Patent ID: 12255426

A multi-plug adapter or travel adapter is shown generally at10in the figures. The travel adapter10is arranged to provide a variety of different plugs to engage in complementary power sockets in several different countries and provide a useful electronic output. The travel adapter10is thus a single device that functions to provide power for electronic devices in different regions around the world by enabling compatibility with several different types of power socket.

The travel adapter10has a multi-part housing comprising an outer housing11, a rotatable housing13, a front cover12and a rear cover18provided to enclose and protect the internal components. Internally, the travel adapter10comprises a printed circuit board (PCB) assembly16, electrically connected to an output70and different sets of deployable pins43,50,51,60. Each of the deployable pins43,50,51,60, has an associated deployment mechanism.

Exploded views of the individual components comprising the travel adapter10are shown inFIGS.1and2. The PCB assembly16is located towards a rear face of the travel adapter10within the outer housing11. The PCB assembly16is aligned with a hole on an underside of the outer housing11to create the electrical output70. The PCB assembly16includes a backing plate provided with two upper holes17to enable other internal components to be securely attached and electrically connected to the PCB assembly16. A plastic internal cover20for the PCB assembly16is provided with two upper holes27that overlie the upper holes17in the PCB assembly16. The internal cover20has several securing slots enabling interconnection of internal components including a central securing shaft49for a locking mechanism. The locking mechanism and haptic feedback mechanism include a first and a second holding shutter22,23, an actuator key24and a key spring25. The internal cover20carries an internal shaft21with a helical thread located substantially centrally and extending perpendicular from a front-facing planar face of the internal cover20.

A compact plug assembly40containing different pin assemblies is secured to the internal cover20. Metal conducting plates19extend around the plug set40and through the aligned pairs of upper holes27,17to provide the necessary electrical connections between the pins43,50,51,60once deployed and the PCB assembly16. The front cover12has a substantially circular face and is fixed over the conducting plates19and the plug assembly40. The front cover12has a plurality of holes15enabling the deployment of pins43,50,5160therethrough. Two circular prong caps63are adapted to fit within two of the circular holes15in the face of the front cover12. The circular prong caps63are rotatable within their respective holes15. The rotatable housing13has a large circular hole14sized to accommodate the front face of the front cover12. The rotatable housing13is coupled to a cam30having an inclined and declined cam surface31. A rear edge of the cam30has four recesses26spaced at 90 degree intervals that form part of the haptic feedback mechanism. Both the rotatable housing13and the cam30are rotatable relative to the other components of the travel adapter10.

FIG.2shows the plug set40in exploded view. The plug set40comprises type-A pins60arranged to engage with complementary sockets typically found in North America and China. The type-A pins60are located within a type-A pin holder61and electrically connected to the PCB assembly16by two metal conducting plates62. The type-A pin holder61has a protrusion64on its lower edge for interaction with the cam30to act as a type-A pin deployment mechanism. The type-A pins60and the circular prong caps63are rotatable within slots located in the type-A pin holder61, such that the type-A pins60may be angled appropriately for engaging with a complementary type-I socket, such as those typically found in Australasia and China.

The plug set also comprises type-G pins50,51that are received in complementary sockets typically found in the UK. The type-G pins comprise one live pin, one neutral pin50and an earth pin51as shown inFIGS.2and12. The type-G pins50are located on a body57that carries a central projecting protrusion58and a cylindrical side locator53at its upper end. The central projecting protrusion58is arranged for selective engagement with the inclined cam surface31to move the type-G pins between the stowed and deployed configurations. The cylindrical locator pin53is shaped for insertion in a circular hole56in the centre of a gear52. The gear52has teeth54and a cylindrical side locator55. The cylindrical side locator55is shaped for accommodation in a circular slot at a rear end of the earth pin51. The cylindrical side locating pins53,55within the respective circular receiving hole56and slot to allow the gear52to rotate with respect to the body57and the pins50,51.

The plug set40further comprises type-C pins43and a pin support body in the form of a pin housing44that is shaped to fit within a complementary recess of a socket and is shown inFIGS.2and5. The type-C pins43and pin housing44are typically used within complementary sockets in European countries and China. The type-C pins43are carried on a pin plate46having a centrally positioned hole47allowing a pin deployment member in the form of a worm gear42to pass therethrough. The centrally positioned hole47is provided with shaped protrusions to act as guide threads247that extend radially into the hole47at two opposing locations (as seen inFIGS.23and24). The guide threads247interact with the external threads of the worm gear42, such that, in use, linear movement of the pin plate46occurs simultaneously with rotation of the worm gear42. A follower342in the form of an internal thread located on an internal surface of the worm gear42is moveable within the helical thread on the shaft21to allow rotation of the worm gear42along the shaft21(FIG.22b). In the stowed configuration, the pins43are located within an internal area defined by the type-C pin housing44. The pin housing44has a front cover41with two circular holes, enabling the pins43to pass therethrough. Two parallel metal conducting bars45are provided for electrical conduction from the pins43to the PCB assembly16. The pin housing44has a side protrusion48, which forms part of the actuation mechanism through interaction with the cam30to move the pins43between the deployed and the stowed configurations.

Part of the locking mechanism is shown inFIG.15in more detail. The locking mechanism comprises a first and a second holding shutter22,23that each have a substantially elongate body37,38respectively and are pivotable around the central securing shaft49. Each holding shutter22,23comprises a respective wing32,33to act as a torsion spring such that both holding shutters22,23are biased to pivot around the central securing shaft49in a clockwise direction. Towards a leading end, each body37,38has a substantially planar locking surface35,36to provide a supported stop behind the respective pin assembly in the deployed and locked configuration. The rear end of each elongate body37,38comprises an arcuate end member65,66. An end face of the arcuate end member65of the first holding shutter22has a lower cutaway portion34and an upper key receiving notch59. The key receiving notch59is shaped to receive a tail end67of the shutter key24. Operation of the locking mechanism is described hereinafter.

Components shown inFIGS.1and2are assembled to form a travel adapter10having a compact shape as shown inFIGS.3a,3b,3dand3e.FIGS.3cand3fshow the adapter10has reduced dimensions when compared with an outline of a conventional prior art adapter depicted by numeral39. The dimension with the largest reduction is the length of the adapter10in the direction of pin43deployment and results from the compact design of the type-C pin assembly whereby the pins43are stored within the pin housing44. According to the present embodiment as described above, the type-C pin deployment means embodied by the helical thread21and worm gear42enables simultaneous tandem deployment of the pin housing44and the pins43. Further reduction in length is achieved by the geared placement of the earth pin51on the type-G body57so that the leading end of the earth pin51lies in the same plane as leading ends of the live and neutral pins50in the stowed configuration.

Operation of the travel adapter10will now be described with reference toFIGS.4ato4h. When not in use the travel adapter10has a compact configuration with all pins43retracted as shown inFIG.4a. When a user requires power through use of a socket in a particular region, the user can select the required set of pins43,50,51,60, which are deployable by rotating the rotatable housing13relative to the outer housing11. A user holds the outer housing11and uses their fingers to twist the rotatable housing13to actuate the deployment of the required set of pins43,50,51,60.

Initially the type-G pins50,51are aligned such that the leading end of each pin50,51lies in the same plane in the stowed configuration as shown in sectional view inFIG.13a. Rotation of the rotatable housing13brings the protrusion58on the type-G plug body57into contact with the inclined cam surface31of the cam30. Continued rotation of the rotatable housing13, rotates the inclined cam surface31to guide outward linear movement of the plug body57and the attached pins50,51. As shown inFIG.13b, a first tooth54of the gear52locks into an internal profile within the adapter10. Continued forward movement of the plug body57causes rotation of the gear52and further extension of the leading end of the earth pin51relative to the live and neutral pins50as shown inFIG.13c. Following relative rotation of the rotatable housing13and the outer housing11by 45 degrees, the type-G pins50,51are partially deployed as shown inFIGS.4band13c.FIGS.14ato14cshow that after 45 degrees of relative rotation, the shutter key24has been urged inwardly out of a recess26and against the bias of the key spring25. The tail end67of the key24acts to push the first shutter22against the bias of the torsion spring wing32and thus restrict movement or engagement of the locking mechanism. The elongate body38of the second shutter23is unable to move under the bias of the torsion spring wing33because the type-C pin housing44is directly above and blocks any rotation around the central securing shaft49.

Further rotation of the rotatable housing13relative to the outer housing11continues to guide the protrusion58attached to the body57along the inclined rotating cam31surface and urge linear forward movement of the body57and the attached pins50,51. A second gear tooth54engages an internal profile to cause another rotation of the gear52and further linear extension of the earth pin51relative to the live and neutral pins50. Following rotation of the rotatable housing13relative to the outer housing11through 90 degrees from the starting position, the protrusion58is at the apex of the cam surface31and the type-G pins are fully deployed as shown inFIGS.4cand13f. In this position,FIGS.15ato15c, show that the shutter key24is urged into the recess26under the bias of the spring25to provide haptic feedback to a user and confirmation that the type-G pins are fully deployed. In this position, the tail end67of the shutter key24releases the locking mechanism. The first shutter22is free to pivot under the bias of the torsion spring wing32. Thus, the first shutter22pivots around the central securing shaft49into the position recently occupied by the now deployed type-G pin50,51assembly. This pivoting of the first shutter22moves the first locking surface35beneath the type-G pin50,51assembly to provide an impediment to prevent inadvertent retraction of the pins50,51as the type-G pins50,51are plugged into a complementary socket. In the fully deployed configuration, the earth pin51has a greater linear extension relative to the live and neutral pins50as required for complementary mating with type-G plug sockets. The travel adapter10is now ready to be plugged into a type-G socket by the user to provide electrical power via the output70.

Clockwise rotation of the rotatable housing13relative to the outer housing11moves the rotatable cam30and the recess26on the base of the cam30. Movement of the recess26forces the shutter key24inwardly against the bias of the key spring25. In this position, the tail end67of the shutter key24enters the key receiving notch59to pivot the first shutter22in an anticlockwise direction to unlock the mechanism and allow space for the type-G pin50,51assembly to retract. Simultaneously, the base of the inclined cam surface31is brought into contact with the protrusion64attached to the type-A pin holder61. Further rotation of the cam30guides movement of the protrusion64up the inclined cam surface31to move the pin holder61outwardly such that the type-A pins60move in a linear outward direction. At the same time, the protrusion58on the type-G pin body57is guided along the declined cam surface31to cause linear rearward movement of the body57to thereby retract the type-G pins50,51as shown inFIG.13g-13j. The earth pin51is retracted in a reverse process to that previously described with reference toFIG.13a-13f.FIG.4dshows the rotation of the rotatable housing13through 135 degrees relative to the starting position with the type-A pins60partially deployed and the type-G pins50,51returning to the stowed configuration.

Relative rotation of the rotatable housing13and the outer housing11through 180 degrees results in full extension and deployment of the type-A pins60and retraction of the type-G pins50,51into the stowed configuration as shown inFIGS.4e,13kand13l. In this positon, the protrusion64rests on the apex of the cam surface31. As previously described, the haptic mechanism provides feedback for the user as the shutter key24pops into one of the recesses26in the fully deployed configuration of the type-A pins60. As seen in the rear view ofFIG.14c, the type-A pins60are in close proximity to the protrusion64. As a result, pressure on the type-A pins60in the deployed configuration is translated to the protrusion64that is held at the apex of the cam surface31. Tolerances between the internal components are small within the travel adapter10and therefore the protrusion64acts as a lock to inhibit rearward movement of the type-A pins60once deployed. No bending moments are generated since the type-A pins60are in close proximity to the protrusion64and no separate additional locking mechanism is required. In this fully deployed configuration, a user may plug the pins60of the travel adapter10into a complementary socket to provide power via the output70.

The type-A pins60are rotatable in opposing directions as shown inFIG.4e. A user holds the pins60and twists to rotate the pins60and prong caps63within the front cover12to form a type-I pin configuration. In the type-I configuration the pins60of the travel adapter10are mateable with a complementary type-I socket.

Clockwise rotation of the rotatable housing13relative to the outer housing11brings the protrusion48on the pin housing44into contact with the leading end of the inclined cam surface31. Further rotation causes the protrusion48to follow the inclined cam surface31resulting in linear outward movement of the pin housing44. Since the external worm gear42is carried within the pin housing44, the worm gear42also moves with the housing44relative to the internal cover20. The worm gear42rotates along the internal helical shaft21because the follower342on the internal surface of the worm gear42is located in the helical thread on the shaft21. Thus, linear movement of the pin housing44results in linear as well as rotational movement of the worm gear42. The pins43carried on the pin plate46, which are housed within the pin housing44and coupled to the external worm gear42, are urged outwardly in a linear direction as the worm gear42rotates. The guide threads247in the pin plate46interact with the external thread on the rotating worm gear42, which results in the linear outward movement of the pin plate46and attached pins43. Thus, the pins43move out with the pin housing44to project through the pin holes in the front cover41of the pin housing44as shown inFIG.4f, with reference toFIGS.5,6,8, and25b-c. Rotation of the rotatable housing13relative to the outer housing11through 225 degrees from the initial position results in partial deployment of the type-C pins43and the pin housing44and partial retraction of the type-A pins60. Retraction of the type-A pins60occurs because the protrusion64on the base of the type-A pin housing61is guided along the trailing face of the declined cam surface31.

Continued rotation urges the protrusion48on the pin housing44up the inclined cam surface31to cause further linear movement of the pin housing44. This outward movement of the pin housing44is translated to the pins43via the worm gear assembly21,42, which simultaneously pushes the pins43through the front cover41until they are fully deployed as shown inFIG.25d. This overall linear extension corresponds with a helix screw length88for moving the type-C pins43,46into the fully deployed configuration (FIGS.22c, dand25d). In this position, the type-C pins are fully deployed relative to the pin housing44, but the pin housing44is not yet fully deployed relative to the body of the adapter10. A small amount of additional rotation of the rotatable housing13causes the protrusion48to reach the peak of the inclined surface of the cam, resulting in a corresponding small further linear movement of the pin housing44and rotation of the worm gear42therein until the pin housing44is fully deployed in the operational configuration as shown inFIG.25e. This occurs when the rotatable housing13has rotated relative to the outer housing11by 270 degrees from the starting position. In this position, both the type-C pins43and the pin housing44are in the fully deployed configurations.

Deployment of the pin housing44creates an internal void within the outer housing11and provides a space into which the elongate body38of the second shutter23is pivotable. This is enabled since the shutter key24is biased into the recess26and therefore the tail end67of the shutter key24is removed from the notch59to allow movement of the first shutter22. The first shutter22pivots around the central securing shaft49such that the cutaway portion34abuts the type-G pin assembly therebelow. Thus, both shutters22,23have the space required to pivot around the central securing shaft49such that the second locking surface36moves beneath the type-C pin housing44to resist rearward movement thereof. In addition, the type-C pins43are locked in the deployed configuration by means of a locking area442of the worm gear assembly21,42(FIGS.22c,d,23and25e). The type-C pins43are fully deployed when the worm gear42has traversed along the full length88of the helix screw area. Further incremental linear movement of the pin housing44(betweenFIGS.25dandein the type-C pin locking area442) causes a small rotation of the worm gear42within the pin housing44. This extra rotation of the worm gear42causes a worm gear locking surface42L at the leading end of the worm gear42to abut a guide thread247locking surface247L (FIG.25e). This abutment of the worm gear locking surface42L and guide thread locking surface247L substantially restricts rotation of the external worm gear42and rearward movement of the type-C pins43on the application of an external force thereto. At this point the type-A pins60are fully retracted and retained within the adapter10housing11in the stowed configuration. The type-C pins43and pin housing44of the travel adapter10are fully deployed and locked and therefore can be safely inserted in a complementary European socket to provide power via the output70.

The type-C pins43can be retracted in order to store the adapter10in the most compact configuration with all pins43,50,51,60stowed within the outer housing11when not in use. This is achieved by further rotation of the rotatable housing13to cause movement of the recess26so that the shutter key24pops out of the recess26and is urged against the bias of the spring25. The tail end67of the shutter key24pushes against the first shutter22to pivot both shutters22,23in an anticlockwise direction around the central securing shaft49and unlock the locking mechanism to remove the impediment to retraction of the type-C pin43assembly. The protrusion48on the pin housing44follows the declined trailing cam surface31to cause linear rearward movement of the pin housing44. The initial rearward movement of the pin housing44causes an initial rotation of the worm gear42in an opposing direction within the locking area442to space the worm gear locking surface42L and the guide thread locking surface247L. This unlocks the type-C pins43and pin plate46, which are now able to commence linear rearward movement in tandem with the pin housing44. Movement of the type-C pin43assembly into the stowed configuration continues in a reverse process of that described in connection with the type-C43pin deployment.

FIGS.9ato9cshow the worm gear assembly21,42, the pins43and the pin housing44all in an extended deployed configuration. Rotation of the rotatable housing13by 315 degrees from the starting position results in retraction of the pin housing44and the pins43via the worm gear assembly21,42. The components of the adapter10are in partially retracted positions as shown inFIGS.4h,10a,10band10c. Continued rotation of the rotatable cover13through 360 degrees from the starting position causes full retraction of the external worm gear42, the type-C pins43within the pin housing44, and the pin housing44itself, such that the adapter returns10to the compact configuration with all pins43,50,51,60stowed within the housing as shown inFIG.4a.

Each deployment of selected pins50,51,60,43occurs after rotation of the rotatable cover13in the appropriate position through 90 degree intervals. Therefore there is a clear visual indicator of each pin deployment50,51,60,43position, when the rotatable cover13is aligned with the outer housing11such that the adapter10forms a substantially cuboid shape with rounded edges. This provides visual feedback for a user to confirm that plug assemblies are in the fully deployed and/or stowed configurations.

As shown inFIG.14, the travel adapter10is insertable into a socket matching any of the pin types, -A, -C, -G and -I, and the USB-C output70connected via wires71to a hub72. The hub72may include a wireless charger for charging devices such as phones and watches. The hub72may also have output slots enabling wires to connect the hub72to other electronic devices73, such as laptop computers and tablets to supply electric power and charge these devices.

One key benefit of all embodiments of the present invention is that the overall dimensions of the adapter10are reduced compared with conventional alternatives. In particular, the length of the power adapter10in the direction of pin deployment is significantly reduced in the stowed configuration when compared with conventional alternatives as shown inFIG.3c. Features enabling this reduction in size are the stowing of the pins43within the volume defined by the pin housing44of the type-C pin assembly, the type-C pin deployment means enabling simultaneous tandem deployment of the pin housing44and the type-C pins43and the gear52mechanism to allow more compact storage of the earth pin51of the type-G pin assembly.

The locking mechanism is advantageous to prevent inadvertent retraction or damage to the pins43,50,51,60on application of a force thereto. The bending moment applied to type-C and type-G pins43,50,51is greater since the protrusions48,53holding the respective pins43,50,51in the deployed configurations are further away from the pins43,50,51. Thus, without the locking mechanism the pins43,50,51would be subject to a bending moment with potential for pin damage. Furthermore, the locking mechanism functions automatically on deployment of the pins43,50,51so that no additional input is required by a user to ensure the pins43,50,51are safely deployed and locked in this configuration.

FIGS.26a-dand27a-cshow an alternative embodiment of the type-C actuation means for movement of the type-C pins between the stowed and deployed configurations. In order to minimise repetition, similar features of the apparatus described subsequently are numbered with a common two-digit reference numeral and are differentiated by a third digit placed before the two common digits. Such features are structured similarly, operate similarly, and/or have similar functions as previously described unless otherwise indicated. As shown inFIG.26b, the pin deployment member takes the form of a worm gear542with embedded dual helix screw582. The internal cover20carries a cylindrical shaft521extending perpendicular to the front facing planar face of the internal cover20. The helical screw582is embedded within the worm gear542so that the smooth internal surface of the worm gear542is movable along the cylindrical shaft521. The cylindrical shaft521has a T-shaped end stop521ethat is arranged to abut an internal surface of a worm gear end stop542ewhen the type-C pins43are in the fully deployed configuration. The end stops521e,542eensure that the worm gear542with embedded dual helix screw582remains coupled to the internal shaft521throughout actuation of the adapter10.

With reference toFIGS.27a-c, the type-C pins43attached to the pin plate46and the pin housing44are moved, deployed and stowed in the same manner described with reference to the previous embodiment. The worm gear542is carried within the pin housing44, and rotates along with linear movement of the pin housing44while sliding along the internal cylindrical shaft521. The type-C pins43carried on the pin plate46, which are housed within the pin housing44and coupled to the external worm gear542, are urged in a linear direction as the external worm gear542translates along the cylindrical shaft21within the pin housing44. The locking mechanisms and haptic feedback mechanisms all operate in the manner previously described.

According to alternative embodiments of the invention, different outputs70are provided. The USB type-C (USBC) output70provides one example of a power output. However, the adapter10may be modified to provide alternative sockets or power outputs for usefully engaging with devices requiring a power source.

With reference toFIGS.18to21, further embodiments of the present invention will now be described. The travel adapter110ofFIGS.18to20is similar in structure and is provided with the plug set40, actuation and locking mechanisms. However, the travel adapter110has an alternative output170in the form of two metal conducting pins located within an interconnecting means in the form of a slot. There is no PCB assembly16within the travel adapter110, but instead, the conducting pins output170maintains an electric conduction path to the pins43,50,51,60when the pin assemblies are in the deployed configuration. Several power packs128of different sizes and power outputs are provided for connecting with the travel adapter110. An electric connection is made between the travel adapter110and the power packs128via an interconnecting interface in the form of keys129arranged to slide and lock within the slot at the rear of the travel adapter110. This allows the travel adapter110to be used as part of a modular system interchangeably with other adapters, such as a foldable adapter180, and with power packs128of different sizes and ratings to provide power to devices having differing power requirements.

Another embodiment of the invention is shown inFIG.21. The multi-plug adapter210is a conventional design having actuators in the form of levers190slidable within slots in the housing11. The levers190are directly coupled to each respective pin assembly such that linear movement of each lever190causes linear movement of the coupled pin assembly. However, the design is modified by the incorporation of the type-C pin assembly of the invention including the pins43stowed within the housing44and connected to the internal helical shaft21on the rear cover20via a worm gear42, which are operable as previously described. The pin housing44is provided with a side protrusion248for engaging with the lever190such that actuation and deployment of the type-C pins can be controlled by a user.

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 the appended claims. Relative terms such as “front”, “clockwise”, “anticlockwise”, “rear”, “end”, “upper”, “lower” and “rear” are illustrative and are not intended to be limiting.

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.