PATENT DOCUMENT

Publication Number: US-8021198-B2
Application Number: US-13504408-A
Country: US
Kind Code: B2

Title: Low-profile power adapter

Abstract:
A low-profile power adapter is disclosed. In one embodiment, a low profile power adapter is facilitated by improved approaches to construct and assembly of a power adapter plug for the power adapter. According to one aspect, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug. According to another aspect, internal terminals used by a power adapter plug of a power adapter can be flexibly positioned on the power adapter plug, thereby facilitating interconnection with electrical components used by the power adapter. 
     A molded base can be formed around the metal base leaving the blade and terminals exposed.

Claims:
1. A power adapter, comprising:
 a first metal prong having a front end and a back end; 
 a first metal base formed of a thin stainless steel sheet having a first metal opening to mechanically and electrically connect to the back end of said first prong, said first metal base including or coupling to at least a first terminal; 
 a second metal prong having a front end and a back end; 
 a second metal base formed from a thin stainless steel sheet having a second opening to mechanically and electrically connect to the back end of said second metal prong, said second metal base including or coupling to at least a second terminal; and 
 a molded base formed around said first and second metal bases such that said first and second metal prongs are at least partially exposed and said first and second metal bases are not exposed except for the first and second terminals which are at least partially exposed, said molded base being non-conductive, 
 wherein said first and second metal prongs extend outward from a first side of said molded base, and the first and second terminals extend outward from a second side of said molded base, and wherein the second side is opposite the first side. 
 
     
     
       2. A power adapter as recited in  claim 1 , wherein said molded base is plastic. 
     
     
       3. A power adapter as recited in  claim 1 , wherein said molded base has a thickness of less than or equal to about three (3) millimeters. 
     
     
       4. A power adapter as recited in  claim 1 , wherein the first and second terminals are positionable anywhere on the second side of said molded base. 
     
     
       5. A power adapter as recited in  claim 1 , wherein at least the first terminal comprises a connector mechanically and electrically connected to said first metal base. 
     
     
       6. A power adapter as recited in  claim 1 , wherein the first terminal is integrally formed with said first metal base. 
     
     
       7. A power adapter as recited in  claim 1 , wherein the first terminal is formed from a bent portion of said first metal base. 
     
     
       8. A power adapter as recited in  claim 1 , wherein at least one of the first and second terminals comprises a connector. 
     
     
       9. A power adapter as recited in  claim 1 ,
 wherein said first metal base includes or couples to a first connection member, and 
 wherein one end of the first connection member is integral with or connected to said first metal base, and another end of the first connection member is connected to the first terminal. 
 
     
     
       10. A power adapter as recited in  claim 9 , wherein the first terminal comprises a connector. 
     
     
       11. A power adapter as recited in  claim 1 , wherein the thickness of said molded base is less than the thickness of either of said first and second prongs. 
     
     
       12. A power adapter as recited in  claim 1 , wherein the thickness of said molded base is about 2.5 millimeters. 
     
     
       13. A method for assembling a power adapter, said method comprising:
 obtaining a first metal prong for the power adapter, the first metal prong having a front end and a back end, with the back end having at least one attachment feature; 
 forming a first metal base from a thin stainless steel sheet having at least a first terminal and one opening to receive the at least one attachment feature of the first metal prong, wherein the first terminal is formed from a bent portion of the first metal base; 
 securing the first metal prong proximate to the at least one opening of the first metal base using the at least one attachment feature, thereby providing a mechanical and electrical connection between the first metal prong and the first metal base; and 
 forming a non-conductive base around the first metal base to encapsulate the first metal base while the first metal prong and the first terminal remain at least substantially exposed, 
 wherein the first metal prong extends outward from a first side of the non-conductive base, and the first terminal extends outward from a second side of the non-conductive base, and wherein the second side is opposite the first side. 
 
     
     
       14. A method as recited in  claim 13 , wherein said forming comprises injection molding to form the non-conductive base. 
     
     
       15. A method as recited in  claim 13 , wherein the first terminal is formed by bending a first terminal portion of the first metal base. 
     
     
       16. A method as recited in  claim 13 , wherein the first terminal is offset from the position of the first metal prong. 
     
     
       17. A method as recited in  claim 13 , wherein the first terminal comprises a first connector. 
     
     
       18. A method as recited in  claim 17 , wherein said method further comprises:
 attaching a first end of a first connection member to the first metal base; 
 attaching the first connector to a second end of the first connection member; and 
 positioning the first connector with respect to the first metal base. 
 
     
     
       19. A method as recited in  claim 13 , wherein the power adapter includes a first terminal, and wherein a first connection member offsets the first terminal from the first metal base. 
     
     
       20. A method as recited in  claim 13 , wherein said method, prior to said forming, further comprises:
 obtaining a second metal prong for the power adapter, the second metal prong having a front end and a back end, with the back end having at least one attachment feature; 
 obtaining a second metal base having at least one opening to receive the at least one attachment feature of the second metal prong; and 
 securing the second metal prong to the at least one opening of the second metal base using the at least one attachment feature, thereby providing a mechanical and electrical connection between the second metal prong and the second metal base. 
 
     
     
       21. A method as recited in  claim 20 , wherein said forming operates to form the non-conductive base around the first metal base as well as the second metal base so as to encapsulate the first metal base and the second metal base while the first metal prong and the second metal prong remain at least partially exposed. 
     
     
       22. A method for assembling a power adapter, said method comprising:
 obtaining a first metal prong for the power adapter, the first metal prong having a front end and a back end, with the back end having at least one attachment feature; 
 obtaining a first metal base having at least a first terminal and one opening to receive the at least one attachment feature of the first metal prong; 
 securing the first metal prong proximate to the at least one opening of the first metal base using the at least one attachment feature, thereby providing a mechanical and electrical connection between the first metal prong and the first metal base; and 
 forming a non-conductive base around the first metal base to encapsulate the first metal base while the first metal prong and the first terminal remain at least substantially exposed, 
 wherein said obtaining of the first metal prong comprises:
 receiving an extruded metal bar having a width of the first metal prong; and 
 separating the first metal prong having a length from the extruded metal bar. 
 
 
     
     
       23. A power adapter plug, comprising:
 a first metal prong having a front end and a back end; 
 a first metal base formed from a stainless steel sheet having a first opening to mechanically and electrically connected to the back end of said first metal prong, said first metal base including or coupling to at least a first terminal formed from a bent portion of said first metal base; 
 a second metal prong having a front end and a back end; 
 a second metal base formed from a stainless steel sheet having a second opening to mechanically and electrically connected to the back end of said second metal prong, said second metal base including or coupling to at least a second terminal formed from a bent portion of said second metal base; and 
 a non-conductive base formed around said first and second metal bases such that said first and second metal prongs and the first and second terminals are at least partially exposed, 
 wherein said first and second metal prongs extend outward from a first side of said non-conductive base, and the first and second terminals extend outward from a second side of said non-conductive base, and wherein the second side is opposite the first side. 
 
     
     
       24. A power adapter plug as recited in  claim 23 , wherein said non-conductive base has a thickness of less than or equal to about three (3) millimeters, and wherein said first metal base or said second metal base has a thickness of less than or equal to about 0.1-0.5 millimeters. 
     
     
       25. A power adapter plug as recited in  claim 24 , wherein said non-conductive base is plastic and formed by injection molding. 
     
     
       26. A power adapter plug as recited in  claim 23 , wherein said first metal prong is formed from a first extruded metal bar having a width of said first metal prong, and wherein said second metal prong is formed from the first extruded metal bar or a second extruded metal bar having a width of said second metal prong.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to power adapters for electronic devices. 
     2. Description of the Related Art 
     There exists today may different portable electronic devices that are powered by rechargeable batteries. Examples of such portable electronic devices include mobile phones, portable media players, personal digital assistants (PDAs), etc. To facilitate recharging of the rechargeable batteries, a portable electronic device is normally sold with a power adapter. Typically, the power adapter has a power plug for coupling to an AC outlet. The power plug is a significant part of a power adapter that is required to meet certain specifications for safety reasons. The power adapter also contains electronic circuitry that converts AC power acquired from the AC outlet into DC power and outputs DC power via a cord having a connector. The connector of the cord connects to the portable electronic device and allows the DC power to be received at the portable electronic device so as to power the portable electronic device and/or charge the rechargeable battery. There is, however, an ongoing demand for small and thinner power adapters. Accordingly, there is a need to provide improved power adapters are efficient in their construction and operation. 
     SUMMARY OF THE INVENTION 
     The invention relates to low-profile power adapters. In one embodiment, a low profile power adapter is facilitated by improved approaches to construct and assembly of a power adapter plug for the power adapter. According to one aspect, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug. According to another aspect, internal terminals used by a power adapter plug of a power adapter can be flexibly positioned on the power adapter plug, thereby facilitating interconnection with electrical components used by the power adapter. 
     The invention may be implemented in numerous ways, including, but not limited to, as a system, device, or apparatus, or method. Example embodiments of the present invention are discussed below. 
     As a power adapter, one embodiment of the invention can, for example, include at least: a first metal prong having a front end and a back end; a first metal base mechanically and electrically connected to the back end of the first prong, the first metal base including or coupling to at least a first terminal; a second metal prong having a front end and a back end; a second metal base mechanically and electrically connected to the back end of the second prong, the second metal base including or coupling to at least a second terminal; and a molded base formed around the first and second metal bases such that the first and second metal prongs are at least partially exposed and the first and second metal bases are not exposed except for the first and second terminals which are at least partially exposed, the molded base being non-conductive. 
     As a method for assembling a power adapter, one embodiment of the invention can, for example, include at least: obtaining a first metal prong for the power adapter, the first metal prong having a front end and a back end, with the back end having at least one attachment feature; obtaining a first metal base having at least one opening to receive the at least one attachment feature of the first metal prong; securing the first metal prong proximate to the at least one opening of the first metal base using the at least one attachment feature, thereby providing a mechanical and electrical connection between the first metal prong and the first metal base; and forming a non-conductive base around the first metal base to encapsulate the first metal base while the first metal prong remains at least substantially exposed. 
     As a power adapter plug, one embodiment of the invention can, for example, include at least: a first metal prong having a front end and a back end; a first metal base mechanically and electrically connected to the back end of the first prong, the first metal base including or coupling to at least a first terminal; a second metal prong having a front end and a back end; a second metal base mechanically and electrically connected to the back end of the second prong, the second metal base including or coupling to at least a second terminal; and a non-conductive base formed around the first and second metal bases such that the first and second metal prongs and the first and second terminals are at least partially exposed. 
     Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1A  is a perspective view of a power adapter plug according to one embodiment of the invention. 
         FIG. 1B  illustrates a side view of the power adapter plug according to the embodiment illustrated in  FIG. 1A . 
         FIG. 1C  illustrates a top view of the power adapter plug according to the embodiment illustrated in  FIG. 1A . 
         FIG. 2  is a side view of an electronic device assembly according to one embodiment of the invention. 
         FIG. 3  is a flow diagram of an electronic device assembly process according to one embodiment of the invention. 
         FIG. 4A  is a back view of a power adapter plug according to one embodiment of the invention. 
         FIG. 4B  is a back view of a power adapter plug according to another embodiment of the invention. 
         FIG. 4C  is a back view of a power adapter plug according to still another embodiment of the invention. 
         FIG. 5A  illustrates an exemplary blade according to one embodiment of the invention. 
         FIG. 5B  illustrates an exemplary base plate according to one embodiment of the invention. 
         FIG. 5C  illustrates an assembly of the blade illustrated in  FIG. 5A  and the base plate illustrated in  FIG. 5B . 
         FIG. 5D  illustrates an exemplary metal bar according to one embodiment of the invention. 
         FIG. 6  is a flow diagram of a power adapter assembly process according to one embodiment of the invention. 
         FIG. 7  is flow diagram of a power adapter assembly process according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention relates to low-profile power adapters. In one embodiment, a low profile power adapter is facilitated by improved approaches to construct and assembly of a power adapter plug for the power adapter. According to one aspect, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug. According to another aspect, internal terminals used by a power adapter plug of a power adapter can be flexibly positioned on the power adapter plug, thereby facilitating interconnection with electrical components used by the power adapter. 
     Exemplary embodiments of the present invention are discussed below with reference to the various figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes, as the invention extends beyond these embodiments. 
       FIG. 1A  is a perspective view of a power adapter plug  100  according to one embodiment of the invention. The power adapter plug  100  includes a base  102 , a first blade  104  and a second blade  106 . In addition, the power adapter plug  100  includes a first terminal  108  and a second terminal  110 . The base  102  is typically formed from a non-conductive material, such as plastic, and serves to support the first blade  104  and the second blade  106 . The blades  104  and  106  extend outward from a first side (e.g., front side) of the base  102 . The terminals  108  and  110  extend outward from a second side (e.g., back side) of the base  102 . Although the blades  104  and  106  have a rectangular cross-section, the blades  204  and  106  can have other cross-sectional shapes. Hence, more generally, the blades are referred to as prongs herein. 
     The terminals  108  and  110  can be placed at any location on the second side of the base  102 . In other words, in the terminals  108  and  110  do not have to be positioned directly behind the corresponding blades  104  and  106  as would be the case with conventional approaches. Instead, the terminals  108  and  110  can be offset from the positions of the blades  104  and  106 , such that the terminals  108  and  110  can be positioned anywhere on the second side of the base  102 . By controlling the position of the terminals  108  and  110 , assembly of the power adapter  102  with other electrical components, such as a printed circuit board, can be performed in a space efficient manner. For example, the power adapter plug  100  can be directly attached to a printed circuit board since the position of the terminals  108  and  110  can be designed so as to correspond to connection terminals of the printed circuit board. 
     In one embodiment, advantageously, the thickness t of the base  102  is thin. The thickness t of the base  102  is, for example, less than about 0.5-3.0 millimeters. In one specific example the thickness t of the base  102  can be about 2.5 millimeters. As a result, the power adapter plug  100  can be considered a low-profile power adapter. 
       FIG. 1B  illustrates a side view of the power adapter plug  100  according to the embodiment illustrated in  FIG. 1A . As illustrated in  FIG. 1B , the terminals  108  and  110  of the power adapter plug  100  are repositioned to a lower portion of the base  102 . In addition, to facilitate electrical connection (e.g., solder connection) with respect to other electrical components, such as a printed circuit board, the first terminal  108  can include an opening  112  and the second terminal  110  can include an opening  114 . 
       FIG. 1C  illustrates a top view of the power adapter plug  100  according to the embodiment illustrated in  FIG. 1A . The power adapter plug  100  illustrated in  FIG. 1C  shows that the terminals  108  and  110  have been be positioned (i.e., offset) toward one side of the base  102 . 
       FIG. 2  is a side view of an electronic device assembly  200  according to one embodiment of the invention. The electronic device assembly  200  is for a power adapter, such as a power adapter that connects to an AC outlet and produces a DC output for powering an electronic device and/or charging a rechargeable battery of the electronic device. 
     The electronic device assembly  200  includes a power adapter plug  202 . The power adapter plug  202  can, for example, be constructed similar to the power adapter plug  100  illustrated in  FIGS. 1A-1C . The power adapter plug  202  includes a first blade  204 , a second blade  206 , and a base  208 . The base  208  supports the first blade  204  and the second blade  206 . The base  208  also supports terminals  210 . The electronic device assembly  200  also includes a printed circuit board  212 . The power adapter plug  202  can be mechanically and electrically connected to the printed circuit board  212 . The printed circuit board  212  includes a plurality of electrical components  214  attached onto at least one side of the printed circuit board  212  to provide various electrical operations. The terminals  210  of the base  208  of the power adapter plug  202  can be utilized to couple to corresponding connection points  216  of the printed circuit board  212 . Accordingly, in one embodiment, the terminals  210  of the power adapter plug  202  can be mechanically and electrically connected to corresponding ones of the connection points  216  of the printed circuit board  212 . These connections, for example, can be formed by soldering the terminals  210  (directly or indirectly) to the corresponding connection points  216 . As another example, connectors can be used to provide mechanical and/or electrical connection of the power adapter plug  202  and the printed circuit board  212 . 
     In one embodiment, the power adapter plug  202  is a low-profile adapter plug which is able to couple directly to the printed circuit board  212  without intervening mechanical assistance by other components. As a result, the overall thickness of an electronic device (e.g., power adapter) being formed to enclose the electronic device assembly  200  can be smaller and thinner. As shown in  FIG. 2 , the base  208  of the power adapter plug  200  is positioned adjacent the electrical components  214  mounted on the printed circuit board  212 . However, in another embodiment, the base  208  of the power adapter plug  200  can be positioned immediately adjacent the printed circuit board  212  (without any intervening electrical components  214 ). 
     Once the power adapter plug  202  is electrically (and possibly mechanically) connected to the printed circuit board  212 , the power adapter assembly  200  can be enclosed within an external device housing (not shown), thereby forming a power adapter product. In operation, the power adapter assembly  200  can serve to convert AC power into DC power, and then supply the DC power to electrical components of an electronic device which can be electrically connected to the power adapter assembly  200  directly (e.g., integral with electronic device) or indirectly (e.g., by connector and/or wire (cord). For example, the blades  204  and  206  of the power adapter assembly  200  can be inserted into an AC electrical outlet from which high-voltage alternating current can be acquired. The electrical components  214  associated with the printed circuit board  212  can operate to convert the high-voltage Alternating Current (AC) into a low-voltage Direct Current (DC) which is suitable for use for powering electrical components of the electronic device. 
     Although the power adapter assembly  200  illustrated in  FIG. 2  includes a printed circuit board  212 , in other embodiments, the printed circuit board  212  can be replaced with a different substrate. For example, the substrate can alternatively be a flexible substrate (e.g., flex-circuit). 
       FIG. 3  is a flow diagram of an electronic device assembly process  300  according to one embodiment of the invention. The electronic device assembly process  300  can, for example, correspond to a process utilized to assemble the electronic device assembly  200  illustrated in  FIG. 2 . 
     The electronic device assembly process  300  can initially form  302  a low-profile power adapter plug with positionable terminals. As an example, the low-profile power adapter plug can correspond to the power adapter plug  100  illustrated in  FIGS. 1A-1C  or the power adapter plug  202  illustrated in  FIG. 2 . After the low-profile power adapter plug has been formed  302 , the power adapter plug can be mechanically and electrically connected  304  to a printed circuit substrate. The printed circuit substrate can, for example, pertained to a printed circuit board. However, in other embodiments, the printed circuit substrate can correspond to a flexible printed circuit substrate, such as a flex-circuit. 
     As noted above terminals on a base of a power adapter can be positioned (or repositioned) to a more desirable location. In other words, the terminals can be positioned anywhere on a base of the power adapter. There are various embodiments for positioning the terminals. In one embodiment, a terminal can result from a portion of a metal base that is provided internal the base of the power adapter plug. In another embodiment, one or more connection members can link a metal base to a terminal location. 
       FIG. 4A  is a back view of a power adapter plug  400  according to one embodiment of the invention. The power adapter plug  400  can, for example, correspond to the power adapter plug  100  illustrated in  FIGS. 1A-1C  or the power adapter plug  202  illustrated in  FIG. 2 . The back view illustrated in  FIG. 4A  illustrates a back side of a base  402  of the power adapter plug  400 . The base  402  can, for example, be performed by an injection molding. The corresponding front side (not shown) of the base  402  has a pair of blades  404  and  406  extending therefrom. More generally, the blades  404  and  406  can be referred to as prongs. Internal to the base  402  is a first base plate  408  and a second base plate  410 . Although dependent on implementation, in one embodiment, the first base plate  408  and the second base plates  410  are thin metal plates, such as stainless steel with a thickness of about 0.1-0.5 millimeters. 
     The first base plate  408  is coupled to a rear end of the blade  404 . The first base plate  408  serves as a structural base for the blade  404 . In one implementation, the first base plate  408  is mechanically connected to the blade  404 . The mechanical connection can, for example, be provided by (i) interlocking the blade  404  with the first base plate  408 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the first base plate  408  is connected to the blade  404 , the blade  404  and the first base plate  408  are also electrically connected. 
     Similarly, the second base plate  410  is coupled to a rear end of the blade  406 . The second base plate  410  serves as a structural base for the blade  406 . In one implementation, the second base plate  410  is mechanically connected to the blade  406 . The mechanical connection can, for example, be provided by (i) interlocking the blade  406  with the second base plate  410 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the second base plate  410  is connected to the blade  406 , the blade  406  and the second base plate  410  are also electrically connected. 
     The first base plate  408  and the second base plate  410  can also respectively serve to support a first terminal  412  and a second terminal  414 . The terminals  412  and  414  are at least partially exposed and thus accessible on the back side of the base  402 . The terminals  412  and  414  serve as internal connection points for the power adapter plug  400 . Hence, the terminals  412  and  414  can also be referred to as internal terminals. The utilization of the base plates  408  and  410  operates to facilitate the placement of the terminals  412  and  414  anywhere along the back side of the base  402 . Consequently, the interconnection of the power adapter plug  400  with respect to other electrical circuitry or components is greatly facilitated. 
       FIG. 4B  is a back view of a power adapter plug  450  according to another embodiment of the invention. The power adapter plug  450  can, for example, correspond to the power adapter plug  100  illustrated in  FIGS. 1A-1C  or the power adapter plug  202  illustrated in  FIG. 2 . The back view illustrated in  FIG. 4B  illustrates a back side of a base  452  of the power adapter plug  450 . The base  452  can, for example, be performed by an injection molding. The corresponding front side (not shown) of the base  452  has a pair of blades  454  and  456  extending therefrom. More generally, the blades  454  and  456  can be referred to as prongs. Internal to the base  452  is a first base plate  458  and a second base plate  460 . In one embodiment, the first base plate  458  and the second base plates  460  are thin metal plates, such as stainless steel with a thickness of about 0.1-0.5 millimeters. 
     The first base plate  458  is coupled to a rear end of the blade  454 . The first base plate  458  serves as a structural base for the blade  454 . In one implementation, the first base plate  458  is mechanically connected to the blade  454 . The mechanical connection can, for example, be provided by (i) interlocking the blade  454  with the first base plate  458 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the first base plate  458  is connected to the blade  454 , the blade  454  and the first base plate  458  are also electrically connected. In addition, the base  452  can further include a first connection member  462  that provides a path within the base  452  from the first base plate  458  to a first terminal  464 . The first terminal  464  is electrically connected to the first base plate  458  via the first connection member  462 . The first terminal  464  is at least partially exposed and thus accessible on the back side of the base  452 . The first connection member  462  can be integrally formed with the first base plate  458 . Alternatively, the first connection member  462  can be separately formed and subsequently connected to the first base plate  458 . The first connection member  462  thus permits the first terminal  464  to be positioned (and oriented) in any position along the back side of the base  452 . 
     Similarly, the second base plate  460  is coupled to a rear end of the blade  456 . The second base plate  460  serves as a structural base for the blade  456 . In one implementation, the second base plate  460  is mechanically connected to the blade  456 . The mechanical connection can, for example, be provided by (i) interlocking the blade  456  with the second base plate  460 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the second base plate  460  is connected to the blade  456 , the blade  456  and the second base plate  460  are also electrically connected. In addition, the base  452  can further include a second connection member  466  that provides a path within the base  452  from the second base plate  460  to a second terminal  468 . The second terminal  468  is electrically connected to the second base plate  460  via the second connection member  466 . The second terminal  468  is at least partially exposed and thus accessible on the back side of the base  452 . The second connection member  466  can be integrally formed with the second base plate  460 . Alternatively, the second connection member  466  can be separately formed and subsequently connected to the second base plate  460 . The second connection member  466  thus permits the second terminal  468  to be positioned (and oriented) in any position along the back side of the base  452 . 
     The terminals  464  and  468  serve as internal connection points for the power adapter plug  450 . Hence, the terminals  464  and  468  can also be referred to as internal terminals. The utilization of the base plates  458  and  460  together with the respective connection members  462  and  466  facilitates the placement of the terminals  464  and  468  anywhere along the back side of the base  452 . Consequently, the interconnection of the power adapter plug  450  with respect to other electrical circuitry or components is greatly facilitated. 
       FIG. 4C  is a back view of a power adapter plug  470  according to still another embodiment of the invention. The power adapter plug  470  is generally similar to the power adapter plug  450  illustrated in  FIG. 4B . However, the power adapter plug  470  has a European plug configuration. The back view illustrated in  FIG. 4C  illustrates a back side of a base  472  of the power adapter plug  470 . The base  472  can, for example, be performed by an injection molding. The corresponding front side (not shown) of the base  472  has a front prong  473  and a pair of rear prongs  474  and  476  extending therefrom. Internal to the base  472  is a first base plate  478  and a second base plate  480 . In one embodiment, the first base plate  478  and the second base plates  480  are thin metal plates, such as stainless steel with a thickness of about 0.1-0.5 millimeters. 
     The first base plate  478  is coupled to a rear end of the prong  474 . The first base plate  478  serves as a structural base for the prong  474 . In one implementation, the first base plate  478  is mechanically connected to the prong  474 . The mechanical connection can, for example, be provided by (i) interlocking the prong  474  with the first base plate  458 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the first base plate  478  is connected to the prong  474 , the prong  474  and the first base plate  478  are also electrically connected. In addition, the base  472  can further include a first connection member  482  that provides a path within the base  472  from the first base plate  478  to a first connector  484  (e.g., pin or post type connector), which serves as a first terminal. The first connector  484  is electrically connected to the first base plate  478  via the first connection member  482 . The first connector  484  is at least partially exposed and thus accessible on the back side of the base  472 . The first connection member  482  can be integrally formed with the first base plate  478 . Alternatively, the first connection member  482  can be separately formed and subsequently connected to the first base plate  478 . The first connection member  482  thus permits the first connector  484  to be positioned (and oriented) in any position along the back side of the base  472 . 
     Similarly, the second base plate  480  is coupled to a rear end of the prong  476 . The second base plate  480  serves as a structural base for the prong  476 . In one implementation, the second base plate  460  is mechanically connected to the prong  476 . The mechanical connection can, for example, be provided by (i) interlocking the prong  476  with the second base plate  480 , (ii) soldering the parts together, and/or (iii) using some attachment members (such as screws, fasteners or rivets). In addition to providing mechanical connection, once the second base plate  480  is connected to the prong  476 , the prong  476  and the second base plate  480  are also electrically connected. In addition, the base  472  can further include a second connection member  486  that provides a path within the base  472  from the second base plate  480  to a second connector  488  (e.g., pin or post type connector), which serves as a second terminal. The second connector  488  is electrically connected to the second base plate  480  via the second connection member  486 . The second connector  488  is at least partially exposed and thus accessible on the back side of the base  472 . The second connection member  486  can be integrally formed with the second base plate  480 . Alternatively, the second connection member  486  can be separately formed and subsequently connected to the second base plate  480 . The second connection member  486  thus permits the second terminal  488  to be positioned (and oriented) in any position along the back side of the base  472 . 
     The connectors  484  and  488  serve as internal connection points for the power adapter plug  470 . Hence, the connectors  484  and  488  can also be referred to as internal terminals. The utilization of the base plates  478  and  480  together with the respective connection members  482  and  486  facilitates the placement of the terminals  484  and  488  anywhere along the back side of the base  472 . Consequently, the interconnection of the power adapter  470  with respect to other electrical circuitry or components is greatly facilitated. 
     The blades (or probes) and base plates utilized in accordance with the invention can take may different sizes and configurations. The blades can also attach to the base plates in various different ways. 
       FIG. 5A  illustrates an exemplary blade  500  according to one embodiment of the invention. The blade  500  has a front end  502  and a back end  504 . The front end  502  can be a rounded or tapered. The back end  504  can include attachment features, which in this embodiment includes notches  508 . The attachment features are used to attach the blade  500  to a base plate. The blade  500  can also have an opening  510  proximate to the front end  502 . 
       FIG. 5B  illustrates an exemplary base plate  520  according to one embodiment of the invention. The base plate  520  is typically a thin metal sheet of metal, such as stainless steel. For example, the thickness of the base plate  520  can be about 0.1-0.5 millimeters. The base plate  520  has an opening  522  for receiving a blade, such as the blade  500 . The base plate  520  also includes a terminal  524  which can have a small opening  526 . The terminal  524  can be formed by bending a portion of the base plate  520 . For example, the terminal can be formed by bending the portion of the base plate  520  normal to the surface of the base plate  520 . The opening  526  facilitates electrical connection to the terminal  524 . 
       FIG. 5C  illustrates an assembly of the blade  500  illustrated in  FIG. 5A  and the base plate  520  illustrated in  FIG. 5B . The base plate  520  can be affixed to the blade  500  using the attachment features. Namely, the edge of the opening  522  of the base plate  520  can be received in the notches  508  of the blade  500 , thereby securing the blade  500  to the base plate  520 . In some cases, the attachment features can be mechanically altered (e.g., press-fit) to secure the attachment of the blade  500  to the base plate  520 . 
     The blades (or prongs) used with the power adapter plug are metal. For example, the blades can be stainless steel or cooper. The formation of the blades can done using an extruding or stamping techniques. Stamping tends to leave shear marks which can be undesirable. Hence, it may be preferred to extrude the blades since the surface quality of the edges of the blades can clean, smooth and without shear marks. In one embodiment, the blades can be formed by extruding a metal bar having a width as desired for the height of the blades. Then, individual blades can be separated (or singulated) from the metal bar using a stamping process. Since the stamping of the metal bar does not stamp the sides of the blades (since the width is accurately set by the extruded bar), the surface quality of the sides of the blades is excellent. The exposed end (i.e., exposed tip) of the blades can usually thereafter be smoothed or rounded by a polishing or grinding step so that insertion into an AC outlet facilitated. 
       FIG. 5D  illustrates an exemplary metal bar  560  according to one embodiment of the invention. The metal bar  560  is an extruded metal bar of metal, such as sheet metal, from which a plurality of blades  562  for plugs (e.g., for power adapters) can be formed. The metal bar  560  has a width W that represents the width of the blades. Individual ones of the blades  562  having a length L can be stamped or cut from the metal bar  560 . Since the metal bar  560  is extruded at the width W, the surface quality along the length L of the sides of the blades  562  is excellent. For example, there are no shear marks along the length of the blades. 
       FIG. 6  is a flow diagram of a power adapter assembly process  600  according to one embodiment of the invention. The power adapter assembly process  600  pertains to assembly or construction of a power adapter plug that is part of a power adapter. The power adapter assembly process  600  obtains  602  first and second metal prongs. In addition, first and second metal bases can be obtained  604 . Next, the first metal base can be mechanically and electrically connected  606  to the first metal prong. Similarly, the second metal base can be mechanically and electrically connected  608  to the second metal prong. Thereafter, a non-conductive base can be formed  610  around the first and second metal bases. Following the block  610 , the power adapter assembly process  600  can end. 
     In one implementation, the non-conductive base is formed  610  using an injection molding process. The utilization of the metal bases to mechanically support and electrically connect with the metal prongs allows the thickness of the non-conductive base to be relatively thin. In other words, the non-conductive base can be formed with a minimized thickness which facilitates smaller and more compact power adapter designs. 
       FIG. 7  is flow diagram of a power adapter assembly process  700  according to one embodiment of the invention. The power adapter assembly process  700  pertains to assembly or construction of a power adapter plug that is part of a power adapter. The power adapter assembly process  700  can obtain  702  first and second metal prongs. In addition, first and second metal bases can be obtained  704 . Then, depending upon implementation, the internal terminals that are to be provided on the resulting power adapter plug can be a formed from either a portion of the metal bases or from connection members with or without use of additional parts (such as pin or post connectors). In one implementation, terminals can be formed  706  on the first and second metal bases. As an example, a portion of the first and second metal bases can be designed to be bent on assembly. Then, during assembly, the bendable portion of the metal bases can be bent into position so as to form a respective terminal. In another implementation, one or more internal connection members can be connected  708  to the first and/or second metal bases. The internal connection members can facilitate repositioning of the resulting terminals with respect to the non-conductive base of the power adapter plug. For example, one end of a connection member can be mechanically and electrically connected to the metal base and then the other end of the internal connection member can be provided with a pin or post connector that is to serve as the terminal. 
     In any case, following the block  706  or the block  708 , the power adapter assembly process  700  can mechanically and electrically connect  710  the first metal base to the first metal prong. Similarly, the second metal base can be mechanically and electrically connected  712  to the second metal prong. Thereafter, a non-conductive base can be formed at  714  around the first and second metal bases. The non-conductive base that is formed  714  has the terminals at least partially exposed on the surface of the non-conductive base. 
     Additionally, after constructing the power adapter plug in accordance with the power adapter assembly process  600  illustrated in  FIG. 6  or the power adapter assembly process  700  illustrated in  FIG. 7 , further assembly can be performed. In one embodiment, the power adapter plug can then be coupled to a printed substrate (e.g., PCB, flex-circuit) containing electrical components for adapting AC power to suitable DC power. Thereafter, if the power adapter is a stand-alone product, a housing can be placed around the assembly of the power adapter plug and the printed substrate. 
     The various aspects, embodiments, implementations or features of the invention can be used separately or in any combination. 
     The advantages of the invention are numerous. Different embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage of certain embodiments of the invention is that power adapters, or power adapter plugs, can be formed with low profiles which facilitates smaller and thinner power adapters. Another advantage of certain embodiments of the invention is that in forming a power adapter plug base plates can provide structural support for blades. Still another advantage of certain embodiments of the invention is that blades for power adapters, or power adapter plugs, can be fabricated without undesired shear marks along the length of the blades. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20080606
Publication Date: 20110920
Grant Date: 20110920
Priority Date: 20080606
Inventors: LIM WAY CHET
FRAZIER CAMERON
WALSH KEVIN
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2103/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2103/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R27/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/68", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R27/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/68", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41051889