COMPACT CONTOUR ELECTRICAL CONVERTER PACKAGE

• US 20060292905A1
• Filed: 07/20/2006
• Published: 12/28/2006
• Est. Priority Date: 06/08/2005
• Status: Active Grant

• Current Assignee: Patrick Gilliland
• Original Assignee: Patrick Gilliland
• Inventors: Gilliland, Patrick
• Granted Patent: US 7,477,533 B2
• Time in Patent Office: Days
• US Class Current: 439/107
• CPC Class Codes: H01R 13/652 with earth pin, blade or socket
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 2103/00 Two poles
• CPC Class Codes: H01R 2201/16 for telephony
• CPC Class Codes: H01R 24/30 with additional earth or shield contacts
• CPC Class Codes: H01R 31/065 with built-in electric apparatus
• CPC Class Codes: Y10S 439/936 Potting material or coating, e.g. grease, insulative coating, sealant or, adhesive
• CPC Class Codes: Y10S 439/957 Auxiliary contact part for circuit adaptation

Abstract

A circuit assembly and package incorporates a front cover with power contacting blades extending from a front surface thereof for electrical engagement in a receptacle having a standard peripheral dimension. A housing is attached to the front cover and extends perpendicularly therefrom. The housing contains an electrical circuit connected to the power contacting blades which is contained on a plurality of circuit boards mounted substantially perpendicular to the front cover. The housing and front cover create a footprint less than the peripheral dimension of the receptacle. A connecting cable extends from the housing and is connected to the electrical circuit.

Claims

1. An electrical converter comprising:

a plug body with electrical contacts extending perpendicularly from a front surface thereof for electrical engagement in a receptacle having a peripheral dimension, said plug body having a footprint less than the peripheral dimension of the receptacle and containing

a power entry circuit with a line voltage input connected to at least one electrical contact and having at least one means for interrupting the line voltage input;

a startup regulator having a first rectifier connected intermediate the power entry circuit and a regulation circuit charging a startup voltage storage capacitor, the startup regulator further having a feedback circuit for setting the startup voltage level;

a power supply having a second rectifier connected to the power entry circuit and having;

a power storage capacitor connected to the second rectifier,

a first power FET connected to the power storage capacitor;

an output inductor connected to the power FET, and

a first switching regulator control circuit powered by the startup regulator for regulating switching of the first power FET,

a converter and isolation circuit having

a first isolation device connected between the power supply output and a converter output,

a second power FET controlling power through the first isolation device,

a second switching regulator control circuit powered by the startup regulator and regulating switching of the second power FET, and

a feedback circuit for control of the second switching regulator control circuit.

2. An electrical converter as defined in claim 1 wherein the feed back circuit incorporates a second isolation device.

3. An electrical converter as defined in claim 1 wherein the first isolation device is an isolation transformer having a primary winding connecting the power supply output inductor and the second power FET and a secondary winding connected to the converter output.

4. An electrical converter as defined in claim 1 wherein a first power storage capacitor is connected to the output inductor.

5. An electrical converter as defined in claim 1 wherein the converter output is provided through a second storage capacitor.

6. An electrical converter as defined in claim 1 wherein an output rectifier is connected intermediate the first isolation device and the converter output.

7. An electrical converter as defined in claim 3 further comprising a catch diode connected across the primary winding.

8. An electrical converter as defined in claim 2 wherein the second isolation device is an optocoupler.

9. An electrical converter as defined in claim 1 wherein the power entry circuit has a means for surge and transient protection.

10. An electrical converter as defined in claim 9 wherein the means for surge and transient protection is a parallel transient protection diode connected across the line voltage input.

11. An electrical converter as defined in claim 1 wherein the interruption means is a fuse.

12. An electrical converter as defined in claim 1 further comprising a second power storage capacitor connected to the output inductor.

13. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a peripheral dimension substantially contained within a maximum peripheral dimension of a mating AC receptacle, the plug body containing

a power entry circuit with a line voltage input;

a startup regulator having a first rectifier connected to the power entry circuit and having a first voltage output;

a power supply connected to the power entry circuit and controlled by the first voltage output, the power supply having a second voltage output;

a converter and isolation circuit having

a first isolation device connected between the second voltage output and a converter output,

a power FET controlling power through the first isolation device,

a switching regulator control circuit powered by the first voltage output and regulating switching of the power FET, and

a feedback circuit having a second isolation device for control of the switching regulator control circuit.

14. An electrical converter as defined in claim 13 wherein the first isolation device is an isolation transformer having a primary winding connecting the power supply second voltage output and the power FET and a secondary winding connected to the converter output.

15. An electrical converter as defined in claim 13 wherein the second isolation device is an optocoupler.

16. An electrical converter as defined in claim 13 wherein the power entry circuit has at least one means for disconnecting the line voltage input;

17. An electrical converter as defined in claim 13 wherein the power supply includes a second rectifier connected to the power entry circuit and has:

a power storage capacitor connected to the second rectifier,

a supply power FET connected to the power storage capacitor;

an output inductor connected to the power FET to provide the second voltage output, and

a supply switching regulator control circuit powered by the startup regulator for regulating switching of the first power FET.

18. An electrical converter as defined in claim 13 wherein the startup regulator has a regulation circuit charging a first storage capacitor to provide the first voltage output.

19. An electrical converter as defined in claim 17 wherein the output inductor charges a second storage capacitor providing the second voltage output.

20. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a peripheral dimension substantially contained within a maximum peripheral dimension of a mating AC receptacle, the plug body containing

a power entry circuit with a line voltage input;

a startup regulator having a first rectifier connected to the power entry circuit and having a first voltage output;

a power supply connected to the power entry circuit having a second rectifier and further having

a power storage capacitor connected to the second rectifier,

a first power FET connected to the power storage capacitor;

an output inductor connected to the power FET and charging a storage capacitor for a second voltage output, and

a first switching regulator control circuit powered by the first voltage output for regulating switching of the first power FET,

a converter and isolation circuit having

a first isolation device connected between the second voltage output and a converter output; and

means for controlling power through the first isolation device.

21. An electrical converter as defined in claim 20 wherein the first isolation device is an isolation transformer and the means for controlling power through the first isolation device comprises:

a power FET controlling power across a primary winding of the transformer,

a switching regulator control circuit powered by the first voltage output and regulating switching of the power FET, and

a feedback circuit having a second isolation device for control of the switching regulator control circuit.

22. An electrical converter as defined in claim 20 wherein the startup regulator further comprises a regulation circuit connected to the first rectifier and charging an output capacitor providing the first output voltage, the startup regulator further having a feedback circuit for setting the first output voltage level.

23. An electrical converter as defined in claim 21 wherein the second isolation device is an optocoupler.

24. An electrical converter as defined in claim 23 wherein the optocoupler is controlled by a comparator receiving a bandgap voltage derived from the converter output.

25. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a peripheral dimension substantially conforming to a mating AC receptacle, the plug body containing

a power entry circuit with a line voltage input;

a startup regulator having a first rectifier connected intermediate the power entry circuit and a regulation circuit charging an output capacitor providing a first output voltage, the startup regulator further having a feedback circuit for setting output voltage level;

a power supply connected to the power entry circuit and controlled by the first voltage output, the power supply having a second voltage output;

a converter and isolation circuit having

a first isolation device connected between the second voltage output and a converter output; and

means for controlling power through the first isolation device.

26. An electrical converter as defined in claim 25 wherein the first isolation device is an isolation transformer and the means for controlling power through the first isolation device comprises:

a power FET controlling power across a primary winding of the transformer,

a switching regulator control circuit powered by the first voltage output and regulating switching of the power FET, and

a feedback circuit having a second isolation device for control of the switching regulator control circuit.

27. An electrical converter as defined in claim 26 wherein second isolation device is an optocoupler.

28. An electrical converter as defined in claim 27 wherein the optocoupler is controlled by a comparator receiving a bandgap voltage derived from the converter output.

29. An electrical converter as defined in claim 25 wherein the power supply includes a second rectifier connected to the power entry circuit and has:

a power storage capacitor connected to the second rectifier,

a supply power FET connected to the power storage capacitor;

an output inductor connected to the power FET, and

a supply switching regulator control circuit powered by the startup regulator for regulating switching of the first power FET.

30. An electrical converter as defined in claim 29 wherein the output inductor charges a second storage capacitor connected to the converter output.

31. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a footprint substantially conforming to a mating AC receptacle, the plug body containing

a power entry circuit with a line voltage input and having a fuse for disconnecting the line voltage input and a parallel transient protection diode connected across the line voltage input;

a startup regulator having a first rectifier connected to the power entry circuit and a regulation circuit charging an output storage capacitor, the startup regulator further having a feedback circuit for setting output voltage level;

a power supply having a second rectifier connected to the output capacitor of the power entry circuit and having;

a power storage capacitor connected to the second rectifier,

a first power FET connected to the power storage capacitor;

an output inductor connected to the power FET and providing an output through a second storage capacitor, and

a first switching regulator control circuit powered by the startup regulator for regulating switching of the first power FET,

a converter and isolation circuit having

an isolation transformer having a primary winding connected to the power supply output and secondary winding connected through a rectifier to a capacitor bank providing a converter output,

a catch diode across the primary winding,

a second power FET controlling power through the primary winding,

a second switching regulator control circuit powered by the startup regulator and regulating switching of the second power FET, and

a feedback circuit for control of the second switching regulator control circuit incorporating an optocoupler controlled by a comparator receiving a bandgap voltage derived from the converter output.

32. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a peripheral dimension substantially contained within a maximum peripheral dimension of a mating AC receptacle, the plug body containing

means for providing a regulated voltage output;

an isolation circuit having

a first isolation device connected between the regulated voltage output and a converter output,

a power FET controlling power through the first isolation device,

a switching regulator control circuit powered by the first voltage output and regulating switching of the power FET.

33. An electrical converter as defined in claim 32 further comprising:

a feedback circuit having a second isolation device for control of the switching regulator control circuit.

34. An electrical converter as defined in claim 33 wherein the second isolation device comprises an optocoupler.

35. An electrical converter as defined in claim 32 wherein the means for providing a regulated voltage comprises:

a power entry circuit with a line voltage input;

a startup regulator having a first rectifier connected to the power entry circuit and having a first voltage output;

a power supply connected to the power entry circuit and controlled by the first voltage output, the power supply having a second voltage output.

36. An electrical converter as defined in claim 35 wherein the first rectifier charges a first storage capacitor to provide the first voltage output.

37. An electrical converter as defined in claim 36 wherein the power supply provides the second voltage output by charging a second storage capacitor.

38. An electrical converter as defined in claim 36 wherein the power supply includes a second rectifier connected to the power entry circuit and has:

a power storage capacitor connected to the second rectifier,

a supply power FET connected to the power storage capacitor;

an output inductor connected to the power FET to charge the second storage capacitor.

39. An electrical converter comprising:

an alternating current (AC) plug body having a front surface with electrical contacts having an orienting indicia extending therefrom, the plug body having a peripheral dimension allowing two of said plug bodies to be inserted in a mating dulex AC receptacle, each plug body containing

means for providing a regulated voltage output;

an isolation circuit having a first isolation device connected between the regulated voltage output and a converter output.

40. An electrical converter as defined in claim 39 wherein the orienting indicia comprises a ground pin.

41. A circuit assembly and package comprising:

a male alternating current connector plug with a plug body for gripping to insert and remove said male alternating current connector plug from a mating female alternating current connector receptacle, said male alternating current connector plug and female alternating current connector receptacle defining a mating plane perpendicular to an insertion and removal axis, said female alternating current connector receptacle having maximum dimensions in a plane parallel to the mating plane thus defining a footprint and a periphery, said male alternating current connector plug body having a front surface parallel to the mating plane and said male alternating current connector plug front surface having electrical contacts extending therefrom in conformance with a set of intermating dimensions, for engaging with mating electrical contacts of said female alternating current connector receptacle, said male alternating current connector plug body and front surface having a profile along its entire length substantially within the footprint of said alternating current female connector receptacle;

at least one circuit substrate contained within said male alternating current connector plug body and having an electrical circuit, with at least one input of said electrical circuit making electrical connection to at least one of said electrical contacts extending from the front surface of the male alternating current connector plug body, and said electrical circuit including a power entry circuit having at least one rectifying diode with a first end connected to at least one of said electrical contacts extending from the front surface of the male alternating current connector plug body and said rectifying diode with a second end connected to a first storage capacitor, said at least one rectifying diode and first storage capacitor providing a rectified and filtered direct current electrical power source connected to a power conversion circuit having a power regulation circuit with feedback control with an input connected to said power entry circuit, and providing an output end with regulated electrical power for use by a power consuming device, and,

a connecting cable with a plurality of conductors extending from the male alternating current plug body distal the front surface and connected to an output end of the electrical circuit.

42. A circuit assembly and package comprising:

a male alternating current connector plug with a plug body for gripping to insert and remove said male alternating current connector plug from a mating female alternating current connector receptacle, said male alternating current connector plug and female alternating current connector receptacle defining a mating plane perpendicular to an insertion and removal axis, said female alternating current connector receptacle having maximum dimensions in a plane parallel to the mating plane thus defining a footprint and a periphery, said male alternating current connector plug body having a front surface parallel to the mating plane and said male alternating current connector plug front surface having electrical contacts extending therefrom in conformance with a set of intermating dimensions, for engaging with mating electrical contacts of said female alternating current connector receptacle, said male alternating current connector plug body and front surface having a profile along its entire length less than the footprint of said alternating current female connector receptacle;

at least one circuit substrate contained within said male alternating current connector plug body and having an electrical circuit, with at least one input of said electrical circuit making electrical connection to at least one of said electrical contacts extending from the front surface of the male alternating current connector plug body, and said electrical circuit including a power entry circuit having at least one rectifying diode with a first end connected to at least one of said electrical contacts extending from the front surface of the male alternating current connector plug body and said rectifying diode with a second end connected to a first storage capacitor, said at least one rectifying diode and first storage capacitor providing a rectified and filtered direct current electrical power source connected to a power conversion circuit having a power regulation circuit with feedback control with an input connected to said power entry circuit, and providing an output end with regulated electrical power for use by a power consuming device, and,

a connector with a plurality of conductors extending from the male alternating current plug body distal the front surface and connected to an output end of the electrical circuit.

43. A circuit assembly and package comprising:

a plug body with power contacting blades extending perpendicularly from a front surface thereof for electrical engagement in a receptacle having a peripheral dimension, said plug body containing a charging circuit connected to the power contacting blades, said plug body having a footprint less than the peripheral dimension of the receptacle;

a power entry circuit connected to the power contacting blades having at least one rectifying diode with a first end connected to at least one of said power contacting blades and said rectifying diode with a second end connected to a first storage capacitor;

a DC/DC converter with feedback control connected to and receiving power from the power entry circuit; and

,

a connecting cable extending from the plug body distal the front surface and connected to the electrical circuit.

44. A circuit assembly and package comprising:

an alternating current plug body with electrical contacts extending from a front surface thereof for electrical engagement in a receptacle having a peripheral dimension;

said alternating current plug body having a footprint less than the peripheral dimension of the receptacle;

an electrical circuit including at least one input of said electrical circuit making electrical connection to at least one of said electrical contacts extending from the front surface of the alternating current plug body, and said electrical circuit including a power entry circuit having at least one rectifying diode with a first end connected to at least one of said electrical contacts extending from the front surface of the alternating current plug body and said rectifying diode with a second end connected to a first storage capacitor, said first storage capacitor connected to a power conversion circuit having a power regulation circuit with feedback control, said electrical circuit contained on at least one circuit board mounted substantially perpendicular to the alternating current plug body front surface and connected to the electrical contacts, said alternating current plug body enclosing said at least one circuit board; and

,

a connecting device connected to the electrical circuit and including a connecting device body received in an opening in the alternating current plug body distal the front surface and extending from the housing alternating current plug body.

45. A circuit assembly and package comprising:

an alternating current plug body with electrical contacts extending from a front surface thereof for electrical engagement in an alternating current receptacle having a peripheral dimension;

said alternating current plug body containing an electrical circuit connected to the electrical contacts , said alternating current plug body having a footprint less than the peripheral dimension of the receptacle and said electrical circuit including a power entry circuit having at least one rectifying diode with a first end connected to at least one of said electrical contacts extending from the front surface of the alternating current plug body and said rectifying diode with a second end connected to a first storage capacitor, said at least one rectifying diode and capacitor providing a rectified and filtered direct current electrical power source connected to a power conversion circuit having a power regulation circuit with feedback control; and

,

a means for connecting an external power consuming device.

46. A circuit assembly and package comprising:

a male alternating current connector plug with a plug body for gripping to insert and remove said male alternating current connector plug from a mating female alternating current connector receptacle, said male alternating current connector plug and female alternating current connector receptacle defining a mating plane perpendicular to an insertion and removal axis, said female alternating current connector receptacle having maximum dimensions in a plane parallel to the mating plane thus defining a footprint and a periphery, said male alternating current connector plug body having a front surface parallel to the mating plane and said male alternating current connector plug front surface having electrical contacts extending therefrom in conformance with a set of intermating dimensions, for engaging with mating electrical contacts of said female alternating current connector receptacle, said male alternating current connector plug body and front surface having a profile along its entire length substantially conforming to the footprint of said alternating current female connector receptacle so that when the properly mated pair is viewed from a rear perspective of the male alternating current connector plug in the direction of the axis, the periphery of the female alternating current receptacle is visible;

at least one circuit substrate contained within said male alternating current connector plug body and having an electrical circuit, with at least one input of said electrical circuit drawing power through a power entry circuit which conditions input AC electrical power with minimal losses, by limiting maximum current, rectifying the AC power, and filtering a resulting raw DC power from said input AC electrical power provided by at least one of said electrical contacts extending from the front surface of the male alternating current connector plug body, said electrical circuit further having a power conversion circuit including a switch mode power regulation circuit having feedback control with an input connected to said power entry circuit, and providing an output end with regulated electrical power for use by a power consuming device, and,

a connecting device with a plurality of conductors extending from the male alternating current plug body distal the front surface and connected to the output end of the electrical circuit.

47. A circuit assembly and body comprising;

an alternating current (AC) plug with electrical input power contacts, including a body with a front surface having a maximum outer profile dimension;

a power supply, power entry circuit, a DC/DC converter circuit and a startup regulator circuit disposed in the body, the power supply having an AC to DC rectifying circuit and connected to and receiving power from the power entry circuit, the startup regulator circuit connected to the power entry circuit, and providing a circuit initiation voltage to the power supply and the DC to DC converter circuits;

an alternating current receptacle outlet having a peripheral dimension as specified in NEMA standard 5-15R defining the front face of the outlet for receiving the AC plug, the maximum outer profile dimension of the AC plug body less than the peripheral dimension of the alternating current receptacle.

48. A circuit assembly and alternating current plug comprising;

an alternating current (AC) plug body having a front surface with electrical contacts extending therefrom, the plug body having a peripheral dimension less than a maximum peripheral dimension of a mating AC receptacle;

an electrical circuit within said AC plug body with a primary circuit and a secondary circuit, said primary circuit having an input connected to and receiving power from at least one of said electrical contacts and said primary circuit connected to a transformer primary winding as a switchmode power regulation circuit, said secondary circuit input connected to and receiving power from a secondary winding of said transformer, and said secondary circuit with an output providing a transformer isolated electrical output.