Compact device housing and assembly techniques therefor

Abstract

High density electronic device assemblies and techniques for forming high density electronic device assemblies are disclosed. These assemblies and techniques can be used to form compact electronic devices, such as portable power adapters. In one embodiment, substrate arrangements that include a multiple-part substrate can be used to form a high density electronic device assembly. In another embodiment, one or more clips can be used in a high density electronic device assembly to provide mechanical and electrical interconnection between electrical structures that are to be removably coupled together as parts of the high density electronic device assembly. In still another embodiment, a removable cap (and a method for forming the removable cap) can be used for an electronic device housing.

1 . A portable power adapter for a portable electronic device, said portable power adapter comprising:
 a housing having a removable cap;   at least one metal contact pin;   a printed circuit board provided within said housing; and   a metal clip configured to secure said at least one metal contact pin to the removable cap and to removable attach to said printed circuit board when the removable cap is attached to said housing.   
     
     
         2 . A portable power adapter as recited in  claim 1 , wherein said metal clip comprises:
 a base portion having an opening, the opening including a plurality of interference tabs;   at least one upper flexure extending outward from said base portion; and   at least one lower flexure extending outward from said base portion,   wherein said at least one upper flexure and said at least one lower flexure are biased towards each other.   
     
     
         3 . A portable power adapter as recited in  claim 2 , wherein the opening of said base portion is configured to receive said at least one metal contact pin of said portable power adapter, and wherein the interference tabs secure said metal clip to said at least one metal contact pin. 
     
     
         4 . A portable power adapter as recited in  claim 1 , wherein the removable cap is form by a molded plastic, and wherein said metal contact pin is substantially covered in a molded plastic plug, whereby said metal contact pin extends through the molded plastic plug. 
     
     
         5 . A portable power adapter as recited in  claim 4 , wherein the removable cap and the molded plastic plug are molded simultaneously and in the direction of said metal contact pin. 
     
     
         6 . A portable power adapter as recited in  claim 1 , wherein said metal contact pin includes at least an attachment feature at an extended tip, and an attachable cap that is configured to be attachable to the attachment feature of the extended tip. 
     
     
         7 . A portable power adapter as recited in  claim 1 , wherein said metal contact pin has at least an extended tip, and an attachable cap that is configured to be attachable to the extended tip. 
     
     
         8 . A portable power adapter as recited in  claim 1 , wherein said metal clip comprising:
 a base portion having an opening, the opening including a plurality of interference tabs;   at least one upper flexure extending outward from said base portion; and   at least one lower flexure extending outward from said base portion,   wherein said at least one upper flexure and said at least one lower flexure are biased towards each other.   
     
     
         9 . A portable power adapter as recited in  claim 8 ,
 wherein the opening of said base portion is configured to receive the metal contact pin of said portable power adapter, and wherein the interference tabs secure said clip to the metal contact pin.   
     
     
         10 . A portable power adapter as recited in  claim 8 , wherein said at least one upper flexure includes first and second upper flexures, and wherein said at least one lower flexure includes a first lower flexure. 
     
     
         11 . A portable power adapter as recited in  claim 10 , wherein the biasing of said first and second upper flexures opposes the biasing of said first lower flexure. 
     
     
         12 . A portable power adapter as recited in  claim 8 ,
 wherein said flexures are configured to receive and couple to an edge of the printed circuit board,   wherein once the edge of the printed circuit board is received between said flexures, the printed circuit board is mechanically coupled and electrically connected to said metal clip in a removable manner.   
     
     
         13 . A portable power adapter as recited in  claim 12 ,
 wherein the opening of said base portion is configured to receive the metal contact pin of the portable power adapter, and wherein the interference tabs secure said metal clip to the metal contact pin,   whereby the metal contact pin is electrically connected to the printed circuit board biased via said metal clip.   
     
     
         14 . A portable power adapter as recited in  claim 8 , herein said base portion further comprises an alignment notch. 
     
     
         15 . A portable power adapter as recited in  claim 8 , wherein said metal clip provides electrical connection between the metal contact pin and the printed circuit board. 
     
     
         16 . A portable power adapter as recited in  claim 1 ,
 wherein the printed circuit board is part of a printed circuit assembly, and   wherein the printed circuit assembly includes at least:
 a bottom printed circuit board provided in a first plane; 
 a first side printed circuit board attached to said bottom printed circuit board, said first side printed circuit board being provided in a second plane that is substantially orthogonal to the first plane; 
 a second side printed circuit board attached to said bottom printed circuit board, said first side printed circuit board being provided in the second plane offset from said first side printed circuit board; and 
 a top printed circuit board attached to said first side printed circuit board and said second side printed circuit board, said top printed circuit board being provided in the first plane offset from said bottom printed circuit board. 
   
     
     
         17 . A portable power adapter as recited in  claim 16 , wherein said printed circuit assembly has a substantially rectangular cross-sectional configuration. 
     
     
         18 . A portable power adapter as recited in  claim 16 , wherein each of said bottom printed circuit board, said first side printed circuit board, said second side printed circuit board, and said top printed circuit board includes a plurality of electrical components. 
     
     
         19 . A portable power adapter as recited in  claim 16 ,
 wherein said top printed circuit board is physically and electrically connected to said first side printed circuit board and said second side printed circuit board, and   wherein said bottom printed circuit board is physically and electrically connected to said first side printed circuit board and said second side printed circuit board.   
     
     
         20 . A power adapter for a portable electronic device, said portable power adapter comprising:
 a housing having a removable cap;   at least one metal contact pin;   a printed circuit board provided within said housing; and   a metal clip configured to secure said at least one metal contact pin to the removable cap and to removable attach to said printed circuit board when the removable cap is attached to said housing,   wherein said metal clip provides electrical connection between the metal contact pin and the printed circuit board.   
     
     
         21 . A power adapter as recited in  claim 20 ,
 wherein said flexures are configured to receive and couple to an edge of the printed circuit board, and   wherein once the edge of the printed circuit board is received between said flexures, the printed circuit board is mechanically coupled and electrically connected to said metal clip in a removable manner.   
     
     
         22 . A power adapter as recited in  claim 20 ,
 wherein the opening of said base portion is configured to receive the metal contact pin of the power adapter, and wherein the interference tabs secure said metal clip to the metal contact pin.   
     
     
         23 . A method for assembly a portable power adapter having at least one contact pin for electrical connection, said method comprising:
 providing a housing portion for the portable power adapter, the housing portion including at least one opening;   inserting the at least one contact pin into the at least one opening of the housing portion;   attaching a clip to the at least one contact pin to facilitate electrical connection with an electrical component of the portable power adapter; and   attaching the housing portion to a housing of the portable power adapter.   
     
     
         24 . A method as recited in  claim 23 , wherein when the housing portion is attached to the housing of the portable power adapter, the clip provides a removable electrical connection between the at least one contact pin and the electrical component internal to the housing of the portable power adapter. 
     
     
         25 . A method as recited in  claim 24 , wherein the electrical component is a printed circuit board. 
     
     
         26 . A method as recited in  claim 25 , wherein the clip includes a plurality of flexures, and
 wherein said method further comprises:
 receiving the printed circuit board within the flexures of the clip, thereby providing mechanical and electrical coupling between the clip and the printed circuit board. 
   
     
     
         27 . A method as recited in  claim 26 , wherein the clip portion removably attaches to the printed circuit board when the housing portion is attached to the housing of the portable power adapter.