Patent Grant
8944857
Electronic devices often receive power from power adapters that receive power of a first type then convert it to a second type. For example, a power adapter may receive AC power at a first voltage and translate it to DC power at a second voltage. Prongs on a power plug for the power adapter may arranged to receive power a power outlet, such as a wall outlet. The power adapter may provide power over a specialized connector to the electronic device. Power may thus be provided from the wall outlet to the electronic device.
Different regions and counties may have individual infrastructures each having their own protocols for providing power at wall outlets. These protocols may involve different voltages being provided by the wall outlets as well as different physical connections for receiving power from the outlets. For example, the United States may use two flat prong or blade power connections to receive 110 Volts, where Europe may use round power prongs to receive 220 Volts.
Given the difference between regions, it may be difficult and time consuming to design different power connectors for each protocol. Accordingly, it may be desirable to be able use at least parts of these connectors in more than one region.
These power plugs may need to be functionally reliable. It may be very discouraging for a user to have an expensive electronic device become even temporarily unusable due to a defective power plug. Such a failure may also undermine a user's confidence in the device itself, and with the company that manufactured the device.
Also, it is often the case that many millions of devices may be manufactured, each needing a power plug. Even a small failure rate in manufacturing, or yield loss, may result in the loss of large numbers of plugs. Accordingly, it may be useful for these plugs to be designed such that they may be reliably manufactured.
Further, the appearance of these power plugs may inform a user's opinion as to the quality of not just the plug, but of the electronic device itself. A pleasant appearance may go a long way to informing user's appreciation of an electronic device as well as the levels of user satisfaction and enjoyment of the electronic device.
Thus, what is needed are power plugs that may have portions that can be used in more than one region, provide reliable functionality, may be reliably manufactured, and have a pleasant appearance.
Accordingly, embodiments of the present invention may provide power plugs that may include portions that can be used in different regions, may provide reliable functionality, may be reliably manufactured, and have a pleasant appearance.
An illustrative embodiment of the present invention may provide power plugs for different regions having portions that may be reused among the different regions. For example, power plugs according to embodiments of the present invention may include a prong assembly that includes prongs for a particular region. The prong assembly may be attached to a clip assembly that may mate with a power adapter. The clip assembly may be common among multiple regions while the prong assembly is tailored for use with power outlets for a particular region.
An illustrative embodiment of the present invention may provide power plugs that function in a highly reliable manner. In one embodiment of the present invention, the prong assembly may be formed by injecting an inner mold over portions of the power prongs. An additional overmold may then be formed over the inner mold such that the overmold forms a large portion of the power plug. This molding may provide a durable housing for the power plug such that it may function in a highly reliable manner.
The overmold may further include guard portions around ends of the prongs. In this way, if the power plug is damaged or destroyed such that the clip assembly is dislodged while the prongs remain in an outlet, the prongs are guarded and are less likely to come into human or other type of contact.
An illustrative embodiment of the present invention may provide power plugs that may be reliably manufactured. In one embodiment of the present invention, a contact having a clip portion may be used to form a connection to a power prong. Using this contact may remove the need for wires, as well as the need for soldering or welding in the assembly of the power plugs, thereby increasing reliability and simplifying the manufacturing process.
Another embodiment of the present invention may provide locating or alignment features to aid in assembling the prong assembly and the clip assembly. These alignment features may protect the contacts during assembly, thereby improving yield and reducing defects. In one specific embodiment of the present invention, tabs located on the clip assembly are arranged to fit in specific openings in the overmold. When the tabs one the clip are aligned with these openings, ends of the power prongs in the prong assembly are aligned with clip portions of the contacts on the clip assembly.
An illustrative embodiment of the present invention may provide power plugs that may have a desirable appearance. In a specific embodiment of the present invention, an inner mold may include a central passage. This central passage may be used as a pathway for a nozzle to inject material for an overmold over the inner mold. Injecting the overmold from front-to-back in this way greatly reduces the occurrence of seams and other artifacts due to the flow of material during the injection of the overmold.
An illustrative embodiment of the present invention may provide a power plug that includes a prong assembly and a clip assembly. The prong assembly may include a plurality of power prongs, an inner mold formed over central sections of the prongs, and an overmold around the inner mold. The clip assembly may include a plurality of contacts each having a clip portion to accept an end of one of the plurality of power prongs, a contact holder to support the plurality of contacts, and a clip to support the contact holder.
An illustrative embodiment of the present invention may provide a method of assembling a power plug. This method may include forming a prong assembly and forming a clip assembly. The prong assembly may be formed by receiving a plurality of power prongs, forming an inner mold over central portions of the power prongs, and forming an overmold over the inner mold. The clip assembly may be formed by receiving a plurality of contacts each having a clip portion to accept an end of one of the plurality of power prongs, placing the contacts on a contact holder, and inserting the contact holder in a clip.
Various materials may be used in the manufacturing of power plugs according to embodiments of the present invention. The contacts and prongs may be formed using stainless steel, copper, copper titanium, phosphor bronze, nickel, or other appropriate material, and they may be plated with copper, nickel, palladium, gold, or other appropriate material. The clip, contact support, inner mold, and overmold may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), polycarbonates, or other nonconductive material or combination of materials. Power plugs consistent with embodiments of the present invention may provide portions of power paths through power adapters for electronic devices such as portable computers, laptops, tablets, desktops, all-in-one computers, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors and other devices.
Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings.
Power plug 100 may include power prongs 120 which may be electrically connected to contact terminals (not shown) located in clip terminal 140. Clip terminal 140 may fit in an opening in a power adapter. Contact terminals located in clip terminal 140 may form electrical connections with circuitry inside the power adapter. Power received at power prongs 120 may thus be provided to the power adapter. The power adapter may convert power received at prongs 120 and provide the converted power to an electronic device. For example, power prongs 120 may receive power at a first voltage and the power adapter may provide power at a second voltage to the electronic device. The power adapter may also convert AC power to DC power.
Power plug 100 may further include an overmold 110 covering portions of prongs 120 as well as internal electrical connections. Power plug 100 may further include clip 130, which may include clip terminals 140 and may provide support for overmold 110.
By providing a large overmold 110, power plug 100 may be robust, durable, and reliable. Also, embodiments of the present invention may be readily assembled. In various embodiments of the present invention, power plug 100 may include a prong assembly mated to a clip assembly. An example of such a prong assembly is shown in the following figure.
Again, embodiments of the present invention may provide power plugs having portions that may be used in power plugs for different regions. In various embodiments of the present invention, a clip assembly may be commonly used among power plugs for different reasons. An example of such a clip assembly is shown in the following figure.
This prong assembly may then be fitted to the clip assembly to form power plug 100. An example of how this may be done is shown in the following figure.
Specifically, a prong assembly including prong 120, inner mold 210, and overmold 110, may be assembled to a clip assembly including clip 130, contact 310 including clip 314, and clip terminal 140. To ensure proper assembly, contact holder 320 may include locating feature 322. Locating future 322 may be a tab. Overmold 110 may include an opening to allow insertion of tab 322 during assembly. In this way, when tab 322 is aligned to this opening in overmold 110, end 122 of prong 120 may be properly aligned to clip 314 of contacts 310.
In this example, overmold 110 and clip 130 may meet along a seam 410. This seam may include notches such that narrow portions of overmold 110 and clip 130 are formed. After assembly, overmold 110 may be subject to ultrasound vibration. This ultrasound vibration may cause localized heating in these narrow areas, locally melting overmold 110 and forming a seal around the edge of clip 130.
Overmold 110 may include guard portions 116 and 114. In the event that power plug 110 is damaged such that the clip assembly and contacts are removed, ends 122 of prongs 120 may remain protected by guards 114 and 116. By protecting the ends 122 of prongs 120 in this way, even when prongs 120 remaining in an outlet, the chance of human or other contact with prong ends 122 is reduced. Guards 114 and 116 may be portions of guard rings 510.
Again, embodiments of the present invention may provide clip assemblies that may be used for power plugs for different regions. Another such power plugs is shown in the following figures.
Again, the clip assembly for power plug 600 may be the same as the clip assembly for power plug 100. Accordingly,
Again, power plugs according to embodiments of the present invention may be formed by attaching a prong assembly to a clip assembly. An example is shown in the following figure.
The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4984998 | Duncan et al. | Jan 1991 | A |
| 5123071 | Mulholland et al. | Jun 1992 | A |
| 5199886 | Patterson | Apr 1993 | A |
| Number | Date | Country | |
|---|---|---|---|
| 20140113499 A1 | Apr 2014 | US |
