Charger plug with improved package

Abstract

A reduced plug-size charger plug for power conversion is disclosed utilizing a pair of blades that are slidably mounted into a charger housing, obviating the need for insertion molding. To promote and maintain electrical contact while minimizing package size and charger plug cost, a pair of spring contacts are provided for electrically connecting the blades with internal circuitry.

What is claimed is: 
     
       1. A charger plug capable of connecting with a two or three receptacle power source to convert 120V input power received from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto, the charger plug including a housing, the charger plug comprising:
 first and second separate blade members secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removably receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device;   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is equal to or less than 2.0 inches and   ii) the outer profile having no interference with an adjacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles,   so that when space is limited by an obstacle adjacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle.   
     
     
       2. The charger plug of  claim 1  wherein the charger plug face area has a perimeter that defines generally one of a polygonal, squared-off circle, ovoid or circular shape and the receptacle face area has a periphery that defines generally one of a polygonal, squared-off circle, ovoid or circular shape. 
     
     
       3. The charger plug of  claim 2  wherein the perimeter of the charger plug defines a footprint that is not the same shape as the periphery of the receptacle. 
     
     
       4. The charger plug of  claim 2  wherein the periphery of the receptacle surrounds less than all sides of a group of the receptacles. 
     
     
       5. The charger plug of  claim 4  wherein the power source comprises a receptacle having two or three groups of receptacle openings disposed in a single continuous plate comprising the first and second receptacles. 
     
     
       6. The charger plug of  claim 1  wherein the power source comprises four receptacles disposed in the wall outlet. 
     
     
       7. The charger plug of  claim 1  wherein the power source includes three receptacle openings disposed in each of the first, second and third receptacles. 
     
     
       8. The charger plug of  claim 1 , further comprising the housing having a tapered portion at a rear end thereof, the tapered portion having an opening, and the connector being accessible through the tapered portion opening. 
     
     
       9. The charger plug of  claim 1 , further comprising a supporting substrate on which internal circuitry for converting power is mounted, the supporting substrate being a board extending in a lateral direction relative to the prong portions, and the housing has a shape to provide a tactile indication of an orientation of the connector. 
     
     
       10. The charger plug of  claim 1  wherein the housing forms an outer profile having a longitudinal length of the housing outer profile being less than approximately 2.0 inches and a width of the housing outer profile being less than approximately 1.7 inches. 
     
     
       11. The charger plug of  claim 1 , wherein the connector is USB receptacle. 
     
     
       12. The charger plug of  claim 1 , wherein the aperture of the connector for receiving the power cord plug end has an insertion depth that is less than an insertion depth of the receptacle of the power source, the insertion depth of the receptacle being defined by the blade members of the charger plug being measured between an exit point where the blade member exits the housing and a terminal point on the blade member furthest from the exit point, so that the power cord plug end can be conveniently removed in a small space leaving the charger plug connected to the receptacle. 
     
     
       13. The charger plug of  claim 1  wherein the connector is positioned on the housing so that a second direction of insertion of the connector aperture is substantially in-line with the first direction of the blade members of the charger plug to provide a shorter travel path for inserting and removing the power cord plug end when space is limited by an adjacent obstacle. 
     
     
       14. The charger plug of  claim 1  wherein the charger plug includes a rear end on a side opposite the front wall and the connector is positioned on the housing so that a second direction of insertion of the connector aperture is substantially perpendicular with the first direction of the blade members of the charger plug to provide a shorter travel path for inserting and removing the power cord plug end when space is limited by an obstacle adjacent the rear end of the charger plug. 
     
     
       15. The charger plug of  claim 1 , wherein the power source comprises a power strip having multiple receptacles aligned side by side along the power strip. 
     
     
       16. The charger plug of  claim 1 , wherein the power source comprises a wall outlet. 
     
     
       17. The charger plug of  claim 1 , wherein the charger plug includes the DC connector oriented in order to provide a first removal force to remove the power cord plug end from the DC connector that is less than a second removal force to remove the blade members from the receptacle openings of the power source. 
     
     
       18. The charger plug of  claim 1 , wherein the DC connector has an aperture adapted for removably receiving a corresponding power cord plug end for transmitting DC power to the electronic device, the power cord plug end insertable within the aperture along a second longitudinal insertion axis of the connector aperture that is substantially in-line with the first direction. 
     
     
       19. The charger plug of  claim 1 , wherein the blade members are non-movably mounted to the housing. 
     
     
       20. A charger plug capable of connecting with a two or three receptacle power source to convert l20V input power received from the power source to DC output power, the charger plug being electricallv connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto, the charger plug including a housing, the charger plug comprising:
 first and second separate blade members non-movably secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removablv receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device;   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall;   a printed circuit board located within the housing and haying the DC connector mounted thereon, wherein a rearward extent of the blade members ends before a front edge of the printed circuit board and the housing has a connector opening at the rear end for proyiding access to the DC connector aperture by the power cord plug;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches and   ii) the outer profile haying no interference with an adiacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all ayailable orientations in any of the other receptacles,   so that when space is limited by an obstacle adiacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle.   
     
     
       21. A charger plug capable of connecting with a two or three receptacle power source to conyert 120V input power receiyed from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic deyice yia a power cord for providing the DC output power thereto, the charger plug including a housing, the charger plug comprising:
 first and second separate blade members secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removablv receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device;   the charger plug housing forming a) a charger plug face area defined bv the front wall b) an outer profile defined bv a perimeter of the front wall and defined bv a plug bodv extending rearward from the front wall and c) a rear end opposite the front wall;   a printed circuit board located within the housing and having the DC connector mounted thereon. the housing having a connector opening at the rear end for providing access to the DC connector aperture by the power cord plug;   spring contacts electricallv connected to the blade members. wherein the spring contacts are elastically deformed bv respective blade members to provide an elastic contacting force on the printed circuit board electrically connecting it to the blade members, each said blade member having a forwardmost portion in contact with the inside of the housing front wall and a rearmost portion in contact with a respective spring contact in front of the printed circuit board;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches and   ii) the outer profile having no interference with an adiacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles.   so that when space is limited by an obstacle adiacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle.   
     
     
       22. A charger plug capable of connecting with a two or three receptacle power source to convert 120V input power received from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto. the charger plug including a housing, the charger plug comprising:
 first and second separate blade members secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removably receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device;   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall;   a printed circuit board located within the housing and haying the DC connector mounted thereon, the housing haying a connector opening at the rear end for providing access to the DC connector aperture by the power cord plug;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches and comprises an outer profile haying a width less than 1. 75 inches, and   ii) the outer profile having no interference with an adjacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles,   so that when space is limited by an obstacle adjacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle.   
     
     
       23. A charger plug capable of connecting with a two or three receptacle power source to convert 120V input power received from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto, the charger plug including a housing, the charger plug comprising:
 first and second separate blade members non-movably secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from openings through a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source:   the charger plug including a DC connector having an aperture adapted to removably receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device:   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall;   a printed circuit board located within the housing and having a front end adiacent the inside of the front wall;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches and   ii) the outer profile having no interference with an adiacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles,   so that when space is limited bv an obstacle adiacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end mav be conveniently received bv the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle and   (iii) having permanent spring-loaded electrical connections between the non-movable blade members and the front end of the printed circuit board.   
     
     
       24. The charger plug of  claim 23 , further comprising first and second spring contacts elastically deformed bv respective first and second blade members spaced in the longitudinal direction from a front edge of said printed circuit board. 
     
     
       25. The charger plug of  claim 23 , wherein the spring contacts are elastically deformed by respective blade members. each said blade member having a forwardmost portion in contact with the inside of the housing front wall and a rearmost portion in contact with a respective spring contact in front of the printed circuit board. 
     
     
       26. The charger plug of  claim 23 , wherein the spring-loaded electrical connections are made by spring contacts that connect electrically to the printed circuit board and the blade members without being soldered to either. 
     
     
       27. The charger plug of  claim 23 , wherein the rearward extent of the blade members ends before a front edge of the printed circuit board. 
     
     
       28. The charger plug of  claim 23 , wherein:
 the DC connector is mounted on a surface of the printed circuit board at a location within the charger plug housing;   the charging plug housing has a connector opening at the rear end for providing access to the DC connector aperture by the power cord plug; and   the power cord plug end is insertable within the DC connector aperture along a second longitudinal insertion axis of the connector aperture that is substantially in-line with the first direction.   
     
     
       29. The charger plug of  claim 23 , wherein the charger plug housing exterior includes indicia with information relating to requirements of applicable regulatory bodies. 
     
     
       30. A charger plug capable of connecting with a two or three receptacle power source to convert 120V AC input power received from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto. the charger plug including a housing, the charger plug comprising:
 first and second separate blade members secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removably receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device and converter circuitry mounted on a printed circuit board located within the housing for converting the AC input power to the DC output power;   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches, a width of the housing outer profile being less than 1.75 inches, and   ii) the outer profile having no interference with an adjacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles,   so that when space is limited by an obstacle adjacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle and   (iii) the charger plug housing exterior including indicia with information relating to requirements of applicable regulatory bodies.   
     
     
       31. The charger plug of  claim 30 , wherein the indicia are imprinted on the charger plug face area. 
     
     
       32. The charger plug of  claim 31 , wherein the indicia are imprinted on a label comprising a front face of the charger plug housing. 
     
     
       33. The charger plug of  claim 30 , wherein the blade members make permanent spring-loaded electrical connections with the printed circuit board by spring contacts that connect electrically to the printed circuit board and the blade members without being soldered to either. 
     
     
       34. The charger plug of  claim 33 , wherein respective first and second spring contacts are elastically deformed by respective first and second blade members, each said blade member having a forwardmost portion in contact with the inside of the housing front wall and a rearmost portion in contact with a respective spring contact in front of the printed circuit board. 
     
     
       35. The charger plug of  claim 30 , wherein the rearward extent of the blade members ends before a front edge of the printed circuit board. 
     
     
       36. A charger plug capable of connecting with a two or three receptacle power source to convert 120V AC input power received from the power source to DC output power, the charger plug being electrically connectable to a rechargeable electronic device via a power cord for providing the DC output power thereto. the charger plug including a housing, the charger plug comprising:
 first and second separate blade members non-movably secured within the housing so as to have prong portions of the blade members positioned in order to extend in a first direction from openings through a front wall of the housing, the prong portions adapted to be received in the receptacle openings of the power source;   the charger plug including a DC connector having an aperture adapted to removably receive a corresponding power cord plug end for transmitting DC power to the rechargeable electronic device and converter circuitry mounted on a printed circuit board located within the housing for converting the AC input power to the DC output power;   the charger plug housing forming a) a charger plug face area defined by the front wall b) an outer profile defined by a perimeter of the front wall and defined by a plug body extending rearward from the front wall and c) a rear end opposite the front wall. the printed circuit board having a front end adjacent the inside of the front wall;   the charger plug configured to be capable of plugging into a standard wall outlet and further:   i) being sized so that the charger plug housing comprises a longitudinal length extending between the front wall and the rear end and the longitudinal length is less than 2.0 inches, a width of the housing outer profile being less than 1.75 inches, and   ii) the outer profile having no interference with an adjacent receptacle of the power source located on all sides of the first receptacle when a like charger plug is mounted in all available orientations in any of the other receptacles,   so that when space is limited by an obstacle adjacent or in front of the power source the charger plug is capable of being conveniently mounted to one of the receptacles, the power cord plug end may be conveniently received by the DC connector and the power cord plug end can be conveniently removed from the DC connector while leaving the charger plug connected to the receptacle and   (iii) having permanent spring-loaded electrical connections between the non-movable blade members and a front end of the printed circuit board.   
     
     
       37. The charger plug of  claim 36 , wherein:
 the DC connector is mounted on a surface of the printed circuit board at a location within the charger plug housing;   the charger plug housing has a connector opening at the rear end for providing access to the DC connector aperture by the power cord plug; and   the power cord plug end is insertable within the DC connector aperture along a second longitudinal insertion axis of the connector aperture that is substantially in-line with the first direction.   
     
     
       38. The charger plug of  claim 36 , wherein the permanent spring-loaded electrical connections are made by spring contacts that connect electrically to the printed circuit board and the blade members without being soldered to either. 
     
     
       39. The charger plug of  claim 38 , wherein first and second spring contacts are elastically deformed by respective first and second blade members, each said blade member having a forwardmost extent in contact with the inside of the housing front wall and a rearmost extent in contact with a respective spring contact in front of the printed circuit board. 
     
     
       40. The charger plug of  claim 36 , wherein the rearward extent of the blade members ends before a front edge of the printed circuit board. 
     
     
       41. The charger plug of  claim 36 , wherein the charger plug housing exterior includes indicia with information relating to requirements of applicable regulatory bodies.