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 comprising a plurality of AC to DC converter components, wherein the first electrical assembly is configured to receive an incoming AC voltage and convert it to a DC voltage using the plurality of AC to DC converter components;
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 including one or more first recesses that receive at least one of the plurality of AC to DC converter components and a second side including one or more second recesses that receive at least a portion of the second electrical assembly, wherein the first electrical assembly is disposed adjacent to the first side and the second electrical assembly is disposed adjacent to the second side; and
a housing enclosing the single-piece insulator unit and the first and the second electrical assemblies;
wherein the single-piece insulator unit electrically insulates the first electrical assembly from the second electrical assembly and comprises a region that is recessed from the housing and one or more electrical conductors are routed in the recessed region electrically coupling the first electrical assembly to the second electrical assembly.
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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.
24 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 comprising a plurality of AC to DC converter components, wherein the first electrical assembly is configured to receive an incoming AC voltage and convert it to a DC voltage using the plurality of AC to DC converter components; 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 including one or more first recesses that receive at least one of the plurality of AC to DC converter components and a second side including one or more second recesses that receive at least a portion of the second electrical assembly, wherein the first electrical assembly is disposed adjacent to the first side and the second electrical assembly is disposed adjacent to the second side; and a housing enclosing the single-piece insulator unit and the first and the second electrical assemblies; wherein the single-piece insulator unit electrically insulates the first electrical assembly from the second electrical assembly and comprises a region that is recessed from the housing and one or more electrical conductors are routed in the recessed region electrically coupling the first electrical assembly to the second electrical assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. 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 using a plurality of AC to DC converter components attached to the first electrical assembly; 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; an insulative shell having a first side including one or more first recesses that receive at least one of the plurality of AC to DC converter components and a second side including one or more second recesses configured to receive at least a portion of the second electrical assembly such that the insulative shell electrically insulates the first electrical assembly from the second electrical assembly; and one or more electrical conductors that couple DC voltage from the first electrical assembly to the second electrical assembly. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
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16. 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 using a plurality of AC to DC converter components attached to the first electrical assembly; 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; a contoured plastic shell including one or more first cavities that receive at least one of the plurality of AC to DC converter components and one or more second cavities that receive at least a portion of the second electrical assembly, the contoured plastic shell configured to fit between and provide electrical insulation between the first electrical assembly and the second electrical assembly; and one or more electrical conductors connected between the first and the second electrical assemblies to transfer DC voltage from the first electrical assembly to the second electrical assembly. - View Dependent Claims (17, 18, 19, 20)
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Specification