Power Supply Connector and LED Layout for Smaller Case Openings
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Solution Overview
Problem
The decreasing volume of power supplies due to high power density and integration trends compresses available space, preventing the accommodation of additional electronic devices and requiring larger cases to accommodate exposed LEDs and electrical connectors.
Innovation Solution
A power supply design that omits the LED substrate, allowing the LED to be directly mounted on an extension part of the case, with the electrical connector's contacting ring covering part of the LED base, reducing the case's opening size and enabling a smaller volume case.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the LED substrate is disposed in the power supply case, then the LED can be mounted and function properly, but the available space within the case is compressed
Solution Approach 1:
The patent extracts the LED from its traditional substrate mounting and directly mounts it on the case wall. This removes the need for a separate LED substrate component, thereby eliminating the space it would occupy within the case while still achieving the LED's lighting function.
Solution Approach 2:
The patent merges the LED mounting function with the case structure itself. By directly mounting the LED on the case wall rather than on a separate substrate, the case serves dual purposes: as the housing structure and as the mounting platform for the LED, thereby reducing overall component count and space requirements.
2Ease of operation
If the LED and electrical connector are disposed on the exterior of the case and exposed through an opening, then they can be accessed externally, but the area of the opening must be large enough to accommodate both components
Solution Approach 1:
The patent transitions the LED from a two-dimensional planar arrangement (where it would occupy horizontal space next to the connector) to a three-dimensional vertical arrangement (mounting it on the side wall). This dimensional change allows the LED and connector to be accessed through a smaller opening while maintaining external accessibility.
Solution Approach 2:
The patent nests the LED within the spatial envelope defined by the case wall and opening. By mounting the LED on the side wall rather than placing it externally alongside the connector, the LED effectively uses the vertical space within the case profile, allowing both components to be accessed through a reduced opening area.
3Reliability
If the case volume is increased to accommodate the LED and electrical connector, then both components can be properly exposed, but the overall power supply size increases
Solution Approach 1:
The patent extracts the LED from the traditional substrate assembly and repositions it on the case wall. This extraction eliminates the need for additional space to accommodate a separate substrate, allowing the case to maintain a compact volume while still providing proper exposure and access to both the LED and electrical connector.
Solution Approach 2:
By moving the LED to a vertical mounting position on the case wall rather than a horizontal position within the case cavity, the patent utilizes the third dimension (height/vertical space) rather than increasing the horizontal footprint. This allows proper component exposure without increasing the overall case volume.
Data Source
AI summary
A power supply is provided. The power supply includes a case, an electrical connector and a LED. The case includes a first side wall including an extension part. The extension part is extended from the first side wall toward a second side wall and has an aperture. Portion of the electrical connector is disposed in an accommodation space through an opening and includes a first base and a contacting ring. The first base is disposed in the accommodation space. The contacting ring is disposed on an exterior of the accommodation space. The LED is disposed in the aperture and includes a second base and a lens disposed on the second base. The second base and the contacting ring are located on different surfaces. The lens and portion of the second base are exposed from the opening. The other portion of the second base is covered by the contacting ring.