CHARGER PLUG WITH IMPROVED PACKAGE

• US 20090289596A1
• Filed: 05/21/2008
• Published: 11/26/2009
• Est. Priority Date: 05/21/2008
• Status: Active Grant

• Current Assignee: VoltStar Technologies, Inc.
• Original Assignee: VoltStar Technologies, Inc.
• Inventors: McGinley, James W., Rimdzius, Donald, Marcusen, David P.
• Granted Patent: US 9,024,581 B2
• Time in Patent Office: Days
• US Class Current: 320/111
• CPC Class Codes: H01R 13/24 resilient; resiliently-mounted
• CPC Class Codes: H01R 31/065 with built-in electric apparatus
• CPC Class Codes: H02J 7/0042 characterised by the mechanical construction

Abstract

A reduced plug-size charger plug for power conversion is disclosed utilizing a pair of blades that are slidably mounted into a charger housing, obviating the need for insertion molding. To promote and maintain electrical contact while minimizing package size and charger plug cost, a pair of spring contacts are provided for electrically connecting the blades with internal circuitry.

Claims

1. A charger plug comprising:

internal circuitry for converting input electrical power to output electrical power;

a housing comprising upper and lower halves defining an interior space for the internal circuitry;

an input assembly including prong portions for connecting with a power outlet and at least one leg portion, wherein at least one of the upper and lower halves includes an opening for slidably receiving each leg portion; and

a pair of electrically conducting spring contacts in biased engagement with respective portions of the input assembly for receiving input electrical power therefrom, the spring contacts in electrical connection with the internal circuitry, the spring contacts electrically isolated from each other.

2. The charger plug of claim 1 wherein the input assembly includes a pair of electrically conducting blade members including respective prong portions, a portion of each blade member being received in respective openings in the upper and lower halves, the respective prong portions electrically isolated from each other for receipt in the power outlet.

3. The charger plug of claim 2 wherein the upper and lower halves each include a pair of blind openings oriented generally vertically for receiving respective portions of the blade members therein for securing the blade members.

4. The charger plug of claim 3 wherein the spring contacts are mounted on the internal circuitry and are biased against a portion of the blade members.

5. The charger plug of claim 1 wherein the input assembly includes first and second blade members including respective prong portions, each of the blade members having a portion rearwardly located from the prong portions and slidably received in openings in each of the upper and lower halves for slidably mounting therein.

6. The charger plug of claim 5 wherein the openings and blade member rearward portions are configured for a frictional and non-rotational fit therebetween.

7. The charger plug of claim 5 wherein the spring contacts are in biased engagement with the blade member rearward portions.

8. The charger plug of claim 5 wherein the spring contacts are formed of wire.

9. The charger plug of claim 5 wherein the spring contacts include a spring arm portion for contacting the blade member and include a portion snap-fit with the internal circuitry.

10. The charger plug of claim 9 wherein the spring arm portion extends in a longitudinal direction and is resiliently flexible in a lateral direction thereto, and shifting of the spring arm portion from a natural position by the blade members creates a contacting force therebetween for providing and maintaining electrical connection between the spring contact and its respective blade member.

11. The charger plug of claim 9 wherein the spring contacts further include a portion secured with the internal circuitry to resist rotation of the snap-fit portion.

12. The charger plug of claim 9 wherein the spring arm includes a forwardly extending portion for biased engagement with the blade members.

13. The charger plug of claim 5 wherein the spring contacts further include a torsionally flexing spring arm portion for providing an elastic contacting force with the blade members.

14. The charger plug of claim 1 wherein the input assembly including the prong portions is secured without molding.

15. The charger plug of claim 1 wherein the electrical connection between the input assembly and the spring contacts is solder-less.

16. A charger plug providing power conversion for rechargeable electronic devices, the charger plug comprising:

internal circuitry for converting input electrical power to output electrical power including a plurality of components for power conversion mounted on a board and including electrical connections for receiving power;

an input assembly including first and second blades having prong portions for connecting with a power outlet and transmitting input electrical power to the internal circuitry via the electrical connections; and

a housing defining an interior space for the internal circuitry and slidably mounting the input power assembly therewithin in electrical contact with the electrical connections, the electrical connections being forwardly biased into engagement with the blade members.

17. The charger plug of claim 16 wherein the blades are separate members having a rearward structure having a rearwardly oriented surface, the housing includes openings for slidably receiving portions of the blades, and the electrical connections are forwardly biased into engagement with the rearwardly oriented surface.

18. The charger plug of claim 16 wherein the housing includes upper and lower halves, and each of the halves includes openings for receiving generally vertically oriented leg portions of the blades, and each of the halves includes slots for forwardly extending prong portions.

19. A charger plug for converting input alternating current power received from a power outlet to output direct current power, the charger plug being electrically connectable to a rechargeable electronic device for providing power thereto, the charger plug comprising:

a housing having a first end oriented towards a power outlet when connected thereto and a second end extending in a first direction away from the first end; and

first and second separate blade members secured with the first end of the housing so as to have prong portions extending in the first direction from slots formed in the housing, the blade members having mounting portions extending in a second direction that is transverse to the first direction, wherein the housing includes openings for slidably receiving the mounting portions.

20. The charger plug of claim 19 wherein each of the blade members is shaped with a prong portion extending in the first direction, with an elbow portion connected with the prong portion, and with the mounting portions connected to the elbow portion, wherein at least either the elbow portion or the prong portion extends through the slots.

21. The charger plug of claim 20 wherein the housing includes upper and lower halves, the blade mounting portions have generally rectangular cross-sections, each of the halves includes respective openings of generally rectangular cross-section for receiving the rectangular blade mounting portions, and the slots are defined by slot portions of both of the halves.

22. The charger plug of claim 19 further including:

internal circuitry for converting the power, the internal circuitry having a board for supporting components thereon, the board including an elongated slot and an opening;

spring contacts formed of wire and including a compressible elbow portion for snap-fit receipt in the elongated slot and including an extending portion received in the board opening for resisting forces on the spring contacts, wherein the spring contacts are biased into engagement with the blade members for electrical communication.

23. The charger plug of claim 19 wherein the charger plug is sized so as not to impede access to or use of an adjacent outlet.

24. The charger plug of clam 19 further including a power cord mounted at the second end of the housing for providing output power to the electronic device.

25. The charger plug of clam 19 further including a connector for connecting with a power cord to provide output power to the electronic device.

26. The charger plug of claim 25 wherein the connector is mounted for connecting with the power cord proximate the second end of the housing.

27. The charger plug of claim 25 wherein the blades are connectable with the power outlet when advanced in said first direction and are removable from the power outlet when advanced in a direction opposite said first direction, and the power cord is electrically connectable with the connector when advanced in said first direction and is removable from the connector when advanced in said direction opposite said first direction.

28. The charger plug of claim 27 wherein the connector and blades are generally aligned relative to each other.

29. A method of assembling a charger plug for converting input electrical power to output electrical power, the method comprising the steps of:

providing a pair of blade members including a first portion in the form of a prong for each of two terminals of the charger plug and including a second portion for mounting;

forming a housing having at least respective openings for receiving the second portion of each of the blade members in an interior of the housing, and having at least a slot for permitting the prong of each blade to extend forwardly from the housing for connection to an electrical outlet;

providing internal circuitry for power conversion, the internal circuitry including a board for supporting components thereon;

for each of the two terminals, providing a spring contact member having a spring arm;

mounting the spring contact members on the board in electrical communication with the internal circuitry;

slidably inserting the second portion of each blade member in the interior openings of the housing for mounting the blade members therewith;

after the slidably inserting step, pressing the spring contacts against a rearward surface of the blade members to shift the spring arms towards the board; and

after the pressing the spring contacts step, closing the housing.

30. The method of claim 29 further including the step of, after the pressing the spring contacts step, pivoting the board towards the housing to bring the board into registry with structure on the interior of the housing.

31. A charger plug for connecting with a power outlet to converting input current power received from the power outlet to output current power, the charger plug being electrically connectable to a rechargeable electronic device for providing the output current power thereto, the charger plug including a housing having a first portion oriented towards a power outlet when connected thereto and a second portion, the charger plug including first and second separate blade members secured with the first portion of the housing so as to have prong portions of the blade members extending in the first direction from the housing, and the charger plug including a connector at the second portion of the housing, the connector adapted for removably receiving a corresponding apparatus for transmitting power to the electronic device, the improvement comprising:

the connector being aligned with the prong portions, the connector receiving the corresponding apparatus in a direction substantially opposite the first direction and the housing being sized to be receivable in a receptacle of a power source without avoid interfering with an adjacent receptacle of the power source.

32. The charger plug of claim 31, the improvement further comprising the housing having a tapered portion at a rear end thereof, the tapered portion having an opening, and the connector being accessible through the tapered portion opening.

33. The charger plug of claim 31, the charger including a supporting substrate on which internal circuitry for converting power is mounted, the improvement further comprising the supporting substrate being a board extending in a lateral direction relative to the prong portions, the connector is mounted on the board, and the housing has a shape to provide a tactile indication of an orientation of the connector.