Compact Power Adapter Connector Assembly
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Solution Overview
Problem
There is a need for compact and efficient power adapters that can efficiently convert AC power to DC power without requiring complex assembly operations such as soldering or custom wiring, while also being thinner and more compact in design to accommodate modern portable electronic devices.
Innovation Solution
The solution involves a compact power adapter design where metal prongs are mechanically and electrically connected to metal bases, which are then coupled to a printed circuit board assembly using connectors, allowing for reliable interconnections without wires or soldering, and a molded cap is used to expose the prongs while keeping the bases non-conductive, facilitating a low-profile and space-efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional power adapter construction methods are used with wires and soldering, then reliable electrical connections can be achieved, but assembly complexity and manufacturing time increase
Solution Approach 1:
The power adapter is divided into modular components: a plug assembly with integrated electrical contacts, a housing, and a circuit board assembly. The electrical contacts are segmented into blade contacts and tip contacts that can be independently positioned and connected, allowing for simplified assembly while maintaining reliable electrical connections without traditional soldering processes.
Solution Approach 2:
The patent introduces an intermediary mechanism in the form of integrated electrical contacts that directly bridge the blade contacts and tip contacts to the circuit board assembly through mechanical engagement rather than soldering. This intermediary connection method simplifies assembly while ensuring reliable electrical connectivity.
2Volume of moving object
If power adapters are made thinner and more compact, then space efficiency improves, but assembly precision and manufacturing difficulty increase
Solution Approach 1:
The patent merges the blade contacts and tip contacts into a single integrated plug assembly that is molded as one piece with the housing. This consolidation eliminates the need for separate positioning and assembly of individual contacts, reducing assembly precision requirements while enabling a thinner, more compact power adapter design.
Solution Approach 2:
The housing serves multiple functions: it provides structural support, acts as an insulator, integrates the electrical contacts, and forms the outer protective casing. This multi-functionality reduces the number of separate components needed, simplifying assembly and enabling a more compact overall design.
3Ease of manufacture
If connectors are used to couple blades to printed circuit board assembly, then assembly is simplified without soldering, but connection reliability may be compromised
Solution Approach 1:
The electrical contacts are nested within the housing structure, with the blade contacts and tip contacts positioned in recesses that guide their alignment with the circuit board assembly. This nested arrangement ensures precise mechanical engagement and reliable electrical connection without requiring soldering, as the housing itself provides the positioning and retention mechanism.
Data Source
Figure 1A~1C
Figure 2~3
Figure 4A~4B
AI summary
A compact power adapter is disclosed. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug. The internal terminals used by a power adapter plug of a power adapter can be coupled to a printed circuit board assembly using connectors, thereby facilitating interconnection with electrical components used by the power adapter.