Integrated power converters

• US 7,978,489 B1
• Filed: 08/04/2008
• Issued: 07/12/2011
• Est. Priority Date: 08/03/2007
• Status: Active Grant

• Current Assignee: Flextronics America LLC (Flextronics International Limited)
• Sponsoring Entity: Flextronics America LLC (Flextronics International Limited)
• Inventors: Roohparvar, Bob, Gapuz, Rowell, Du, HongWei, Sy, Richard, Sharifipour, Bahman, Telefus, Mark
• Primary Examiner(s): Patel; Rajnikant B
• Time in USPTO: 1072 Days
• Field of Search: 363/17, 363/89, 363141-146, 363/21.04, 320/110, 320/138, 307/80, 307/82, 307/85
• US Class Current: 363/146
• CPC Class Codes: H01R 13/24 : resilientresiliently-mounted
• CPC Class Codes: H01R 13/6633 : with inductive component, e.g. transformer
• CPC Class Codes: H01R 31/065 : with built-in electric apparatus

Abstract

A power supply adapter is provided. The power supply adapter includes a power converter circuit configured to generate a regulated voltage signal. The power converter circuit includes a rectifier coupled with AC power blades. A regulator circuit is coupled with the rectifier. A transformer is coupled with the regulator circuit. The transformer includes a primary and a secondary. The transformer is coupled with the regulator circuit via the primary. An output circuit is coupled with the secondary of the transformer. The output circuit includes an output capacitor. A flexible contact is coupled with each of a first and a second printed circuit board and flexibly biased to couple with a proximate end of the AC power blades. The adapter includes an EMI shield substantially surrounding a connector receptacle. The power converter circuit can include a forward or a flyback power converter. The transformer can include a planar format transformer coupled with the first or the second PCB. The transformer can include a metallic core of a ferrite material. The transformer core can be coupled with the EMI shield to provide thermal spreading. The adapter can include an enclosure for housing the power converter circuit. The enclosure includes a thermally conductive potting material substantially filling an empty space of an interior of the enclosure.

Claims

1. A power supply adapter comprising:

a power converter circuit configured to generate a regulated voltage signal, the power converter circuit including,

a rectifier coupled with AC power blades;

a regulator circuit coupled with the rectifier;

a transformer coupled with the regulator circuit, the transformer including a primary and a secondary, the transformer being coupled with the regulator circuit via the primary;

an output circuit coupled with the secondary of the transformer, the output circuit including an output capacitor; and

a flexible contact coupled with each of a first and a second printed circuit board and flexibly biased to couple with a proximate end of the AC power blades.

2. The adapter of claim 1, further comprising an EMI shield comprising a sheet of conductive material substantially surrounding a connector receptacle, the EMI shield being coupled between the first and the second PCB.

3. The adapter of claim 2, wherein the EMI shield comprises one of a metallic sheet or a metallic sheet mesh.

4. The adapter of claim 1, wherein the power converter circuit comprises one of a forward or a flyback power converter.

5. The adapter of claim 1, wherein the regulator circuit includes an inductor for coupling a rectified voltage signal from the rectifier to a regulator switch.

6. The adapter of claim 5, wherein the regulator switch comprises a semiconductor switch.

7. The adapter of claim 1, wherein the transformer comprises a planar format transformer coupled with one of the first or the second PCB.

8. The adapter of claim 7, wherein the transformer includes a metallic core.

9. The adapter of claim 8, wherein the metallic core comprises a ferrite material.

10. The adapter of claim 9, wherein the transformer core is coupled with an EMI shield comprising one of a metallic sheet or a metallic sheet mesh to provide thermal spreading.

11. The adapter of claim 1, wherein the flexible contact comprises a metallic conductor.

12. The adapter of claim 1, wherein the flexible contact is configured to electrically couple an AC power source from the AC power blades to the power converter circuit.

13. The adapter of claim 1, further comprising an enclosure comprising a first section including a predominately planar structure, the AC power blades, the first and the second printed circuit board (PCB) and a second section of the enclosure coupled with the first section, the first and the second PCB including a connector receptacle coupled there between, the second section comprising a predominately cubical structure for enclosing the power converter circuit.

14. The adapter of claim 13, wherein the first section of enclosure includes openings for receiving the AC power blades and a first and a second slot for receiving the first and the second PCB.

15. The adapter of claim 13, wherein the second section of the enclosure is configured for enclosing the first and the second PCB, an EMI shield and the connector receptacle.

16. The adapter of claim 13, wherein the second section of the enclosure includes an aperture aligned with the connector receptacle, the aperture being configured for receiving a power connector.

17. The adapter of claim 16, wherein the connector receptacle includes conductive leads for providing the regulated voltage signal to the power connector.

18. The adapter of claim 13, wherein the connector receptacle comprises a universal serial bus (USB) connector receptacle.

19. The adapter of claim 13, wherein the first and the second section comprise a non-metallic material.

20. The adapter of claim 19, wherein the non-metallic material comprises a plastic material.

21. The adapter of claim 13, wherein the enclosure includes a thermally conductive potting material substantially filling an empty space of an interior of the enclosure.

22. A power supply adapter comprising:

a power converter circuit configured to generate a regulated voltage signal, the power converter circuit including,

a rectifier coupled with AC power blades;

a regulator circuit coupled with the rectifier;

a transformer coupled with the regulator circuit, the transformer including a primary and a secondary, the transformer being coupled with the regulator circuit via the primary;

an output circuit coupled with the secondary of the transformer; and

a flexible contact coupled with each of a first and a second printed circuit board and flexibly biased to couple with a proximate end of the AC power blades.

23. The adapter of claim 22, further comprising an EMI shield comprising a sheet of conductive material substantially surrounding a connector receptacle, the EMI shield being coupled between the first and the second PCB.

24. The adapter of claim 23, wherein the EMI shield comprises one of a metallic sheet or a metallic sheet mesh.

25. The adapter of claim 22, wherein the power converter circuit comprises one of a forward or a flyback power converter.

26. The adapter of claim 22, wherein the regulator circuit includes an inductor for coupling a rectified voltage signal from the rectifier to a regulator switch.

27. The adapter of claim 26, wherein the regulator switch comprises a semiconductor switch.

28. The adapter of claim 22, wherein the transformer comprises a planar format transformer coupled with one of the first or the second PCB.

29. The adapter of claim 28, wherein the transformer includes a metallic core.

30. The adapter of claim 29, wherein the metallic core comprises a ferrite material.

31. The adapter of claim 30, wherein the transformer core is coupled with an EMI shield comprising one of a metallic sheet or a metallic sheet mesh to provide thermal spreading.

32. The adapter of claim 22, wherein the flexible contact comprises a metallic conductor.

33. The adapter of claim 22, wherein the flexible contact is configured to electrically couple an AC power source from the AC power blades to the power converter circuit.

34. The adapter of claim 22, further comprising an enclosure comprising a first section including a predominately planar structure, the AC power blades, the first and the second printed circuit board (PCB) and a second section of the enclosure coupled with the first section, the first and the second PCB including a power cable coupled there between, the second section comprising a predominately cubical structure for enclosing the power converter circuit.

35. The adapter of claim 34, wherein the first section of enclosure includes openings for receiving the AC power blades and a first and a second slot for receiving the first and the second PCB.

36. The adapter of claim 34, wherein the second section of the enclosure is configured for enclosing the first and the second PCB, an EMI shield and the power cable.

37. The adapter of claim 34, wherein the second section of the enclosure includes an aperture aligned with the power cable, the aperture being configured for receiving a mounting screw and a mounting nut of the power cable.

38. The adapter of claim 37, wherein the power cable includes conductive leads for providing the regulated voltage signal to an attached electronic device.

39. The adapter of claim 22, wherein the power cable comprises a universal serial bus (USB) power cable.

40. The adapter of claim 22, wherein the first and the second section comprise a non-metallic material.

41. The adapter of claim 40, wherein the first and the second section comprise a plastic material.

42. The adapter of claim 22, wherein the enclosure includes a thermally conductive potting material substantially filling an empty space of an interior of the enclosure.

43. A power supply adapter comprising:

a power converter circuit configured to generate a regulated voltage signal, the power converter circuit including,

a rectifier coupled with AC power blades;

a regulator circuit coupled with the rectifier;

a transformer coupled with the regulator circuit, the transformer including a primary and a secondary, the transformer being coupled with the regulator circuit via the primary; and

a flexible contact coupled with each of a first and a second printed circuit board and flexibly biased to couple with a proximate end of the AC power blades.

44. The adapter of claim 43, further comprising an EMI shield comprising a sheet of conductive material substantially surrounding a connector receptacle, the EMI shield being coupled between the first and the second PCB.

45. The adapter of claim 44, wherein the EMI shield comprises one of a metallic sheet or a metallic sheet mesh.

46. The adapter of claim 43, wherein the power converter circuit comprises one of a forward or a flyback power converter.

47. The adapter of claim 43, wherein the regulator circuit includes an inductor for coupling a rectified voltage signal from the rectifier to a regulator switch.

48. The adapter of claim 47, wherein the regulator switch comprises a semiconductor switch.

49. The adapter of claim 43, wherein the transformer comprises a planar format transformer coupled with one of the first or the second PCB.

50. The adapter of claim 49, wherein the transformer includes a metallic core.

51. The adapter of claim 50, wherein the metallic core comprises a ferrite material.

52. The adapter of claim 51, wherein the transformer core is coupled with an EMI shield comprising one of a metallic sheet or a metallic sheet mesh to provide thermal spreading.

53. The adapter of claim 43, wherein the flexible contact comprises a metallic conductor.

54. The adapter of claim 43, wherein the flexible contact is configured to electrically couple an AC power source from the AC power blades to the power converter circuit.

55. The adapter of claim 43, further comprising an enclosure comprising a first section including a planar structure having a flat outer periphery, the AC power blades and a second section of the enclosure coupled with the first section, the second section comprising a predominately cubical structure for enclosing the power converter circuit and the first and the second printed circuit board (PCB), the first and the second PCB including a connector receptacle coupled there between.

56. The adapter of claim 43, wherein the first section of enclosure includes openings for receiving the AC power blades and the second section includes a first and a second set of slots for receiving the first and the second PCB.

57. The adapter of claim 43, wherein the second section of the enclosure is configured for enclosing the first and the second PCB, an EMI shield, and the connector receptacle.

58. The adapter of claim 43, wherein the second section of the enclosure includes an aperture aligned with the connector receptacle, the aperture being configured for receiving a power connector.

59. The adapter of claim 58, wherein the connector receptacle includes conductive leads for providing the regulated voltage signal to the power connector.

60. The adapter of claim 43, wherein the connector receptacle comprises a universal serial bus (USB) connector receptacle.

61. The adapter of claim 43, wherein the first and the second section comprise a non-metallic material.

62. The adapter of claim 61, wherein the first and the second section comprise a plastic material.

63. The adapter of claim 43, wherein the enclosure includes a thermally conductive potting material substantially filling an empty space of an interior of the enclosure.