Inductor devices – With outer casing or housing – Potted type
Reexamination Certificate
1999-08-19
2001-08-07
Mai, Anh (Department: 2832)
Inductor devices
With outer casing or housing
Potted type
C336S090000, C336S192000
Reexamination Certificate
active
06271742
ABSTRACT:
FIELD OF THE INVENTION
The invention relates to a mains adapter and a method for its production. Mains adapters are used for stepping down the mains voltage so that electrical equipment requiring low voltage, such as, for example, chargers, can be operated thereon.
DESCRIPTION OF THE RELATED ART
European Patent No. EP-A-0 485 341 discloses a mains adapter of the generic type, in which the transformer held together by an integrally moulded holder is surrounded by a mould sleeve, which however leaves large parts of the surface of the transformer free. To ensure that the transformer is completely encased, the mains adapter of the generic type therefore additionally comprises a housing which surrounds the partly encased transformer in part with a spacing. The mains adapter therefore has a relatively large volume. Its production requires insertion of the transformer into the housing after preliminary injection moulding steps, in which, on the one hand, the transformer was completed and, on the other hand, the parts of the housing were produced, and is therefore relatively complicated.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a mains adapter of the generic type which can be designed to be very small and can be produced simply and cheaply. This object is achieved by an integral plastic casing completely enclosing the transformer in an abutting manner, so as to permit only contact elements and connections to extend through the casing and connect to the transformer. In addition, the present invention intended to provide a particularly suitable, very simple and cheap method for the production of a mains adapter. These exemplary objects the invention. This object are achieved by the steps providing a transform including an iron core, a primary winding, and a secondary winding; providing a coil former configured for supporting the iron core, the primary winding and the secondary winding of the transformer; providing an integral shell shaped for covering at least one portion of an outer surface of the transformer; arranging the transformer and the coil former in an injection mould while the coil former supports the iron core, primary winding and secondary winding of the transformer; and moulding the integral shell onto the transformer and the coil former so as to form an integral plastic casing completely enclosing the transformer in an abutting manner, thereby permitting only contact elements and connections to extend through the casing and connect to the transformer.
The advantages achieved by the present invention lie essentially in the fact that no additional housing is required. As a result the mains adapter according to the invention is very small and light and hence easy to accommodate and convenient to transport. Moreover, the mains adapter of the present invention is not only extremely stable, with regard to mechanical or structural properties, but also meets the usual safety requirements with regard to its electrical properties. The mains adapter of the present invention also removes heat in an improved manner. In addition, the present invention includes manufacturing such a main adapter in an extremely simple manner and consuming materials in an efficient matter.
REFERENCES:
patent: 2930011 (1960-03-01), Wigert et al.
patent: 2942214 (1960-06-01), Fruengel
patent: 3467929 (1969-09-01), Derbyshire et al.
patent: 3585450 (1971-06-01), Lane
patent: 0 485 341 A1 (1992-05-01), None
Aspro Technology AG
Finnegan Henderson Farabow Garrett & Dunner L.L.P.
Mai Anh
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