Single-Piece Insulator Assembly for Power Adapter
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Solution Overview
Problem
Conventional power adapter manufacturing processes are prone to quality variations and reliability issues due to manual steps, such as hand-wrapping insulating materials and hand-soldering connections, which can lead to manufacturing problems and safety hazards, especially in compact designs where air insulation is ineffective.
Innovation Solution
A power adapter featuring a single-piece insulator unit with embedded channels and conductive members to establish electrical paths between primary and secondary printed circuit boards, along with a transformer and common mode choke, simplifying assembly and ensuring consistent spacing and reliable electrical connections, and using ultrasonic welding for assembly completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual steps are used for assembling insulating materials and electrical connections, then flexibility in assembly is maintained, but quality consistency and reliability deteriorate due to human error and variations
Solution Approach 1:
The patent combines multiple separate components (insulating material, support structure, and mounting features) into a single integrated insulator assembly. This integration eliminates the need for manual assembly steps while ensuring consistent quality, as the components are pre-positioned and secured together as one unit during automated manufacturing processes.
Solution Approach 2:
The insulating material is pre-secured to the support structure before final assembly, with mounting features already in place. This preliminary preparation allows for automated picking and placement without requiring manual manipulation during the assembly process, thereby improving both reliability and automation capability.
2Reliability
If separate printed circuit boards are used for AC and DC circuits, then electrical isolation is improved, but manufacturing complexity increases due to hand-soldering and component placement requirements
Solution Approach 1:
The patent integrates the mounting structure for both AC and DC circuit boards into a single insulator assembly with pre-formed mounting features. This allows both separate circuit boards to be mounted simultaneously using automated processes, maintaining electrical isolation while simplifying manufacturing by eliminating hand-soldering operations.
3Volume of moving object
If compact power adapter design is implemented, then space efficiency is improved, but insulation effectiveness deteriorates due to reduced air insulation between high and low voltage components
Solution Approach 1:
The patent introduces a dedicated insulator assembly as an intermediary component between high-voltage and low-voltage circuitry. This insulator provides physical separation and electrical isolation, ensuring adequate insulation even in compact designs where air insulation alone would be insufficient. The insulator material and structured design maintain safety tolerances while enabling space-efficient configuration.
4Adaptability or versatility
If multiple separate components are used for insulation and support, then functional flexibility is improved, but assembly time and manufacturing complexity increase
Solution Approach 1:
The patent merges the insulating material, support structure, and mounting features into a single integrated assembly that can be picked and placed as one unit. This integration maintains all necessary functional capabilities while enabling automated assembly, thereby improving productivity without sacrificing functional flexibility.
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 approach results in a more efficient, consistent, and reliable power adapter manufacturing process that meets safety tolerances, reduces manufacturing complexity, and enhances product reliability by eliminating manual errors and providing effective insulation between high and low voltage components.
Implementation Method 1
an insulator assembly that includes a single-piece insulator unit. The insulator assembly provides an electrical path between the primary circuit board and the secondary circuit board at designated locations
Implementation Method 2
The insulator assembly provides an electrical path between the primary circuit board and the secondary circuit board at designated locations
Implementation Method 3
using ultrasonic welding for assembly completion
Data Source
Figure 1A~2
Figure 3A~3B
Figure 4
AI summary
An AC-to-DC power adapter comprises a single-piece insulator unit. The various components of the power adapter such as a transformer, other circuitry, etc. are attached to the single-piece insulator unit. The single-piece insulator unit has embedded channels to provide electrical connectivity between the circuitry, The entire assembly is placed in housing and a cap assembly having prongs to connect to a AC wall outlet is ultrasonically welded to the housing.