Patent ID: 12237631

DETAILED DESCRIPTION OF THE INVENTION

A three prong power adapter according to one embodiment of the present invention is shown generally at15inFIGS.3to9. The power adapter15comprises a plug head part10and an adapter part11. The plug head part10has three prongs12,13,14for connection with a cooperable socket (not shown) so that electrical connection between the prongs12,13,14and the cooperable socket enables power transfer to the electronics within the adapter part11.

The plug head part10has an outer plug head housing with a rear cover18as shown inFIG.1.FIG.2shows a front view of the adapter part11. Two slots19that are circular with an elongate portion, are provided in a central region of the rear cover18. The slots19are arranged to receive and retain two cylindrical keys69. Cylindrical keys69protrude from a front face of the adapter part11and are spaced to align with the slots19on the rear housing18of the adapter part10. The cylindrical keys69are made from a conducting metal to provide the electrical connection between the plug head part10and the adapter part11. The cylindrical keys69form part of the actuation mechanism to actuate movement of the power adapter15between the stowed and deployed configurations. A front face of the adapter housing11is moulded with a planar step61. The planar step61provides an abutment for an end face20of the plug head part10in the deployed configuration.

The power adapter15composed from the plug head part10and the adapter part11slidably coupled via the keys69retained within the slots19is shown inFIGS.3to5. A front of the plug head housing16has a central elongate slot52with a parallel elongate slot53,54on each side of the central slot52. The central elongate slot52accommodates an earth prong12. The earth prong12is substantially cuboid and rotatable around one end in a first direction. Deployment of the earth prong12occurs by rotation of the earth prong12outwith the slot52by approximately 90 degrees. The adjacent parallel slots53,54, accommodate live and neutral prongs13,14respectively. The live and neutral prongs13,14are substantially cuboid and are rotatable around one respective end of each prong13,14in a second direction. Deployment of the live and neutral prongs13,14occurs by rotation of around 90 degrees outwith the respective slot53,54.

FIGS.3,6and7show the prongs12,13,14of the power adapter15in a stowed configuration with the end face20of the plug head part10spaced from the planar step61of the adapter part11. Pressure applied to the power adapter15by a user (not shown) causes the keys69to slide within the slots19and movement of the end face20of the plug head part10towards the planar step61of the adapter part11. This relative movement of the plug head part10and the adapter part11causes actuation of an internal deployment mechanism30(described hereinbelow with reference toFIGS.10to17). The movement causes the prongs12,13,14to rotate and transition between the stowed configuration and the deployed configuration as shown inFIG.4. Relative movement of the plug head part10and the adapter part11ceases when the end face20of the plug head part10abuts the planar step61of the adapter part11. At this point the keys69have travelled to the end of the slots19and the prongs12,13,14are in the fully deployed configuration as shown inFIGS.5,8and9.

The components within the internal deployment mechanism30are shown in an exploded view inFIGS.10and11. An interior of the plug head housing16has a shaped profile50. The shaped profile50includes a moulded slot housing51that forms the slot52in the front of the plug head housing16. The shaped profile50additionally includes a plurality of indents and protrusions for receiving and/or retaining components of the deployment mechanism30. The internal deployment mechanism30includes a first portion67and a second portion68.

The first portion67of the deployment mechanism30is associated with the earth prong12. Towards one end, the earth prong12has a transverse hole22for accommodating a pivot pin28. A cam interaction means in the form of a protrusion32is moulded into each side of the earth prong12adjacent and longitudinally offset from the transverse hole22. Each protrusion32is cylindrical and extends outwardly from the respective side face of the prong12on which it is located. A biasing means in the form of a torsion spring29is coupled to each end of the pivot pin28. The earth prong12is located and retained within the shaped profile50of the plug head housing16by means of the pivot pin28and the torsion spring29. In the stowed configuration, the earth pin12is accommodated in the slot52such that the protrusion32lies adjacent part of the second portion68of the internal deployment mechanism30.

The live and neutral prongs13,14are each substantially cuboid with one cylindrical end. The cylindrical ends of the live and neutral prongs13,14have a protrusion33,34, projecting centrally from each side face. The protrusions33,34act as a pivot point around which the prongs13,14are rotatable. A transverse hole23,24is provided through the cylindrical end of each prong13,14and the holes23,24are radially offset from the protrusions33,34. The transverse holes23,24accept a respective cam coupling means in the form of a pin25,26.

The second portion68of the deployment mechanism30is associated with the live and neutral prongs13,14and includes the cam coupling means or pins25,26and two sliding cams38,39. The sliding cams38,39are mirror image components. Each sliding cam38,39has a central hole40for receiving the keys69of the actuation mechanism. A first end of each sliding cam38,39has two opposing recesses or pin receiving indents42for accepting ends of the pins25,26. Outer edges of the sliding cams38,39each have cylindrical spring retainers43for retaining a cam spring37. A second end of each sliding cam38,39has a curved cam surface41. When the components of the internal deployment mechanism30are assembled, the curved cam surface41of the first portion67of the deployment mechanism30is adjacent the cam interaction means or protrusion32of the second portion68of the deployment mechanism30.

Two metal conducting plates36are located between the shaped internal profile50of the plug head housing16and the sliding cams38,39. The metal conducting plates36are provided with metal tabs35biased towards the shaped profile50within the plug head housing16to provide the necessary electrical connection between the adapter part11and the prongs13,14. One end of the electrical conducting plates36has assembly holes75for accepting a protrusion formed in the shaped internal profile50of the plug head housing16to retain the conducting plates36in position in use.

FIGS.12to14show the two portions67,68of the internal deployment mechanism30with the rear cover18of the plug head housing16removed from the plug head part10.FIGS.15to17show only the first and second portions67,68of the internal deployment mechanism30and the prongs12,13,14, to illustrate the sequence of movement between the stowed and deployed configurations with all other components removed.

As shown inFIGS.12and15, the prongs12,13,14are accommodated within their respective slots52,53,54in the stowed configuration. The stowed configuration reduces the overall dimensions of the power adapter15and is therefore particularly suitable for shipping, packing, transporting and storing of the power adapter15.

In order to use the power adapter15in a socket (not shown), a user must deploy the prongs12,13,14. The user applies a force to cause relative movement of the plug head part10and the adapter part11as hereinbefore described. The cylindrical keys69engaged with the second portion68of the internal deployment mechanism30retain the sliding cams38,39in position while the housing moves downward relative to the cams38,39. This relative movement of the sliding cams38,39and the plug head housing16causes rotation of the live and neutral prongs13,14since the pins25,26are retained in the pin receiving indents42of the sliding cams38,39. Thus, the pin receiving indents42and inserted pins25,26move upwardly with the sliding cams38,39, resulting in rotation of the prongs13,14that are constrained by, but rotatable within, the plug head housing16by means of the protrusions33,34. At an opposing end of each sliding cam38,39, the curved cam surface41simultaneously acts against the protrusion32on the earth prong12. The relative upward movement of the curved cam surface41causes downward movement of the protrusion32attached to the prong12, which is constrained by and rotatable within the plug head housing16by means of the pivot pin28. As a result, the earth prong12rotates around the pivot pin28to move the earth prong12towards the deployed configuration as shown in the transitional phase inFIGS.13and16.

Downward movement of the plug head housing16continues until the end face20of the plug head part10abuts the planar step61of the adapter part11so that relative upward movement of the sliding cams38,39continues until all prongs have rotated approximately 90 degrees and are in the fully deployed configuration as shown inFIGS.14and17. In the fully deployed configuration the prongs12,13,14of the adapter plug15are ready for insertion into a socket.

When the user intends to transport or store the power adapter15, the adapter15is removed from the socket and collapsed into the stowed configuration. This is achieved by pulling the plug head part10away from the adapter part11. Such a force applied by the user to the parts10,11in opposing directions, causes the cylindrical keys69to slide downwardly within the slots19. The cam springs37urge the sliding cams38,39downwardly within the plug head housing16. The pins25,26attached to the prongs13,14, thus also move downwardly, thereby rotating the live and neutral prongs13,14into the stowed configuration. Downward movement of the sliding cams38,39, removes the cam surface41acting against the protrusions32. The torsion spring29becomes the controlling force acting on the earth prong12and the spring29force urges rotation of the earth prong12by around 90 degrees or until it is accommodated in the stowed configuration in the slot52.

Thus the deployment mechanism30involves two structurally separate portions67,68of the deployment mechanism30acting together to achieve simultaneous deployment of the prongs12,13,14. Actuation results in the transition between the stowed and deployed configurations, which is achieved by movement of the sliding cams38,39of the second portion68acting against separate components i.e. the protrusions32of the first portion69of the deployment mechanism30. Thus, simultaneous deployment of the prongs12,13,14, is achieved without direct mechanical interconnection or linkage of the earth prong12with the live and neutral prongs13,14. The transition from the deployed to the stowed configuration for the live and neutral prongs13,14is achieved by relative movement of the sliding cams38,39and the housing16. Transition from the deployed to the stowed configurations for the earth pin12is achieved by spring37return. The first and second portions67,68of the deployment mechanism30are structurally separate and transition from the deployed to the stowed configurations is achieved without any direct mechanical linkage or coupling of the two portions67,68.

All three prongs12,13,14are mechanically separate. There is no linkage mechanism to directly transfer movement of one prong to another.

The two portions67,68of the deployment mechanism30are structurally separate. The lack of direct mechanical linkage or interconnection between the two portions67,68of the deployment mechanism30has several advantages. No direct mechanical linkage means that there is minimal stress transfer between components of the deployment mechanism30. The plug head part10is robust since there are no small delicate components required to provide a miniature direct link to translate movement between the live and neutral prongs13,14, and the earth prong12. The structural separation of the portions67,68of the deployment mechanism30has the additional benefit that the overall number of parts is reduced, resulting in lower tooling, material and overall cost, more efficient and environmentally conscious use of resources, and smaller overall dimensions. The maximum thickness of the plug head part10is 9 mm.

According to the present embodiment, the power adapter15is type G and compatible with British Standards covering this area of technology e.g. BS1363.

According to an alternative embodiment, the second portion of the deployment mechanism can include a single sliding cam that is linked to both the live and neutral prongs13,14.

According to alternative embodiments, the power adapter15is customisable depending on the particular application. For example, the metal plate conductors36can be replaced with plastic dummies should an alternative means of electrical connection be required.

A number of different embodiments of the invention are described subsequently. In order to minimise repetition, similar features of the different embodiments are numbered with a common two-digit reference numeral and are differentiated by one or more digits placed before the two common digits. Such features are structured similarly, operate similarly, and/or have similar functions unless otherwise indicated.

According to another embodiment, power adapters may be a different rating, shape and size. The plug head part10is common to all embodiments shown inFIGS.18to21. The power adapter part11shown inFIG.18is suitable for a device requiring a 5 Watt power connection. Different ratings and sizes of power adapter parts81,91,111are shown inFIGS.19,20and21, and are provided to supply different power ranges of 10-45 Watts; 15-45 Watts, and 45-180 Watts respectively. Each of the adapter parts81,91,111has the conducting cylindrical keys69to slidably couple with the slots19of the plug head part10. Therefore, the plug head part10with the collapsible prongs12,13,14is a common component of each size of power adapter and the mechanism of prong12,13,14movement is the same for each power adapter. Movement of the prongs12,13,14is achieved by relative movement of the plug head part10and the respective power adapter part11,81,91,111. This is advantageous as it reduces manufacturing costs for power adapters of different ratings and sizes as well as providing a consistent user experience with different power adapters used in conjunction with a range of devices.

According to other embodiments of the invention, different numbers of prongs, alternative arrangements, designs and dimensions of the power adapter may be selected according to compatibility with any country or region specific design, code or standard. Each such embodiment may have core features of the first aspect of the invention including the simultaneous prong deployment and the structurally separate portions of the deployment mechanism. Each such embodiment may have core features of any aspect of the invention including the separation of the adapter into a plug head part and an adapter part movable relative to one another to rotate the prongs between the deployed and the stowed configurations.

FIGS.22to25show an alternative embodiment wherein a power adapter215comprises a plug head part210and an adapter part211. The plug head part210is dimensionally similar in length and width to the adapter part211. Internally, the plug head part contains a deployment mechanism similar to that described in connection with the first embodiment. Beneath the prongs212,213,214there is space for a fuse70to be accommodated within a recess at the front of the plug head part210. The plug head part210and the adapter part211may be mechanically interconnected or designed to be separable components. Actuation and deployment of the prongs212,213,214are as previously described. The altered design of the plug head part210enables the fuse70to be easily accessed and replaced.

Embodiments of a power adapter315with alternative actuation mechanisms and forming a single unit enclosed within a housing316are shown inFIGS.26to34. According to all these embodiments, the deployment mechanism is similar to that described with reference to the first embodiment and is located within the housing316.FIGS.26and29to31show a power adapter315with an actuation mechanism in the form of a push switch301and a slide switch302.FIG.27shows a power adapter315having a slide switch302actuation mechanism and the power adapter315ofFIG.28has a push switch301actuation mechanism. Instead of the key69and slot19actuation mechanism of the first embodiment, the push switch301and/or slide switch302is cooperable with a centrally located bar305forming part of the deployment mechanism (FIGS.32to34). The bar305is fixed to the cams338,339on either side and thus, the bar305and the cams338,339move as a single body. The push switch301is coupled to an upper end of the bar305and the slide switch302is coupled to a lower end of the bar305. Thus, movement of either or both of the switches301,302causes corresponding movement of the cams338,339relative to the housing316to thereby cause substantially simultaneous rotation of the prongs312,313,314.

FIGS.35to45show an embodiment of a power adapter415with an alternative output from the plug head part410, and an adapter part411which is a self-contained power adapter with type-A pins such as those used in the US and large parts of Asia. The plug head part410has a connector portion404that contains receiving slots419to accept electrical key connectors469in the form of type A pins. The electrical key connectors469are metal elongate pins. The adapter part411is also a power adapter arranged to mate with type A complementary sockets when the electrical key connectors469are pivoted to stand perpendicular relative to a front face of the adapter part411as shown inFIG.37. When the electrical key connectors469are pivoted into the stowed configuration (FIG.38), they are insertable into the receiving slots419. Both the receiving slots419are coupled to a respective cam438,439, such that engagement of the key connectors469in the slots419causes simultaneous movement of the cams438,439. The cams438,439and remainder of the internal deployment mechanism are structured similarly to that described with reference to the first embodiment. Pushing the plug head part410and the adapter part411towards one another connects the two parts410,411and causes deployment of the prongs412,413,414.

FIGS.46and47show another embodiment of a power adapter515with a plug head part510having an alternative interconnection means. An alternative output is located in a connector portion504of the plug head part510in the form of a C8 connector. The C8 connector has electrical keys569that are insertable into complementary receiving slots519that are located on the adapter part511and act on the internal deployment mechanism in a similar manner to that previously described in association withFIGS.42to45.

According to an alternative embodiment (not shown in the figures), a different actuation mechanism can be incorporated into the adapter515, such that deployment of the prongs may occur by actuation of a switch that is linked to the internal deployment mechanism and provided on a rear face of the plug head part510beneath the connector portion504and/or in the region of the electrical keys569.

Another embodiment is shown inFIGS.48to50in which the plug head part610and the adapter part611of the power adapter615are mechanically engaged by interconnection means. The interconnection means may be keys in a keyway or a sliding retaining connection between the adapter part611and the plug head part610. The internal deployment mechanism630is shown schematically inFIG.54and is the same as previously described with reference to the first embodiment. The interconnection means have a dual function and act as a mechanical interconnection means as well as the actuation mechanism to cause movement of the prongs612,613,614between the stowed and deployed configurations upon relative movement of the plug head part610and the adapter part611.

FIGS.51to53also show a power adapter715having a mechanically engaged and interconnected (as opposed to releasable) plug head part710and adapter part711. The internal deployment mechanism730is arranged in a reverse direction compared with that described in connection with the first embodiment, as shown schematically inFIG.55. The second portion767of the deployment mechanism is associated with the earth prong712. The earth prong712has two cylindrical protrusions726extending perpendicular therefrom and offset from the axis of rotation of the earth prong712about the pivot pin734. The sliding cams738,739each have a pin receiving indent742for accepting the protrusions726on each side of the earth prong712. Opposing ends of each cam738,739have an arcuate cam surface741that lies adjacent the first part767of the internal deployment mechanism730in the form of radially offset protrusions732(only one shown) on the live and neutral prongs714. Movement of the cams738,739causes simultaneous pivoting and movement of the pins712,713,714in the inverse direction to that previously described with reference to the first embodiment.

A power adapter815with an alternative interconnection means is shown inFIGS.59to66. The power adapter815has a plug head part810and an adapter part811with two parallel elongate locating keys869on a front face extending perpendicular to the abutment step861. The elongate keys869are arranged to locate in two parallel slots on a rear face of the plug head part810. The elongate keys869within the parallel slots819act as both an interconnection means and an actuation mechanism. The internal deployment mechanism830is similar to that described with reference to the first embodiment except that the parallel elongate slots819cause elongate keys869to act towards a central side edge of the cams839,838, such that engagement of the elongate keys869within the slots819causes resultant movement of the cams838,839and hence rotation of the prongs812,813,814as shown inFIGS.64to66.

Another embodiment of the invention is shown inFIGS.67to72. A power adapter915is provided with alternative interconnection means in the form of two keys969protruding from a front face of the adapter part911and two parallel slots919in a rear face of the plug head part910, wherein the slots are enlarged towards a lower end and taper towards an upper end. This enables easy interconnection between the two keys969and the enlarged lower part of the slots919to allow the adapter part911to ‘slot into’ the plug head part910as shown inFIG.68. Further force applied in opposing directions to the plug head part910and the adapter part911urges the two keys969into the tapered part of the slots919to effectively ‘lock’ the plug head part910and the adapter part911as shown inFIG.69. Further force applied until the lower end of the plug head part910abuts the planar step961causes deployment of the prongs912,913,914via a similar internal deployment mechanism to that described in connection with the previous embodiment as shown inFIG.71.

According toFIGS.73to75and81to89, an alternative internal deployment mechanism1030is shown. The earth prong1012and live prong1014pivot in opposing directions around a central pivot pin1028and1034respectively. According to the present embodiment, the earth pin1012has an elongate slot1088extending radially relative to the pivot axis of the pivot pin1028. A cam pin1032is inserted and extends through the elongate slot1088of the earth prong1012so that the cam pin1032is slideable within the slot1088and can shift radial position relative to the pivot axis of the pivot pin1028. The cam pin1032forms part of the deployment mechanism1030and is retained within recesses1047of the sliding cams1038,1039. The recesses1047accommodating the cam pin1032effectively close the cams1038,1039around the cam pin1032extending through the earth prong1012. Therefore, there is no requirement for a torsion spring to return the earth prong1012to the stowed configuration because the cam pin1032is constrained by the partially closed recesses1047to follow movement of the cams1038,1039.

The lower live and neutral prongs1013,1014each have two cylindrical protrusions1026(one shown) extending from each side of the prongs1013,1014that form part of the internal deployment mechanism1030. The protrusions1026are located towards an outer side edge of the prongs1013,1014. The protrusions1026locate within elongate receiving indents1042of the sliding cams1038,1039. The elongate receiving indents1042in the cams1038,1039are shaped such that the protrusions1026are constrained to follow the corresponding movement of the cams1038,1039, but the cams1038,1039may also slide relative to the protrusions1026and prongs1013,1014while still retaining the protrusions1026within the elongate receiving indents1042. This allows the cams1038,1039an additional degree of travel relative to the prongs1013,1014.

As a result of this modified internal deployment mechanism1030, the cam pin1032is constrained to follow movement of the cams1038,1039. However, the cam pin1032can also slide within the slot to allow the cam pin1032and the coupled cams1038,1039an additional degree of movement relative to the earth pin1012. This enables the cam pin1032to travel alongside a front face99of the power adapter to advantageously enable the dimensions of the power adapter to be minimised as much as possible. Thus, the elongate slot1088enables the distance between the cam pin1032and the pivot pin1028to be varied so that the cam pin1032and attached cams1038,1039are not constrained to travel along a fixed arc relative to the pivot pin1028during movement between the stowed and deployed configurations. Rather, throughout the transition between the deployed and stowed configurations, the cam pin1032is able to slide within the elongate slot1088closer to the central axis of the pivot pin1028, thereby reducing the amount of space required for successful deployment and stowing of the prongs1012,1014. As a result of this sliding of the cam pin1032within the elongate slot1088, the cam pin1032and attached cams1038,1039travel along a more linear (rather than arcuate) path, alongside the front face99of the power adapter.

As shown inFIGS.73to75and81to89, movement of the sliding cams1038,1039causes corresponding movement of the protrusions1026, and cam pin1032which causes rotation of the prongs1012,1013,1014. The cams1038,1039slidably retain the protrusions1026within the elongate pin receiving indents1042and the cam pin1032is slidable within the elongate slot1088to enable a substantially linear movement of the cams1038,1039, that translates to a rotational movement of the prongs1012,1013,1014. This arrangement of the internal deployment mechanism1030enables the prongs1012,1013,1014to be moved between the stowed and the deployed configurations in the most space efficient manner.

Centrally located holes within the cams1038,1039, can be used to accommodate a biasing means1098to bias the cams1038,1039towards a desired position. The biasing means1098may include flipping/tipping effect springs such as those described in US2011/0024961, the entire contents of which are incorporate by reference. Any of the previously described actuation mechanisms, such as keys, slide and/or push switches may be used to actuate this alternative deployment mechanism1030.

FIGS.76and77show another embodiment with a different internal deployment mechanism1130, which instead comprises open cams1139(one shown) which provide the means to deploy the earth prong1112, but with no torsion spring or cam surface to return the earth prong1112into the stowed configuration. Separate user intervention would be required to return the earth prong1112to the stowed configuration. Otherwise, the internal deployment mechanism1130functions as described with reference to the previous embodiment, with the cam pin1132having the freedom to slide within the elongate slot1188of the earth prong1112and the cams1139allowing slidable retention of the protrusions1126within the elongate receiving indents1142. Again, this arrangement is advantageous as it represents a space efficient design for the internal deployment mechanism1130and enables the dimensions of the adapter to be minimised.

FIGS.78to80show an adapter similar to that ofFIGS.76and77with an open upper cam1238surface in the internal deployment mechanism1230. However, this embodiment has a torsion spring1229associated with the earth prong1212to ensure the prong1212returns to the stowed configuration once the cam surface is moved away from the protrusion1247. The internal deployment mechanism1230is similar to that described with reference to the two previous embodiments.

Although particular embodiments of the invention have been disclosed herein in detail, this is by way of example and for the purposes of illustration only. The aforementioned embodiments are not intended to be limiting with respect to the scope of the statements of invention and/or appended claims. Relative terms such as “upper” and “lower” aid understanding of the invention but do not limit the scope of the invention.

It is contemplated by the inventors that various substitutions, alterations, and modifications may be made to the invention without departing from the scope of the invention as defined by the statements of invention and/or claims. For example, the prongs12,13,14or the housing16may be of different shapes and dimensions. The foldable power adapters of the invention may be adapted for use with any electronic device in any residential or commercial setting.