Patent ID: 8295048
Filing Date: 2012-10-23
Classification: H01R,H05K,Y10T

Abstract:
1. A compact power conversion device comprising: a) AC power supply leads comprising a prong end configured to plug into an AC wall socket coupled to an AC power supply network and a thermally conductive end; b) an AC to DC (AC/DC) power conversion circuit comprising a primary side having heat-generating components and a secondary side, the power conversion circuit configured to receive electric power from the AC power supply network via the AC power supply leads; c) a heat conductive body thermally coupled with the AC/DC power conversion circuit and thermally coupled to the thermally conductive end of the AC power supply leads, wherein the thermally conductive end is configured to conduct heat generated by the AC/DC power conversion circuit to the AC power supply leads, into the AC wall socket, and into the AC power supply network, and further wherein the heat conductive body is molded around substantially all of the heat-generating components of the primary side of the AC/DC power conversion circuit and is molded around at least a portion of the thermally conductive end forming a contact area wherein the contact area is configured for the heat to flow through the AC power supply leads, into the AC wall socket and into the AC power supply network, and wherein the heat conductive body comprises a material providing at least the minimum required electrical insulation between the AC power supply leads to prevent electrical shorting of the AC power supply leads; and d) a substantially rigid body encasing the heat conductive body and at least a portion of the secondary side of the AC/DC power conversion circuit wherein the prong end of the AC power supply leads protrude from the rigid body and wherein a thermal conductivity of the rigid body is configured such that the heat conductive body substantially efficiently transfers heat from AC/DC the power conversion circuit to the AC power supply leads, wherein the substantially rigid body limits thermal conductivity such that the rigid body external surface does not exceed 70° C. in temperature.