Power adapter with a single-piece insulator assembly
First Claim
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1. A power adapter comprising:
- a first connector;
a first electrical assembly coupled to the first connector and configured to receive an incoming AC voltage and convert it to a DC voltage;
a second connector;
a second electrical assembly coupled to the second connector and configured to accept the DC voltage and output the DC voltage via the second connector; and
a single-piece insulator unit having a first side and a second side, wherein the first electrical assembly is coupled to the first side and the second electrical assembly is coupled to the second side; and
wherein the insulator unit electrically insulates the first electrical assembly from the second electrical assembly and comprises one or more channels embedded therein to provide an electrical path between the first electrical assembly and the second electrical assembly at designated locations.
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Abstract
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.
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Citations
20 Claims
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1. A power adapter comprising:
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a first connector; a first electrical assembly coupled to the first connector and configured to receive an incoming AC voltage and convert it to a DC voltage; a second connector; a second electrical assembly coupled to the second connector and configured to accept the DC voltage and output the DC voltage via the second connector; and a single-piece insulator unit having a first side and a second side, wherein the first electrical assembly is coupled to the first side and the second electrical assembly is coupled to the second side; and wherein the insulator unit electrically insulates the first electrical assembly from the second electrical assembly and comprises one or more channels embedded therein to provide an electrical path between the first electrical assembly and the second electrical assembly at designated locations. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. An insulator assembly comprising:
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a single-piece structure having a first side and a second side, the first and the second side, each side having features thereon to accept a first circuitry and a second circuitry, respectively, wherein the single-piece structure electrically insulates the first circuitry from the second circuitry; one or more channels embedded in the single-piece structure, wherein each of the one or more channels extends from the first side to the second side; and electrically conducting members disposed in each of the one or more channels to provide electrical connection between the first circuitry and the second circuitry. - View Dependent Claims (11, 12, 13, 14, 15)
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16. A method comprising:
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providing a single-piece insulator unit having a first side and a second side, wherein each of the first side and the second side includes features formed thereon and the insulator unit electrical insulates the first side from the second side; attaching a transformer at a first predefined location of the single-piece insulator unit; attaching a common mode choke at a second predefined location of the single-piece insulator unit; attaching a primary printed circuit board (PCB) including a first circuitry to the first side of the single-piece insulator unit; attaching a secondary PCB including a second circuitry to the second side of the single-piece insulator unit; providing electrical connectivity between the primary PCB and the secondary PCB through one or more channels within the single-piece insulator unit; attaching a cap assembly to the single-piece insulator unit; placing the single-piece insulator unit inside a housing; and attaching the cap assembly to the housing to seal the single-piece insulator unit within the housing. - View Dependent Claims (17, 18, 19, 20)
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Specification