PATENT DOCUMENT

Publication Number: US-8651879-B2
Application Number: US-201213732288-A
Country: US
Kind Code: B2

Title: Compact power adapter

Abstract:
A compact power adapter is disclosed. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, 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. The internal terminals used by a power adapter plug of a power adapter can be coupled to a printed circuit board assembly using connectors, thereby facilitating interconnection with electrical components used by the power adapter.

Claims:
What is claimed is: 
     
       1. A power adapter comprising:
 a base having first and second surfaces; 
 a bounding piece that is mechanically connected to the base, the bounding piece and the base together defining a receiving volume; 
 a first metal prong having a first end and a second end, wherein the first metal prong extends from the base and the first surface of the base is between the first and second ends of the first metal prong; 
 a second metal prong having a first end and a second end, wherein the second metal prong extends from the base and the first surface of the base is positioned between the first and second ends of the second metal prong; 
 a first metal base having first and second surfaces and a terminal extending from the second surface in a substantially straight direction, the first metal base mechanically and electrically connected to the second end of the first metal prong via an opening in the first and second surfaces of the first metal base, wherein the second surface of the first metal base is parallel to and faces away from the second surface of the base; 
 a second metal base having first and second surfaces and a terminal extending from the second surface in a substantially straight direction, the second metal base mechanically and electrically connected to the second end of the second metal prong via an opening in the first and second surfaces of the second metal base, wherein the second surface of the second metal base is parallel to and faces away from the second surface of the base; and 
 a circuit board disposed within the receiving volume and electrically connecting to the terminal of the first metal base and the terminal of the second metal base. 
 
     
     
       2. The power adapter of  claim 1 , wherein the base comprises a non-conductive material. 
     
     
       3. The power adapter of  claim 1 , wherein the base is injection molded plastic. 
     
     
       4. The power adapter of  claim 1 , wherein the first surface of the base is positioned between the first metal base and the first end of the first metal prong. 
     
     
       5. The power adapter of  claim 1 , further comprising a longitudinal axis extending between the first and second ends of the first metal prong, wherein the terminal of the first metal base extends parallel to the longitudinal axis of the first metal prong and is laterally displaced from the longitudinal axis of the first metal prong. 
     
     
       6. The power adapter of  claim 1 , wherein the position of the circuit board within the receiving volume is fixed by the base. 
     
     
       7. The power adapter of  claim 1  further comprising a USB connector receptacle electrically connected to the circuit board. 
     
     
       8. The power adapter of  claim 1 , wherein the circuit board further comprises an opening that receives the terminal of the first metal base. 
     
     
       9. The power adapter of  claim 1 , wherein the circuit board is parallel to the longitudinal axis of the first and second metal prongs. 
     
     
       10. The power adapter of  claim 1 , wherein the circuit board is perpendicular to the longitudinal axis of the first and second metal prongs. 
     
     
       11. A power adapter comprising:
 a base having first and second surfaces; 
 a bounding piece that is mechanically connected to the base, the base and the bouding piece defining a receiving volume when mechanically connected; 
 a first metal prong having a first end and a second end, wherein the first metal prong extends from the base and the first surface of the base is between the first and second ends of the first metal prong; 
 a second metal prong having a first end and a second end, wherein the second metal prong extends from the base and the first surface of the base is between the first and second ends of the second metal prong; 
 a first metal base having first and second surfaces and a terminal extending from the second surface, the first metal base having an opening in the first and second surfaces of the first metal base that retains the second end of the first metal prong, wherein the second surface of the first metal base faces away from the second surface of the base; 
 a second metal base having first and second surfaces and a terminal extending from the second surface, the second metal base having an opening in the first and second surfaces of the second metal base that retains the second end of the second metal prong, wherein the second surface of the second metal base faces away from the second surface of the base; 
 a circuit board disposed within the receiving volume and electrically connecting to the terminal of the first metal base and the terminal of the second metal base; and 
 a USB connector receptacle electrically connected to the circuit board. 
 
     
     
       12. The power adapter of  claim 11 , wherein the base comprises a non-conductive material. 
     
     
       13. The power adapter of  claim 11 , wherein the first surface of the base is positioned between the first metal base and the first end of the first metal prong. 
     
     
       14. The power adapter of  claim 11 , wherein the base is injection molded plastic. 
     
     
       15. The power adapter of  claim 11 , further comprising a longitudinal axis extending between the first and second ends of the first metal prong, wherein the terminal of the first metal base extends parallel to the longitudinal axis of the first metal prong and is laterally displaced from the longitudinal axis of the first metal prong. 
     
     
       16. The power adapter of  claim 11 , wherein the position of the circuit board within the receiving volume is fixed by the base. 
     
     
       17. The power adapter of  claim 11 , wherein the circuit board is parallel to the longitudinal axis of the first and second metal prongs. 
     
     
       18. The power adapter of  claim 11 , wherein the circuit board is perpendicular to the longitudinal axis of the first and second metal prongs.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/018,208, filed Jan. 31, 2011, now U.S. Pat. No. 8,342,861 entitled “COMPACT POWER ADAPTER” which is a continuation application of U.S. patent application Ser. No. 12/480,602, filed Jun. 8, 2009, entitled “LOW-PROFILE POWER ADAPTER”, now U.S. Pat. No. 7,897,702, which is hereby incorporated herein by reference, and which is a continuation-in-part application of U.S. patent application Ser. No. 12/135,044, filed Jun. 6, 2008, entitled “LOW-PROFILE POWER ADAPTER”, now U.S. Pat. No. 8,021,198, which is hereby incorporated herein by reference. 
    
    
     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. 
     BRIEF SUMMARY OF THE INVENTION 
     The invention relates to compact power adapters. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, 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. The internal terminals used by a power adapter plug of a power adapter can be coupled to a printed circuit board assembly using connectors, 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 portable power adapter for a portable electronic device, one embodiment of the invention can, for example, include at least: a cap; at least one metal member extending through the cap; a housing having a body with an opening configured to receive the cap; a printed circuit board assembly having a plurality of electrical components coupled thereto can be provided in the housing; and at least one connector mounted on the printed circuit board assembly. The at least one connector can be configured to electrically connect the at least one metal member to the printed circuit board when the cap is attached to the housing. 
     As an electronic device, one embodiment of the invention can, for example, include at least: a housing having a plurality of external blades and at least one opening; an electrical connector accessible from the opening in the housing; and a printed circuit board assembly having a plurality of electrical components coupled thereto. The printed circuit board assembly can be provided within the housing and can be electrically connected to the electrical connector. The printed circuit board assembly can include a plurality of connector receptacles arranged to receive conductive members internal to the housing that electrically correspond to the external blades. The conductive members can be positionally offset from the external blades. 
     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 metal prong, the first metal base including or coupling to at least a first connection member; 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 metal prong, the second metal base including or coupling to at least a second connection member; a molded cap 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 connection members which are at least partially exposed, the molded base being non-conductive; a housing having a body with an opening configured to receive the molded cap; and a printed circuit board assembly having a plurality of electrical components coupled thereto, the printed circuit board assembly being provided within the housing. When the molded cap is attached to the housing, the first metal prong is electrically connected to the printed circuit board assembly via first connection member, and the second metal prong is electrically connected to the printed circuit board assembly via second connection member. 
     As a power adapter, another embodiment of the invention can, for example, include at least: a first metal member including a first metal prong and a first connection member; a second metal member including a second metal prong and a second connection member; a molded cap formed around the first and second metal members such that the first and second metal prongs are at least partially exposed and the first and second connection members are at least partially exposed, the molded base being non-conductive; a housing having a body with an opening configured to receive the molded cap; a printed circuit board assembly having a plurality of electrical components coupled thereto, the printed circuit board assembly being provided within the housing; a first connector mounted on the printed circuit board assembly, the first connector being configured to receive the first connection member when the molded cap is attached to the housing, thereby electrically connecting the first connection member, and thus the first metal prong, to the printed circuit board assembly; and a second connector mounted on the printed circuit board assembly, the second connector being configured to receive the second connection member when the molded cap is attached to the housing, thereby electrically connecting the second connection member, and thus the second metal prong, to the printed circuit board assembly. 
     As a method for assembling a power adapter, one embodiment of the invention can, for example, include at least: obtaining a printed circuit board assembly having first and second electrical connectors and a plurality of electrical components mounted thereon; obtaining a housing for the power adapter, the housing including at least one opening for receiving the printed circuit board assembly; inserting the printed circuit board assembly into the housing via the at least one opening in the housing, wherein once the printed circuit board assembly is inserted into the housing, the first and second electrical connectors remain accessible via the opening in the housing; securing the printed circuit board assembly within the housing; and attaching a cap having first and second exposed inner contact members to the opening in the housing, wherein once the cap is attached to the opening in the housing, the first and second exposed inner contact member respectively electrically connect with the first and second electrical connectors. 
     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. 
         FIG. 8  is flow diagram of a power adapter assembly process according to one embodiment of the invention. 
         FIG. 9A  is a side view of an electronic device assembly according to one embodiment of the invention. 
         FIG. 9B  is a side view of an electronic device assembly according to one embodiment of the invention. 
         FIG. 10  is a side view of an assembly illustration for a power adapter according to one embodiment of the invention. 
         FIG. 11A  is a perspective view of a housing for a power adapter according to one embodiment of the invention. 
         FIG. 11B  is a perspective view of a printed circuit board assembly according to one embodiment of the invention. 
         FIG. 11C  is a perspective view of an end piece according to one embodiment of the invention. 
         FIG. 11D  is a perspective view of an assembled power adapter according to one embodiment of the invention. 
         FIG. 11E  is a perspective view of an assembled power adapter with a protective cover provided according to one embodiment of the invention. 
         FIG. 12  is a side view of an electronic device assembly according to one embodiment of the invention. 
         FIG. 13A  illustrates a side perspective view of the electronic device according to one embodiment of the invention. 
         FIG. 13B  illustrates a first end perspective view of the electronic device according to one embodiment of the invention. 
         FIG. 13C  illustrates a second end perspective view of the electronic device according to one embodiment of the invention. 
         FIG. 13D  is a perspective view of a printed circuit board assembly according to one embodiment of the invention. 
         FIG. 13E  a top perspective view of the cap according to one embodiment of the invention. 
         FIG. 13F  a bottom perspective view of the cap according to one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention relates to compact power adapters. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, 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. The internal terminals used by a power adapter plug of a power adapter can be coupled to a printed circuit board assembly using connectors, 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  104  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  478 , (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 1-5 millimeters. The base plate  520  has an opening  522  for receiving a blade, such as the blade  500 . The base plate  520  also include 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. 
       FIG. 8  is flow diagram of a power adapter assembly process  800  according to one embodiment of the invention. The power adapter assembly process  800  pertains to assembly or construction of a power adapter product. 
     The power adapter assembly process  800  can obtain  802  a printed circuit board assembly. The printed circuit board assembly includes electrical connectors and electrical components mounted thereon. A housing having an opening is also obtained  804 . The housing serves as the external surface for the power adapter product. Next, the printed circuit board assembly can be inserted  806  into the housing via the opening. In one embodiment, the housing can provide a single opening through which articles to be included within the housing can be inserted. Namely, the printed circuit board assembly can be inserted  806  into the housing through the opening. Additionally, the printed circuit board assembly can then be secured  808  within the housing. The printed circuit board assembly can be secured within the housing in a variety of different ways. For example, the printed circuit board assembly can be secured  808  by an adhesive, such as glue. Alternatively, as another example, the printed circuit board assembly can be secured  808  within the housing through use of heat stakes, snaps or various other mechanical members. Thereafter, an end piece can be attached  810  to the opening in the housing. Here, the end piece can serve to close the opening in the housing, thereby essentially sealing the opening in the housing. In doing so, exposed inner contact members of the end piece can respectively electrically connect with electrical connectors on the printed circuit board assembly. Hence, when the end piece is attached  810  to the opening, the inner contact members of the end piece can electrically coupled to the electrical connectors on the printed circuit board assembly. Consequently, electrical connection between the blades of the end piece can be made to the printed circuit board assembly by way of the inner contact members. 
     In general, the number, position, size and shape of blades (prongs) of a power adapter can vary depending on country or standard. In embodiments discussed herein the power adapters utilize two or three blades (prongs). If a third blade is provide, the third blade is typically provided as a ground or earthing member. 
       FIG. 9A  is a side view of an electronic device assembly  900  according to one embodiment of the invention. The electronic device assembly  900  is, for example, 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  900  includes a power adapter end piece  902 . The power adapter end piece  902  can, for example, be constructed similar to the power adapter plug  100  illustrated in  FIGS. 1A-1C . The power adapter end piece  902  includes a first blade  904 , a second blade  906 , and a base  908 . The base  908  supports the first blade  904  and the second blade  906 . The base  908  also supports connection members  910  (or inner contact members). The electronic device assembly  900  also includes a printed circuit board  912 . The power adapter end piece  902  can be mechanically and electrically connected to the printed circuit board  912 . The printed circuit board  912  includes a plurality of electrical components  914  attached onto at least one side of the printed circuit board  912  to provide various electrical operations. The connection members  910  of the base  908  of the power adapter end piece  902  can be utilized to couple to corresponding connection devices  916  of the printed circuit board  912 . Accordingly, in one embodiment, the connection members  910  of the power adapter end piece  902  can be mechanically and electrically connected to corresponding ones of the connection devices  916  of the printed circuit board  912 . In one embodiment, the connection devices  916  are connectors that receive the connection members  910 , thereby electrically connecting the first and second blades  904  and  906  of the power adapter end piece  902  with the printed circuit board  912 . 
     In one embodiment, the power adapter end piece  902  is a low-profile power adapter cap which is able to couple directly to the printed circuit board  912  with little or no intervening by other components. As a result, the overall thickness of an electronic device (e.g., power adapter) being formed by the electronic device assembly  900  can be smaller and thinner. As shown in  FIG. 9A , the base  908  of the power adapter end piece  902  is positioned adjacent the electrical components  914  mounted on the printed circuit board  912 . However, in another embodiment, the base  908  of the power adapter end piece  900  can be positioned immediately adjacent the printed circuit board  912  (without any intervening electrical components  914 ). 
     As shown in  FIG. 9A , the electronic device assembly  900  can be enclosed within an external device housing  918 , thereby forming a power adapter product. The external device housing  918  is, for example, a compact enclosure that has an assembly opening at one side. The printed circuit board  912  can be placed within the external device housing  918  via the assembly opening. The printed circuit board  912  can, for example, be secured in the external device housing  918  by way of adhesive or mechanical members. The power adapter end piece  902  can then be placed in or over the assembly opening in the external device housing  918 . In doing so, the connection members  910  of the base  908  are respectively aligned with and connect to the connection devices  916  of the printed circuit board  912 . For example, the connection members  910  can be connector pins or posts, and the connection devices  916  can be connectors configured to receive the connector pins or posts when the power adapter end piece  902  is placed in or over the assembly opening in the external device housing  918 . The power adapter end piece  902  can, for example, be secured in the external device housing  918  by way of adhesive, mechanical members and/or processing (e.g., ultrasonic welding). 
     In operation, the electronic device assembly  900 , namely, power adapter product, 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  900  directly (e.g., integral with electronic device) or indirectly (e.g., by connector and/or wire (cord)). For example, the blades  904  and  906  of the electronic device assembly  900  can be inserted into an AC electrical outlet from which high-voltage Alternating Current (AC) can be acquired. The electrical components  914  associated with the printed circuit board  912  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 electronic device assembly  900  illustrated in  FIG. 9A  includes a printed circuit board  912 , in other embodiments, the printed circuit board  912  can be replaced with a different substrate. For example, the substrate can alternatively be a flexible substrate (e.g., flex-circuit). 
       FIG. 9B  is a side view of an electronic device assembly  900 ′ according to one embodiment of the invention. The electronic device assembly  900 ′ is similar to the electronic device assembly  900  illustrated in  FIG. 9A , except that the electronic device housing further includes a protective cover  920 . The protective cover  920  serves to mitigate any damage to the base  908  due to electrical arcing or chemical leaching from the blades  904  and  906 . In one implementation, the protective cover  920  is a label that is adhered to the base  908  by an adhesive. For example, the protective cover  920  can be a paper or plastic label with an adhesive backing. In one embodiment, the protective cover  920  covers the entire exposed surface of the base  908  and has openings for receiving the blades  904  and  906 . 
       FIG. 10  is a side view of an assembly illustration for a power adapter  1000  according to one embodiment of the invention. As will be discussed below, the power adapter  1000  is assembled from an end piece, a printed circuit board assembly and a housing. The power adapter  1000  can be assembled in accordance with the power adapter assembly process  800  illustrated in  FIG. 8 . 
     An end piece  1002  can be formed. The end piece  1002  has first and second blades (plugs)  1004  and  1005 , which can be inserted into an AC outlet. From the view in  FIG. 10 , the second blade  1005  is not visible as it is directly behind the first blade  1004 . 
     The end piece  1002  also has an additional blade  1006 . A base  1008  supports the first and second blades  1004 ,  1005  and the additional blade  1006  on an output surface of the base  1008 . The inner surface of the base  1008  includes a first connection member  1010  and a second connection member  1012 . The first connection member  1010  is electrically connected to the first blade  1004 , and the second connection member  1012  is electrically connected to the second blade  1005 . As discussed above, the first and second connection members  1010  and  1012  are able to be moved or offset from the position of the first and second blades  1004  and  1005 . 
     A printed circuit board assembly  1014  is also formed. The printed circuit board assembly  1014  includes a printed circuit board  1016  having a plurality of electrical components  1018  attached onto at least one side of the printed circuit board  1016  to provide various electrical operations. Also attached to the printed circuit board  1016  are a first connector  1020  and a second connector  1022 . The first connector  1020  includes an opening  1024  (e.g., slot), and the second connector  1022  includes an opening  1026 . 
     After the printed circuit board assembly  1014  has been formed, the printed circuit board assembly  1014  can be inserted into a housing  1028 . The housing  1028  includes an outer surface  1030 , which acts as an outer surface for much of the power adapter  1100 . The printed circuit board assembly  1014  can be secured to an inner surface  1032  of the housing  1028 . Thereafter, the end piece  1002  can be placed into the opening  1034  of the housing  1028 . The end piece  1002  can also be secured to the opening  1034  and/or the housing  1028 . When the end piece  1002  is placed within the opening  1034  of the housing  1028 , the opening  1024  in the first connector  1020  receives the first connection member  1010 , thereby providing an electrical connection between the first blade  1004  and the printed circuit board assembly  1014 , and the opening  1026  in the second connector  1022  receives the second connection member,  1012  thereby providing an electrical connection between the second blade  1005  and the printed circuit board assembly  1014 . The additional blade  1006  can be a guide or orientation member or may provide a ground (or earthed) connection. Hence, the additional blade  1006  may not need to connect with the printed circuit board assembly  1014 . 
     In operation, the power adapter  1100  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  1100  directly (e.g., integral with electronic device) or indirectly (e.g., by connector and/or wire (cord)). For example, the blades  1004  and  1005  as well as the additional blade  1006  of the power adapter  1100  can be inserted into an AC electrical outlet from which high-voltage alternating current can be acquired. The electrical components  1018  associated with the printed circuit board  1016  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. 
     Electrical plugs and their sockets differ by country in shape, size and type of connectors. The type used in each country is set by national standards legislation. The power adapters described herein are not limited to any particular type or configuration. Hence, as an example, the number, size and configuration of blades depicted and described in the various embodiments can vary. 
       FIGS. 11A-11E  are diagrams illustrating a power adapter according to one embodiment of the invention. The power adapter illustrated in  FIGS. 11A-11E  use a particular plug used in Europe, for example. 
       FIG. 11A  is a perspective view of a housing  1100  for a power adapter according to one embodiment of the invention. The housing  1100  includes an opening  1102  for receiving electrical components as well as an end piece. In one embodiment, the housing  1100  can also include a connector opening  1104  to allow access to a peripheral connector provided within the power adapter  1100 . For example, the peripheral connector can pertain to a Universal Serial Bus (USB) port. 
       FIG. 11B  is a perspective view of a printed circuit board assembly  1120  according to one embodiment of the invention. The printed circuit board assembly  1120  is assembled and then inserted into the housing  1100 . In the embodiment illustrated in  FIG. 11B , the printed circuit board assembly  1120  includes a printed circuit board  1122 . The printed circuit board  1122  can have electrical components mounted thereto. Examples of electrical components are capacitors, resistors, inductors, transistors, and integrated circuit chips. For example, the printed circuit board  1122  has resistors  1123 , capacitors  1124 , transistors, inductors  1126 , and/or integrated circuit packages  1127  mounted thereto. Besides electrical components, the printed circuit board  1122  typically also includes metal (e.g., cooper, aluminum, solder) traces, solder connections, metal wires and/or metal leads. Still further, the printed circuit board assembly  1120  further includes a first connector  1128  and a second connector  1130 . These connectors  1128  and  1130  are mounted on and electrically connect to the printed circuit board  1122 . The printed circuit board  1122  can also have an electrical connector  1125 , e.g., a peripheral bus connector, connected thereto. For example, the electrical connector  1125  can be a Universal Serial Bus (USB) connector. The electrical connector  1125  can be attached to the printed circuit board  1122 . A bracket  1121  can be used to attach or support the electrical connector  1125  with respect to the printed circuit board  1122 . 
       FIG. 11C  is a perspective view of an end piece  1140  according to one embodiment of the invention. The end piece  1140  is formed and then inserted into the opening  1102  in the housing  1100  to close the opening and thereby encase the printed circuit board assembly  1120 . Once the end piece  1140  is attached to the opening  1102  in the housing  1100 , the opening  1102  is sealed (e.g., water-tight seal) The end piece  1140  includes a base portion  1142 , a first blade  1144 , a second blade  1146  and an additional blade  1148 . In one embodiment, the additional blade member  1148  is electrically inactive. Although not shown, the back side of the base  1142  includes a first connection member that is electrically connected to the first blade  1144 , and a second connection member that is electrically connected to the second blade  1146 . The first connection member can electrically couple to one of the first blade  1144  and the second blade  1146 , and the second connection member can electrically couple to the other of the first blade  1144  and the second blade  1146 . 
       FIG. 11D  is a perspective view of an assembled power adapter  1160  according to one embodiment of the invention. The housing  1100  can have an opening  1104  for access to a peripheral connector. As shown in  FIG. 11D , the end piece  1140  (see  FIG. 11C ) has been inserted into the opening  1102  of the housing  1100 . The printed circuit board assembly  1120  is contained within the housing  1100 , and the blades of  1144  and  1146  are electrically connected to the printed circuit board assembly  1120  as discussed above. The outer surface of the end piece  1142  serves as an inner surface for the housing  1100 . The additional blade  1148  of the end piece  1140  is also provided. It should be noted that the end piece  1140  can be secured to the housing  1100  by a variety of different techniques. For example, the end piece  1140  can be glued to the housing  1100 . As another example, the end piece  1140  can be ultrasonically welded to the housing  1100 . In one embodiment, the end piece  1140  is secured to the housing  1100  such that a water-tight seal is provided. 
       FIG. 11E  is a perspective view of an assembled power adapter  1180  with a protective cover provided according to one embodiment of the invention. The assembled power adapter  1180  includes the assembled power adapter  1160  illustrated in  FIG. 11D  with the addition of a protective cover  1182 . The protective cover  1182  is provided on the exposed surface of the base  1142 . The protective cover  1182  illustrated in  FIG. 11E  includes openings  1184  to correspond to the blades  1144  and  1146  as well as the additional blade  1148  of the end piece  1140 . The protective cover  1182  can be adhered to the base  1142  through use of an adhesive. The protective cover  1182  can serve to mitigate any damage to the base  1142  due to electrical arcing or chemical leaching from the blades  1144  and  1146 . 
       FIG. 12  is a side view of an electronic device assembly  1200  according to one embodiment of the invention. The electronic device assembly  1200  is, for example, 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  1200  includes a power adapter end piece  1202 . The power adapter end piece  1202  can, for example, be constructed similar to the power adapter plug  100  illustrated in  FIGS. 1A-1C . The power adapter end piece  1202  includes a first blade  1204 , a second blade  1206 , and a base  1208 . The base  1208  supports the first blade  1204  and the second blade  1206 . The base  1208  also supports connection members  1210  (or inner contact members). The electronic device assembly  1200  also includes a printed circuit board  1212 . The power adapter end piece  1202  can be electrically connected (and possibly also mechanically connected) to the printed circuit board  1212 . The printed circuit board  1212  includes a plurality of electrical components  1214  attached onto at least one side of the printed circuit board  1212  to provide various electrical operations. The connection members  1210  of the base  1208  of the power adapter end piece  1202  can be utilized to couple to corresponding connection devices  1216  mounted on the printed circuit board  1212 . Accordingly, in one embodiment, the connection members  1210  of the power adapter end piece  1202  can be connected to corresponding ones of the connection devices  1216  of the printed circuit board  1212 . In one embodiment, the connection devices  1216  are connectors that receive the connection members  1210 , thereby electrically connecting the first and second blades  1204  and  1206  of the power adapter end piece  1202  with the printed circuit board  1212 . 
     In one embodiment, the power adapter end piece  1202  is a low-profile power adapter cap which is able to couple adjacent an end of the printed circuit board  1212  with little or no intervening by other components. As a result, the overall length and thickness of an electronic device (e.g., power adapter) being formed by the electronic device assembly  1200  can be smaller and thinner. As shown in  FIG. 12 , the base  1208  of the power adapter end piece  1202  is positioned adjacent the edge of the printed circuit board  1212 . 
     As shown in  FIG. 12 , the electronic device assembly  1200  can be enclosed within an external device housing  1218 , thereby forming a power adapter product. The external device housing  1218  is, for example, a compact enclosure that has an assembly opening at one side. The printed circuit board  1212  can be placed within the external device housing  1218  via the assembly opening. The printed circuit board  1212  can, for example, be secured in the external device housing  1218  by way of adhesive or mechanical members. The power adapter end piece  1202  can then be placed in or over the assembly opening in the external device housing  1218 . In doing so, the connection members  1210  of the base  1208  are respectively aligned with and connected to the corresponding connection devices  1216  of the printed circuit board  1212 . For example, the connection members  1210  can be connector pins or posts, and the connection devices  1216  can be connectors configured to receive the connector pins or posts when the power adapter end piece  1202  is placed in or over the assembly opening in the external device housing  1218 . The power adapter end piece  1202  can, for example, be secured in the external device housing  1218  by way of adhesive, mechanical members and/or processing (e.g., ultrasonic welding). 
     In operation, the electronic device assembly  1200 , namely, power adapter product, 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  1200  directly (e.g., integral with electronic device) or indirectly (e.g., by connector and/or wire (cord)). For example, the blades  1204  and  1206  of the electronic device assembly  1200  can be inserted into an AC electrical outlet from which high-voltage Alternating Current (AC) can be acquired. The electrical components  1214  associated with the printed circuit board  1212  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 electronic device assembly  1200  illustrated in  FIG. 12  includes a printed circuit board  1212 , in other embodiments, the printed circuit board  1212  can be replaced with a different substrate. For example, the substrate can alternatively be a flexible substrate (e.g., flex-circuit). 
       FIGS. 13A-13C  are perspective views of an electronic device  1300  according to one embodiment of the invention. The electronic device  1300  in this embodiment is a portable power adapter. The portable power adapter can be plugged into an electrical outlet. The portable power adapter can receive AC power from the electrical outlet and convert it into DC power. The DC power can then be made available to another electronic device that can couple to the portable power adapter. 
       FIG. 13A  illustrates a side perspective view of the electronic device  1300  according to one embodiment of the invention. The electronic device  1300  includes a device housing  1302 . As an example, the electronic device assembly  1200  illustrated in  FIG. 12  can be implemented as the electronic device  1300 . A first end of the device housing  1302  is configured to receive a cap  1304  (end cap or end piece). With the cap  1304  removed, an assembled electronic device (e.g., printed circuit board assembly) can be inserted into the device housing  1302 . In  FIG. 13A  the cap  1304  is illustrated as being attached to the device housing  1302 . The cap  1304  includes or supports a first plug  1306  and a second plug  1308 . As illustrated, the plugs  1306  and  1308  are of a European configuration, however various other configurations are equally possible, including the U.S. configuration. The plugs  1306  and  1308  can be inserted into a power outlet (e.g., AC outlet). The plugs  1306  and  1308  can respectively include metal tips  1310  and  1312  which facilitate electrical connection when inserted into the power outlet. A second end  1314  includes an electrical connector  1316  that facilitates electrical connection with another device. When the electronic device  1300  is a portable power adapter, the electrical connector  1316  serves to provide power from the portable power adapter to another device that is electrically connected to the electrical connector  1316 . As one example, the electrical connector  1316  can pertain to a USB connector. 
       FIG. 13B  illustrates a first end perspective view of the electronic device  1300  according to one embodiment of the invention. The cap  1304  is illustrated attached to the device housing  1302 . The plugs  1306  and  1308  of the cap  1304  are illustrated projecting outward from the cap  1304 . The plugs  1306  and  1308  can have an exterior non-conductive shell (e.g., plastic) with an inner metal conductor that electrically connects the metal tips  1310  and  1312  to electronic component (e.g., printed circuit board assembly) within the device housing  1302 . 
       FIG. 13C  illustrates a second end perspective view of the electronic device  1300  according to one embodiment of the invention. The electrical connector  1316  is accessible from an opening  1318  in the second end  1314 . 
       FIG. 13D  is a perspective view of a printed circuit board assembly  1340  according to one embodiment of the invention. The printed circuit board assembly  1340  is assembled and then inserted into the device housing  1302 . In the embodiment illustrated in  FIG. 13D , the printed circuit board assembly  1340  includes a printed circuit board  1342 . The printed circuit board  1342  can have electrical components mounted thereto. Examples of electrical components are capacitors, resistors, inductors, transistors, and integrated circuit chips. For example, the printed circuit board  1342  has resistors  1344 , capacitors  1346 , transistors  1348 , inductors  1350 , and/or integrated circuit packages mounted thereto. Besides electrical components, the printed circuit board  1342  typically also includes metal (e.g., cooper, aluminum, solder) traces, solder connections, metal wires and/or metal leads. Still further, the printed circuit board assembly  1340  further includes a first connector  1352  and a second connector  1354 . These connectors  1352  and  1354  are mounted on and electrically connect to the printed circuit board  1342 . The printed circuit board  1342  can also have an electrical connector  1356 , e.g., a peripheral bus connector, connected thereto at a side opposite the side having the connectors  1352  and  1354 . For example, the electrical connector  1356  can be a Universal Serial Bus (USB) connector. The electrical connector  1356  can be attached to the printed circuit board  1342 . A bracket  1358  can be used to attached or support the electrical connector  1356  with respect to the printed circuit board  1342 . Additionally, in the embodiment shown in  FIG. 13D , the printed circuit board assembly  1340  can also include a daughter printed circuit board  1360 . For additional details on use of a daughter board or a multiple board and/or connectors see U.S. Provisional Patent Application No. 61/140,599, filed Dec. 23, 2008, entitled “COMPACT DEVICE HOUSING AND ASSEMBLY TECHNIQUES THEREFOR”, which is hereby incorporated herein by reference. 
       FIG. 13E  is a top perspective view of the cap  1304  according to one embodiment of the invention, and  FIG. 13F  is a bottom perspective view of the cap  1304  according to one embodiment of the invention. The cap  1304  includes or supports the first plug  1306  and the second plug  1308 . The plugs  1306  and  1308  can respectively include metal tips  1310  and  1312  which facilitate electrical connection when inserted into the power outlet. The cap  1304  also includes a top surface  1366  and a base portion  1368 . The base portion  1368  is recessed in from the top surface  1366 . When the cap  1304  is into an assembly opening of the device housing  1302 , the base portion  1368  is provided inside the device housing  1302  and the top surface  1366  form the outer surface for the electronic device  1300  at the now closed assembly opening. Further, the inside surface of the base portion  1368  has inner connection members  1362  and  1364 , such as a pins or posts. The inner connection member  1362  is coupled to or an extension of the plug  1306  (metal portion) and its associated metal tip  1310 . The inner connection member  1364  is coupled to or an extension of the plug  1308  (metal portion) and its associated metal tip  1312 . The connection members  1362  and  1364  are provided to couple to an electrical component (e.g., printed circuit board assembly) provided internal to the device housing  1302 . Such connection occurs when the cap  1304  is attached to the assembly opening of the device housing  1302 . 
     Additional details on power adapters and compact housings can be fount in (1) U.S. patent application Ser. No. 12/135,044, filed Dec. 6, 2008, entitled “LOW-PROFILE POWER ADAPTER”, which is hereby incorporated herein by reference; and (2) U.S. Provisional Patent Application No. 61/140,599, filed Dec. 23, 2008, entitled “COMPACT DEVICE HOUSING AND ASSEMBLY TECHNIQUES THEREFOR”, which is hereby incorporated herein by reference. 
     The various aspects, embodiments, implementations or features of the invention can be used separately or in any combination. 
     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: 20121231
Publication Date: 20140218
Grant Date: 20140218
Priority Date: 20080606
Inventors: STIEHL KURT
FRAZIER CAMERON
AASE JONATHAN
SCHMIDT MATHIAS W.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R31/065", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R27/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6675", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2103/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/665", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/68", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/53209", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R31/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R27/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/68", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2103/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R31/065", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6675", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/53209", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 42470873