PATENT DOCUMENT

Publication Number: US-11515679-B2
Application Number: US-202017092022-A
Country: US
Kind Code: B2

Title: Power adapter for electronic devices

Abstract:
A power adapter for powering portable electronic devices is disclosed. The modifications and enhancements to the power adapter can reduce or eliminate the need for adhesives, flexible circuitry, and/or wiring. The power adapter includes multiple guide rails used to guide a circuit board (carrying components) to electrical springs. The electrical springs provide not only an electrical coupling, but also a mechanical coupling. As a result, wiring and/or adhesives is not required. Additionally, a cap is secured to the enclosure through melting part of the cap by, for example, ultrasonic welding without causing damage to the circuit board, as welding location(s) is/are in locations away from the electrical springs and other sensitive components. The power adapter further includes a connector connected to the circuit board. During assembly, the circuit board can pivot in three dimensions during assembly to align the connector with the cap.

Claims:
What is claimed is: 
     
       1. A power adapter for electronic devices, the power adapter comprising:
 an enclosure that defines an internal volume; 
 a circuit board located in the internal volume, the circuit board comprising a plurality of ribs; and 
 a cap comprising a plurality of fins, wherein each of plurality of ribs is attached to a respective fin of the plurality of fins. 
 
     
     
       2. The power adapter of  claim 1 , further comprising:
 a first electrical spring electrically coupled to a first electrical pad of the circuit board; and 
 a second electrical spring electrically coupled to a second electrical pad of the circuit board. 
 
     
     
       3. The power adapter of  claim 2 , wherein the enclosure comprises:
 a first guide rail; and 
 a second guide rail, and where the circuit board coupled to the first electrical spring and
 the second electrical spring based on the first guide rail and the second guide rail. 
 
 
     
     
       4. The power adapter of  claim 3 , wherein the enclosure comprises:
 a first wall, wherein the first guide rail is located on the first wall; and 
 a second wall, wherein the second guide rail is located on the second wall. 
 
     
     
       5. The power adapter of  claim 4 , further comprising an extension that extends from the first wall, the extension defining a pivot point in contact with the circuit board. 
     
     
       6. The power adapter of  claim 4 , wherein:
 the first wall defines a first end of the enclosure, 
 the enclosure includes an opening that defines a second end opposite the first end, and 
 the cap is positioned in the opening. 
 
     
     
       7. The power adapter of  claim 1 , further comprising a connector, wherein in the cap includes a cap opening, and the connector is positioned in the cap opening. 
     
     
       8. A power adapter for electronic devices, the power adapter comprising:
 an enclosure that defines an internal volume, the enclosure comprising a first wall and a second wall; 
 an electrical spring secured with the first wall; 
 a first guide rail extending from the first wall; 
 a second guide rail extending from the second wall; and 
 a circuit board positioned in the internal volume between the first guide rail and the second guide rail, the circuit board electrically coupled to the electrical spring. 
 
     
     
       9. The power adapter of  claim 8 , wherein the first wall is perpendicular with respect to the second wall. 
     
     
       10. The power adapter of  claim 9 , further comprising an extension that extends from the first wall, the extension defining a pivot point in contact with the circuit board. 
     
     
       11. The power adapter of  claim 8 , further comprising a prong extending from the first wall and electrically coupled with the electrical spring. 
     
     
       12. The power adapter of  claim 8 , further comprising a cap, wherein the circuit board comprises a rib, and the cap comprises a fin that is interlocked with the circuit board at the rib. 
     
     
       13. The power adapter of  claim 12 , further comprising a connector carried by the circuit board, wherein in the cap includes a cap opening, and the connector is positioned in the cap opening. 
     
     
       14. The power adapter of  claim 12 , wherein the rib comprises a thermoplastic melted to the circuit board. 
     
     
       15. A power adapter for electronic devices, the power adapter comprising:
 an enclosure that defines an internal volume, the enclosure comprising a first end defined by a wall and a second end defined by an opening, the second end opposite the first end; 
 electrical springs coupled with the wall; 
 a cap coupled with the opening, the cap comprising a cap opening; 
 a circuit board disposed in the internal volume and electrically coupled to the electrical springs; and 
 a connector carried by the circuit board, the connector positioned in the cap opening. 
 
     
     
       16. The power adapter of  claim 15 , wherein the cap comprises a flange, and the cap is secured with the enclosure by a weld that is covered by the flange. 
     
     
       17. The power adapter of  claim 15 , wherein the circuit board comprises a rib, and the cap comprises a fin interlocked with the rib. 
     
     
       18. The power adapter of  claim 15 , wherein the enclosure comprises:
 a first wall defined by the wall, wherein the electrical springs are secured with the first wall; 
 a second wall; 
 a first rail extending from the first wall; and 
 a second rail extending from the second wall, wherein the circuit board is positioned in the internal volume between the first rail and the second rail, the circuit board electrically coupled to the electrical springs. 
 
     
     
       19. The power adapter of  claim 18 , further comprising a first prong and second prong, the first prong and the second prong extending from the first wall, wherein the electrical springs comprise:
 a first electrical spring electrically coupled to the first prong; and 
 a second electrical spring electrically coupled to the second prong. 
 
     
     
       20. The power adapter of  claim 18 , wherein the first wall is perpendicular with respect to the second wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Application No. 63/043,773, entitled “POWER ADAPTER FOR ELECTRONIC DEVICES,” filed Jun. 24, 2020, the content of which is incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD 
     The following description relates to power adapters. In particular, the following description relates to enhancements to power adapters that enhance efficiency of assembly, safety, cost, and performance. 
     BACKGROUND 
     Adapters can be used to supply power to electronic devices. Typical adapters can be plugged into a wall to receive electrical energy. Some adapters include circuitry used to convert AC to DC, monitor current flow, and provide indicators (e.g., lights). In order to assemble the various pieces of the adapter together, common adapters require adhesives, wires, and/or fasteners. 
     However, the aforementioned assembly techniques for current adapters provide drawbacks. For instance, using any one of adhesives, wires, or fasteners can add cost to the adapter in terms of parts and/or labor. Furthermore, adhesives tend to fix parts together without the possibility of adjusting/moving the parts during assembly. 
     SUMMARY 
     In one aspect, a power adapter for electronic devices is described. The power adapter may include an enclosure that defines an internal volume. The power adapter may further include a circuit board located in the internal volume. The circuit board may include a rib. The power adapter may further include a cap that includes a fin that interlocks with the rib. 
     In another aspect, a power adapter for electronic devices is described. The power adapter may include an enclosure that defines an internal volume. The enclosure may include a first wall and a second wall. The power adapter may further include an electrical spring secured with the first wall. The power adapter may further include a first guide rail extending from the first wall. The power adapter may further include a second guide rail extending from the second wall. The power adapter may further include a circuit board positioned in the internal volume between the first guide rail and the second guide rail. The circuit board may be electrically coupled to the electrical spring. 
     In another aspect, a power adapter for electronic devices is described. The power adapter may include an enclosure that defines an internal volume. The enclosure may include a first end defined by a wall and a second end defined by an opening. The second end may be opposite the first end. The power adapter may further include electrical springs coupled with the wall. The power adapter may further include a cap coupled with the opening. The cap may include a cap opening. The power adapter may further include a circuit board disposed in the internal volume and electrically coupled to the electrical springs. The power adapter may further include a connector carried by the circuit board, the connector positioned in the cap opening. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. All such additional systems, methods, features and advantages shall be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  illustrates an isometric view of an embodiment of a power adapter; 
         FIG. 2  illustrates an exploded view of the power adapter shown in  FIG. 1 ; 
         FIG. 3  illustrates an isometric view of the cap, showing several fins of the cap; 
         FIG. 4  illustrates a partial cross sectional view of the power adapter, showing the cap prior to assembly with the enclosure; 
         FIG. 5  illustrates a partial cross sectional view of the power adapter, showing the cap assembled with the enclosure and the fins interlocked with the ribs of the circuit board; 
         FIG. 6  illustrates a partial cross sectional view of the power adapter shown in  FIG. 5 , taken along line  6 - 6 , showing the fin interlocked with the circuit board; 
         FIG. 7  illustrates an isometric view of electrical springs, in accordance with some described embodiments; 
         FIG. 8  illustrates an isometric view of a prong, in accordance with some described embodiments; 
         FIG. 9  illustrates a plan view of the enclosure, showing the electrical springs and internal features of the enclosure; 
         FIG. 10  illustrates a cross sectional view of the power adapter, showing the circuit board positioned in the enclosure; 
         FIG. 11  illustrates a plan view of the power adapter, showing relationships between the enclosure and the cap, as well as between the cap and the connector; 
         FIG. 12  illustrates a cross sectional view of the power adapter shown in  FIG. 11 , taken along line  12 - 12 , showing a relationship between the connector and the opening of the cap; 
         FIG. 13  illustrates a plan view of the power adapter shown in  FIG. 11 , showing an enlarged view of Section B shown in  FIG. 11 ; 
         FIG. 14  illustrates a cross sectional view of the power adapter, showing the relative movement capabilities of the circuit board and the connector during assembly between the cap and the enclosure; 
         FIG. 15  illustrates a partial cross sectional view of the power adapter, showing additional movement capabilities of the circuit board during assembly between the cap and the enclosure; and 
         FIG. 16  illustrates a cross sectional view of the power adapter, showing the cap having an extension. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to adapters, such as power adapters, used to supply electrical energy to portable electronic devices including mobile wireless communication devices, laptop computing devices, and tablet computing devices (as non-limiting examples). In particular, the adapters described herein rely on modifications that can limit or remove the need for traditional materials, such as adhesives and wiring. Additionally, the adapters described herein include certain components (such as a circuit board and a connector) that can move relative to other parts in order to provide a desired alignment of the connector. 
     The adapters described herein relies in part on forcing an interference fit between two components of the adapter. The component materials may include a cap formed from a thermoplastic (e.g., polycarbonate) and a circuit board formed from a thermoset (e.g., FR4). During an assembly operation using welding (e.g., ultrasonic welding), mechanical energy is applied to the cap, causing a region of the cap to melt around the circuit board. The ultrasonic welding “horn” provides mechanical energy, usually in the range of 20-30 kHz. Based on the different material makeup, the circuit board, having a higher melting temperature than that of the cap, does not melt when the thermal energy is applied. Due in part to the melting around the circuit board, no gaps remain between the cap and the circuit board when the melted region of the cap solidifies, creating a mechanical constraint along the axis of welding, as well as an axis perpendicular to the axis of welding. The mechanical constraint absorbs the gaps, despite tolerance variations, without the use of adhesives. The resulting plastic geometry forms a line-to-line interface with the circuit board. Also, the thermoplastic selected for the cap may include a relatively higher melting temperature, as compared to other external components of power adapters. As a result of the higher melting temperature, the cap melts in a predictable manner and does not flow into undesired areas. Accordingly, some processes described herein reduce the reliance on additional adhesives to constrain the circuit board after the welding operation, thereby reducing the costs associated with adhesives, which include the material and the equipment required to dispense. However, adhesives can be used in other applications, i.e., not between the circuit board and the enclosure or between the cap and the enclosure, to allow adhesive dispensing without affecting the welding operation. This should not be construed as limiting, and in some embodiments, adhesives can be used between the circuit board and the enclosure, and/or between the cap and the enclosure. 
     Adapters described herein may further include blind mate electrical connections with consistent contact force. The blind mate electrical connections may include electrical springs that create a robust electrical connection in a difficult-to-access location, such as at the bottom of a power adapter enclosure. The electrical springs eliminate the need for long wire service loops to connect the circuit board to the metal prongs of the adapter. Moreover, the enclosure can be modified with features to guide the circuit board through the enclosure during assembly, and further guide the circuit board to the electrical springs, including centering the circuit board with respect to the electrical springs. Additionally, the electrical springs ensure consistent contact force and low electrical impedance. Also, the aforementioned welding operation is performed away from the electrical springs, thereby reducing the likelihood of issues of damage to the electrical springs, as well as damage to components or loosening of components, particularly during assembly. For example, the cap, which undergoes a welding operation, is secured to one end of the enclosure, while the electrical springs are located at the other, opposing end of the enclosure away from the location of the welding operation. Also, by eliminating wiring, the electrical connections are simplified, and the manual labor (and associated manufacturing time) associated with wiring is eliminated. This not only reduces the required manufacturing time, but also reduces the total part count. As a result, the processes described herein enhance safety by reducing variation assembly states and circuit board to electrical spring (and housing) freedom of motion, which can reduce stress and wear on connections. By reducing variation assembly states, the likelihood of faulty assembly is reduced. Accordingly, the processes described herein provide benefits over the use of wired connections and associated issues with the wired connections. 
     Adapters described here may further include self-aligning input-output (“I/O”), thereby allowing gap control at different interfaces. For example, the enclosure is modified to include a pivot rib, thus defining a pivot point for the circuit board. The pivot rib allows for a translation constraint, but allows rotation of circuit board about the pivot rib in multiple directions. As a result, the circuit board can align with the cap at the interface between a connector (connected to the circuit board) and a cap opening in which the connector is located. The self-aligning feature enhances cosmetic and functional alignment of the connector without requiring a flexible printed circuit board (“PCB”) connection. As a result, the processes described herein can contribute to reduce parts and associated costs, as well as the elimination of relatively high heat welding operations, such as laser welding, which is often required to reliably secure a flexible printed circuit (“FPC”) connector to mating enclosure parts. 
     Adapters described here may further include an ultrasonic weld joint between cosmetic parts (e.g., the enclosure and the cap) that provides a balance between joint mechanical strength and cosmetic quality. Traditional shear welds tend to have inefficiencies with respect to using all of the space/volume created for joint strength, allowing for overflow out of the space/volume for increased weld strength. However, the cap can be modified to include a flange that extends similar to a ring around an inner surface of the cap such that the flange extends beyond the weld plane. The flange can be perpendicular, or at least substantially perpendicular, to the weld plane while allowing a small gap (between the enclosure and the flange) for melt overflow. The gap is designed and positioned to redirect and capture the melt overflow in a way that increases weld strength without requiring additional space/volume for the melt overflow. Moreover, the flange hides/covers any melt overflow, thereby increasing the cosmetic appearance of the adapter. The processes described herein can create an enhanced weld strength by as much as 50% without significant risk increase to cosmetics/aesthetics. 
     These and other embodiments are discussed below with reference to  FIGS. 1-16 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these Figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  illustrates an isometric view of an embodiment of a power adapter  100 . Power adapter  100  may refer to a charger designed to plug into a wall outlet (not shown in  FIG. 1 ), which may include a 110-Volt to 120-Volt (“V”) alternating current (“AC”) source. In this regard, power adapter  100  is designed to receive AC and convert to direct current (“DC”), and supply DC at a specified level (e.g., 12-Volt DC) to various electronic devices (not shown in  FIG. 1 ), such as mobile wireless communication devices (e.g., smartphones, tablet computing devices), desktop computing devices, and laptop computing devices. Power adapter  100  can be designed to provide a specified amount of power. In this regard, power adapter  100  may also be referred to as a 5-Watt (“W”), a 12-W, 18-W, or a 20-W adapter, as non-limiting examples, depending upon the electronic components (not shown in  FIG. 1 ) of power adapter  100 . In some embodiments, power adapter  100  is rated for 100-240 V AC. 
     As shown, power adapter  100  includes an enclosure  102 , defined by several walls. Enclosure  102  may define an internal volume used to carry several components (shown later) of power adapter  100 . Enclosure  102  may include a molded enclosure, formed from a polymer (e.g., plastic, as a non-limiting example). Power adapter  100  may further include a cap  106  secured with enclosure  102 . Cap  106  includes an opening  108  that receives a connector  110 . Connector  110  can be designed in accordance with an industry standard, such as Universal Serial Bus (“USB”), including USB-C (as a non-limiting example). Connector  110  is designed to electrically couple with a cord-cable assembly (not shown in  FIG. 1 ), allowing power adapter  100  to receive electrical energy and supply power to one of the aforementioned electronic devices. 
     Power adapter  100  may further include a prong  111   a  and a prong  111   b  designed to couple with an AC socket. Prongs  111   a  and  111   b  may be referred to as a first prong and a second prong, respectively. As shown, prongs  111   a  and  111   b  are designed in accordance with a particular design. For instance, prongs  111   a  and  111   b  represent two pins that are generally flat and parallel with respect to each other. However, power adapter  100  can be modified for use in accordance with another design that conforms to another industry standard. For instance, in some exemplary embodiments, prongs  111   a  and  111   b  are non-parallel prongs. Further, in some exemplary embodiments, power adapter  100  includes three prongs, at least one of which is cylindrical or tubular. Also, in some exemplary embodiments, power adapter  100  is designed for use (in terms of circuitry and power rating) with a 100- to 240-Volt AC source. 
       FIG. 2  illustrates an exploded view of power adapter  100  shown in  FIG. 1 . As shown, enclosure  102  includes an end  103   a  and an end  103   b  that is opposite end  103   a . End  103   a  may be generally defined by a wall (not labeled) of enclosure  102  while end  103   b  is defined by an opening that receives, or at least partially receives, cap  106 . Power adapter  100  further includes a subassembly  112 , which may include a circuit board  114  (such as a printed circuit board, or PCB) that carries several components, including transistors and an AC-to-DC converter, and connector  110 , as non-limiting examples. In this regard, connector  110  may be part of subassembly  112 , and electrically coupled to circuit board  114 . 
     As shown, circuit board  114  includes a dimension  117  corresponding to a thickness of circuit board  114 . Dimension  117  may be approximately in the range of 0.8 to 1.6 millimeters (“mm”). In some embodiments, dimension  117  is 1.2 mm. As a result of dimension  117  of circuit board  114 , strain and other stresses applied to circuit board  114  can be minimized, thereby keeping components, such as a fuse and metal traces, intact. Also, circuit board  114  may include several ribs. For example, circuit board  114  includes a rib  116   a , a rib  116   b , a rib  116   c , and a rib  116   d . While a described number of ribs are shown, the number of ribs can vary in other embodiments. Cap  106  is designed to couple with ribs  116   a ,  116   b ,  116   c , and  116   d  such that connector  110  is positioned in opening  108 . This will be shown and described below. Also, subassembly  112  can be positioned into enclosure  102 . In order to position subassembly  112  within enclosure  102 , enclosure  102  may include several guide rails integrated with the walls of enclosure  102  such that circuit board  114  electrically couples with electrical springs within enclosure  102 . This will also be shown and described below. 
       FIG. 3  illustrates an isometric view of cap  106 , showing several fins of cap  106 . As shown, cap  106  includes a fin  118   a , a fin  118   b , a fin  118   c  and a fin  118   d . Each of fins  118   a ,  118   b ,  118   c , and  118   d  extends from an internal surface of cap  106 . Also, each of fins  118   a ,  118   b ,  118   c , and  118   d  are designed to interlock with circuit board  114  (shown in  FIG. 2 ). For example, fins  118   a ,  118   b ,  118   c , and  118   d  (representing a row of fins  119   a ) can interlock with ribs  116   a ,  116   b ,  116   c , and  116   d  (shown in  FIG. 2 ), respectively, of circuit board  114  (shown in  FIG. 2 ). In this regard, a welding operation, such as an ultrasonic welding operation, can provide thermal energy that melts (and subsequently bonds) fins  118   a ,  118   b ,  118   c , and  118   d  to ribs  116   a ,  116   b ,  116   c , and  116   d , respectively. Cap  106  (including fins  118   a ,  118   b ,  118   c , and  118   d ) enclosure  102  (shown in  FIG. 2 ) may each include a thermoplastic material, and accordingly, cap  106  and enclosure  102  may include the same (or at least substantially similar) melting temperature. In this regard, the aforementioned welding operation can supply heat sufficient to melt fins  118   a ,  118   b ,  118   c , and  118   d , while melting enclosure  102  and cap  106  together at selected regions (shown below). Further, the thermoplastic material may include a melting temperature that is lower than the material (e.g., FR4) of circuit board  114  (including ribs  116   a ,  116   b ,  116   c , and  116   d ), and accordingly, the same welding operation may not melt, or cause damage to, circuit board  114 . In addition to row of fins  119   a , cap  106  may include a row of fins  119   b , thus providing a symmetric design (internally) for cap  106 . In this manner, either of rows of fins  119   a  or  119   b  can be used such that the assembly process does not require a specific orientation of cap  106  during assembly. 
       FIG. 4  illustrates a partial cross sectional view of power adapter  100 , showing cap  106  prior to assembly with enclosure  102 . Cap  106  can be brought toward, and engaged with, enclosure  102 . In order to permanently secure cap  106 , the aforementioned fins (shown in  FIG. 3 ) can be brought into contact with each of the aforementioned ribs (labeled in  FIG. 2 ) of circuit board  114 , where a welding operation can subsequently melt the fins to the ribs. For instance, fin  118   a  (representative of additional fins) can be brought into contact with rib  116   a  (representative of additional ribs) and subsequently melted to rib  116   a  when sufficient thermal energy is provided to melt fin  118   a . Additional welding operations may occur, and will be further discussed below. 
     Alternatively, in some embodiments, circuit board  114  includes a material (e.g., plastic) capable of melting during an assembly operation. For example, rib  116   a  (as well as one or more of the additional ribs) may include plastic, and the ultrasonic welding operation melts fin  118   a  onto the plastic on rib  116   a . As a result, rib  116   a  is melted to circuit board  114 . In this regard, the resultant joint may include enhanced strength. 
       FIG. 5  illustrates a partial cross sectional view of power adapter  100 , showing cap  106  assembled with enclosure  102  and the fins of cap  106  interlocked with the ribs of circuit board  114 . As shown in the enlarged view, fin  118   a  (representative of the remaining fins) is interlocked with circuit board  114  at rib  116   a  (representative of the remaining ribs). During a welding operation, fin  118   a  can melt, or at least partially melt, thereby allowing the rib  116   a  to penetrate fin  118   a . Further, circuit board  114 , including the ribs, includes a relatively higher melting temperature, and accordingly, circuit board  114  will not melt, deform, or become damaged during the welding operation. The process shown and described can eliminate the need for adhesives (or at least reduce the amount of adhesive required) to secure cap  106  with enclosure  102 , and provide an accurate position of circuit board  114  within enclosure  102 . Also, as compared to some polymers used in plastic housing parts for adapters, cap  106  may include a material (or materials) having a melting temperature sufficiently high enough to undergo a welding operation, while not allowing the melted regions of cap  106  (i.e., fins) to flow/extend into undesired locations, resulting in a more controlled welding operation in terms of regulating/controlling the flow of melted material. 
       FIG. 6  illustrates a partial cross sectional view of power adapter  100  shown in  FIG. 5 , taken along line  6 - 6 , showing fin  118   a  interlocked with circuit board  114 . As shown in the enlarged view, fin  118   a  is deformed due in part to the aforementioned welding operation. In particular, as a result of the welding operation, fin  118   a  (representative of additional fins) generally conforms to the exterior shape of rib  116   a  (representative of additional ribs). While fin  118   a , formed from a thermoplastic, melts, circuit board  114 , formed from a thermoset (e.g., FR4), does not. Also, the melting of fin  118   a  to circuit board  114  removes any gaps or spaces between fin  118   a  and circuit board  114 . In this regard, the combination of the interference fit between cap  106  and circuit board  114  and welding operation to melt fin  118   a  causes fin  118   a  to conform to the exterior shape and size of circuit board  114 , providing additional constraint to circuit board  114 . 
       FIG. 7  illustrates an isometric view of electrical springs, in accordance with some described embodiments. Power adapter  100  (shown in  FIG. 1 ) may include an electrical spring  120   a  and an electrical spring  120   b  disposed in enclosure  102  (not shown in  FIG. 7 ). Electrical springs  120   a  and  120   b  may be referred to as a first electrical spring and a second electrical spring, respectively. Electrical springs  120   a  and  120   b  are designed to electrically couple with prongs  111   a  and  111   b  (shown in  FIG. 1 ), respectively. In this regard, electrical springs  120   a  and  120   b  may be formed from a metal (or metals), such as copper or an alloy including copper. Electrical springs  120   a  and  120   b  may include an opening  122   a  and an opening  122   b , respectively. Openings  122   a  and  122   b  can receive a portion of prongs  111   a  and  111   b  (shown in  FIG. 1 ), respectively. Additionally, electrical springs  120   a  and  120   b  are designed to electrical couple with circuit board  114  (shown in  FIG. 2 ). In this regard, electrical springs  120   a  and  120   b  include a clamp  124   a  and a clamp  124   b , respectively. Clamps  124   a  and  124   b  are flexible clamps with a shape and spring constant to provide a contact force to couple with circuit board  114 , and engage electrical pads (not shown in  FIG. 7 ) of circuit board  114 . Also, the general position and orientation of electrical springs  120   a  and  120   b , as shown in  FIG. 7 , is the position and orientation of electrical springs  120   a  and  120   b  when disposed in enclosure  102  (not in  FIG. 7 ). In this regard, electrical springs  120   a  and  120   b  may be symmetrically orientated within enclosure  102 . The symmetric orientation and the integration of electrical springs  120   a  and  120   b  also provide a constraint on circuit board  114 . As a result, power adapter  100  (shown in  FIG. 1 ) need not rely on adhesives and fasteners for these connections. 
       FIG. 8  illustrates an isometric view of prong  111   a , in accordance with some described embodiments. As shown, prong  111   a  is a single piece material. In some embodiments, prong  111   a  is formed through an extrusion process. In the embodiment shown in  FIG. 8 , prong  111   a  is formed from cold forging, which may increase the overall strength of prong  111   a . Prong  111   a  may include a flange  113 . In order to secure prong  111   a  with enclosure  102  (shown in  FIG. 1 ), flange  113  can be secured to enclosure  102  by a molding operation, such as insert molding, thereby embedding flange  113  in enclosure  102 . As a result, prong  111   a  is less susceptible to decoupling from enclosure  102  due to mechanical stress. The molding operation of flange  113  into enclosure  102  creates a consistent mechanical connection between enclosure  102  and prong  111   a.    
     Prong  111   a  may further include a post  115  that connects with an electrical spring. For example, post  115  can mate with opening  122   a  of electrical spring  120   a  (shown in  FIG. 7 ). Post  115  can be formed by a variety of methods, such as orbital swaging, which can form a robust electrical connection. It should be noted that prong  111   b  (shown in  FIG. 1 ) may include any features described herein for prong  111   a.    
       FIG. 9  illustrates a plan view of enclosure  102 , showing electrical springs  120   a  and  120   b  and other features within enclosure  102 . Enclosure  102  may include several walls. As shown, enclosure  102  includes a wall  126   a , a wall  126   b , a wall  126   c , a wall  126   d , and a wall  126   e . Based on the design of enclosure  102 , wall  126   e  may be perpendicular with respect to each of walls  126   a ,  126   b ,  126   c , and  126   d . Electrical springs  120   a  and  120   b  may be disposed against a surface of wall  126   e , and are electrically and mechanically coupled to prongs  111   a  and  111   b , respectively. Also, enclosure  102  includes several guide rails used to support and position circuit board  114  (shown in  FIG. 2 ) within enclosure  102 . For example, enclosure  102  includes a guide rail  128   a , representing several additional guide rails positioned on wall  126   e . Additionally, enclosure  102  includes a guide rail  128   b , representing several additional guide rails positioned on wall  126   c  and/or wall  126   e . Also, enclosure  102  may include a guide rail  128   c  and a guide rail  128   d  disposed at a corner of enclosure  102 , as well as a guide rail  128   e  and a guide rail  128   f  disposed at another corner of enclosure  102 . When circuit board  114  is inserted into enclosure  102 , circuit board  114  is directed to electrical springs  120   a  and  120   b  based on the aforementioned guide rails. For instance, circuit board  114 , when inserted into enclosure  102 , is positioned between guide rails  128   c  and  128   d , as well as between guide rails  128   e  and  128   f . Subsequently, circuit board  114  is further guided by, and positioned between guide rails  128   a  and  128   b , which further direct circuit board  114  to electrical springs  120   a  and  120   b , where circuit board  114  is guided into engagement with clamps  124   a  and  124   b.    
       FIG. 10  illustrates a cross sectional view of power adapter  100 , showing circuit board  114  positioned in enclosure  102 . The electrical springs can electrically couple with the circuit board  114 . For example, as shown in the enlarged view, electrical spring  120   a , using clamp  124   a , electrically couples with an electrical pad  130   a  and an electrical pad  130   b  of circuit board  114 , thereby electrically coupling prong  111   a  to circuit board  114 . Additionally, as shown in  FIG. 10 , nickel shims  131   a  and  131   b  can be positioned between circuit board  114  and electrical pads  130   a  and  130   b , thereby increasing the hardness and wear resistance at the respective interfaces. It should be noted that the electrical spring  120   b  and clamp  124   b  (shown in  FIG. 7 ) may couple with circuit board  114 , electrically and mechanically, in a manner similar to that of electrical spring  120   a  (i.e., with electrical pads of circuit board  114 ), and may electrically couple to prong  111   b  (shown in  FIG. 1 ). Further, electrical connections that see strain from wall  126   e  to the circuit board  114  are solder-less. In other words, solder is not used at these locations. Rather, the electrical connections include high-pressure, electro-mechanical connections to increase strength of the electrical connections, as compared to solder. 
     Additionally, the aforementioned ultrasonic welding operation, known to provide energy with a frequency of approximately 20 kHz, is not required at a connection point between the circuit board  114  and electrical spring  120   a  (nor electrical spring  120   b ). In other words, the welding operation may be limited to securing cap  106  (shown in  FIG. 3 ) at end  103   b  of the enclosure  102  that is away from the electrical springs  120   a  and  120   b  (both generally associated with end  103   a  of enclosure  102 ). As a result, electrical springs  120   a  and  120   b , as well as other components of subassembly  112  (shown in  FIG. 2 ) are prevented from, or at least less susceptible to, damage or other issues during ultrasonic welding operation. 
       FIGS. 7-10  show and describe several features used of power adapter  100  used to facilitate assembly of components. For instance, the design of guide rails  128   a ,  128   b ,  128   c ,  128   d ,  128   e , and  128   f  guide circuit board  114  to electrical springs  120   a  and  120   b , thereby providing a “blind” mating in which visual assembly is not required. Additionally, the blind mating process may remove the need for wiring and tooling. In this manner, power adapter  100  can be made more safely and efficiently, as well as in a more cost effective manner. 
       FIG. 11  illustrates a plan view of power adapter  100 , showing relationships between enclosure  102  and cap  106 , as well as between cap  106  and connector  110 . Ideally, when cap  106  is secured with enclosure  102 , cap  106  is centered within an opening  132  of enclosure  102 . As a result, the gap between cap  106  and enclosure  102  is uniform. Similarly, the aforementioned assembly ideally centers connector  110  within opening  108  of cap  106 . 
       FIG. 12  illustrates a cross sectional view of power adapter  100  shown in  FIG. 11 , taken along line  12 - 12 , showing a relationship between connector  110  and opening  108  of cap  106 . As shown, at least some regions of connector  110  are larger than the size of opening  108  of cap  106 . For example, connector  110  includes an extended region  133  that includes dimensions (e.g., Z-axis and X-axis, the latter of which is not shown in  FIG. 12 ) that are larger than corresponding dimensions of opening  108 . Additionally, opening  108  of cap  106  is further defined by a chamfered region  135  that allows a portion of connector  110  (e.g., extended region  133 ) to be further positioned into opening  108  along the Y-axis (as opposed to opening  108  without chamfered region  135 ). Based on these dimensional relationships, when viewing an exterior surface of cap  106  and connector  110  (such as the viewpoint shown in  FIG. 11 ), there is generally no gap between opening  108  and connector  110 , thus providing a seamless appearance at an interface between opening  108  and connector  110 . Further,  FIG. 13  illustrates a plan view of power adapter  100  shown in  FIG. 11 , showing an enlarged view of Section B shown in  FIG. 11 . As shown, a gap (denoted by arrows) extends between enclosure  102  and cap  106 , and defines a consistent dimension between enclosure  102  and cap  106 . 
     In order to provide power adapter  100  with consistent and repeatable gaps (shown in  FIGS. 11-13 ), power adapter  100  may include some modifications that allow for adjustments during assembly. These adjustments may offset tolerance variations commonly known for fabricated parts. 
       FIG. 14  illustrates a cross sectional view of power adapter  100 , showing the relative movement capabilities of circuit board  114  and connector  110  during assembly between the cap  106  and the enclosure  102 . As shown in the enlarged view, enclosure  102  includes an extension  134  that extends from wall  126   e . Extension  134  may include a rib integrated with wall  126   e . Extension  134  defines a pivot point for circuit board  114 . In other words, in some instances, circuit board  114  may directly contact enclosure  102  at extension  134  along the wall  126   e , and in some instances, circuit board  114  directly contacts enclosure  102  only at extension  134 . As a result, circuit board  114  (including connector  110 ) can move in at least two directions, as denoted by the two-sided arrow prior to cap  106  being permanently secured with enclosure  102 . In this manner, movement of circuit board  114  can provide an adjustment to cap  106  to center cap  106  with respect to enclosure  102 , and connector  110  can be also centered within opening  108  of cap  106 . As a result, connector  110  does not require a flexible circuitry or additional wiring for flexibility/movement during assembly, as the connector  110  moves with circuit board  114  for adjustment (of connector  110 ). 
       FIG. 15  illustrates a partial cross sectional view of power adapter  100 , showing additional movement capabilities of circuit board  114  during assembly between cap  106  and enclosure  102 . Not only is circuit board  114  capable of pivoting, relative to the enclosure  102 , along a two-dimension X-Y plane, but circuit board  114  can also use extension  134  to move along the Z-axis if necessary. The degree of pivoting is approximately in the range of 4 to 8 degrees along each axis. This allows sufficient, but limited, degree of movement for circuit board  114 , if needed. While electrical springs  120   a  and  120   b  (shown in  FIG. 7 ) provide mechanical constraints to circuit board  114 , electrical springs  120   a  and  120   b  nonetheless permit movement of circuit board  114  in three dimensions. Also, due in part of the ability of circuit board  114  to adjust in three different dimensions, connector  110  (shown in  FIG. 14 ) can also move in three dimensions, as connector  110  is mounted to circuit board  114 . 
       FIG. 16  illustrates a cross sectional view of power adapter  100 , showing cap  106  having an extension  136 . Extension  136  defines a flange that includes a ring around an inner surface of cap  106 . Extension  136  provides additional surface area for bonding, through ultrasonic welding (as an example), cap  106  with enclosure  102 . In this regard, extension  136  can promote a stronger bond to increased space/volume for bonding, and accordingly, is less susceptible to failure. Moreover, extension  136  may shield, or hide, any melted or otherwise deformed materials during the ultrasonic welding process. For instance, as shown in the enlarged view, cap  106  is secured with enclosure  102  at a bonding location  138 , defined by the aforementioned ultrasonic welding operation. Despite variances or differences caused by the ultrasonic welding operation to cap  106  and/or enclosure  102 , extension  136  not only increases the area for bonding location  138 , but also masks or hides any cosmetic deficiencies caused at bonding location  138 . Additionally, the energy required by the welding operation is minimized, as compared to the resultant increased weld strength, based in part on extension  136 . Also, bonding location  138  may limit or eliminate the need for adhesives to bond cap  106  with enclosure  102 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing operations or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings. 
     It is well understood that the use of personally identifiable information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining the privacy of users. In particular, personally identifiable information data should be managed and handled so as to minimize risks of unintentional or unauthorized access or use, and the nature of authorized use should be clearly indicated to users.

Metadata:
Filing Date: 20201106
Publication Date: 20221129
Grant Date: 20221129
Priority Date: 20200624
Inventors: Lashinsky, Matthew A.
VARMA, Arun R.
LOZANO VILLARREAL, Cesar
ROY, MATHIEU P.
Khan, Balal
SIMEROTH, Johnathan D.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2201/09145", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/03", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R31/065", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K7/1417", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K5/0052", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/707", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R31/06", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/72", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R31/065", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/714", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09163", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/09163", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/72", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0052", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/006", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R31/065", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 78827131