathways within the adapter's housing rather than requiring separate dedicated spaces
Solution Approach 2:
The patent transitions from planar layout to three-dimensional spatial utilization by routing FPC connections through vertical channels and utilizing the Z-axis dimension for component placement. This dimensional approach allows multiple connector receptacles to be accommodated without proportionally increasing the adapter's footprint
3Reliability
If the power adapter uses a flexible interposer with angled contacts, then it can absorb manufacturing tolerances and physical shocks, but the structural complexity increases
Solution Approach 1:
The flexible interposer with angled contacts is designed to automatically absorb manufacturing tolerances and physical shocks through its inherent flexibility and geometry, without requiring additional active components or complex adjustment mechanisms. The structure serves itself by using the flexibility of the FPC and the angular geometry of contacts to compensate for variations and stresses
4Productivity
If the power adapter delivers a large amount of power to fast charge devices, then charging speed improves, but heat generation and power allocation complexity increase
Solution Approach 1:
The patent incorporates power allocation logic that monitors device connection status and power requirements, dynamically distributing available power among multiple devices. This feedback-based approach enables fast charging capability while managing power allocation complexity through automated monitoring and adjustment of power distribution
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
The solution enables power adapters with a compact design that can efficiently charge multiple devices, withstand physical impacts, and allocate power consistently, while reducing assembly complexity and internal space consumption.
Implementation Method 1
The flexible interposer can absorb energy from a physical shock or impact that can be caused by the power adapter being dropped
Implementation Method 2
The alignment adapter can be located in the pathway from the power prongs, which receive AC power, through a transformer that converts the AC power to DC power
Data Source
AI summary
Power adapters having a small-form factor, are capable of delivering a large amount of power, can charge multiple electronic devices, and can allocate power between the multiple electronic devices in an efficient manner.