U.S. patent application number 17/529845 was filed with the patent office on 2022-06-02 for electric appliance and adapter.
The applicant listed for this patent is SOLUM CO., LTD.. Invention is credited to Young Jun Jang, Sang Keun Ji, Hyun Su Kim, Pill Ju Kim, Jun Kyu Lee, Dong Kyun Ryu.
Application Number | 20220173560 17/529845 |
Document ID | / |
Family ID | |
Filed Date | 2022-06-02 |
United States Patent
Application |
20220173560 |
Kind Code |
A1 |
Jang; Young Jun ; et
al. |
June 2, 2022 |
ELECTRIC APPLIANCE AND ADAPTER
Abstract
Provided are an electric appliance and a method of manufacturing
the same, the electric appliance having a smaller size and a
reduced overall weight by preventing a fluid from flowing into a
space unrelated to a heating component in a state where the fluid
fills its case. The electric appliance includes: a case including a
first space and a second space communicated to each other; a first
component disposed in the first space; a second component disposed
in the second space; a connection portion electrically connecting
the first component and the second component to each other; and a
potting pattern including a resin material and formed in the first
space.
Inventors: |
Jang; Young Jun;
(Gyeonggi-do, KR) ; Kim; Hyun Su; (Gyeonggi-do,
KR) ; Lee; Jun Kyu; (Gyeonggi-do, KR) ; Kim;
Pill Ju; (Gyeonggi-do, KR) ; Ji; Sang Keun;
(Gyeonggi-do, KR) ; Ryu; Dong Kyun; (Seoul,
KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SOLUM CO., LTD. |
Gyeonggi-do |
|
KR |
|
|
Appl. No.: |
17/529845 |
Filed: |
November 18, 2021 |
International
Class: |
H01R 31/06 20060101
H01R031/06; H01R 13/533 20060101 H01R013/533; H02J 7/00 20060101
H02J007/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 2, 2020 |
KR |
10-2020-0166351 |
Claims
1. An electric appliance comprising: a case including a first space
and a second space communicated to each other; a first component
disposed in the first space; a second component disposed in the
second space; a connection portion electrically connecting the
first component and the second component to each other, and
extending from the second space to the first space; a potting
pattern including a resin material and formed in the first space; a
partition wall disposed between the first space and the second
space in the case to separate the first space and the second space
from each other; and a step portion formed on a boundary line
between the first space and the second space by a difference in a
width of the case in the first space between a width of the case in
the second space, wherein the partition wall is disposed on the
step portion, either a guide portion or a partition-wall guide
portion is formed on at least one of the step portion and the
partition wall, the guide portion being formed by making one
surface of the step portion to be recessed and the partition-wall
guide portion being formed by making a predetermined region of the
partition-wall to be recessed inward, and the connection portion is
disposed between the step portion and the partition wall, by being
disposed in at least one of the guide portion and the
partition-wall guide portion.
2. The electric appliance of claim 1, wherein a filling pattern
having a lower specific gravity than the potting pattern is
disposed in the second space.
3. The electric appliance of claim 2, wherein the filling pattern
includes a plurality of air bubbles.
4. The electric appliance of claim 1, wherein the potting pattern
has a viscosity of 50 gf/10 mm or more and 1000 gf/10 mm or
less.
5. The electric appliance of claim 1, wherein the case includes an
observation window formed at a predetermined position in the first
space for checking a filling amount of the potting pattern.
6. The electric appliance of claim 1, wherein the case includes a
fluid level indicator formed in the first space, the fluid level
indicator having a scale shape and indicating an appropriate fluid
level of the potting pattern.
7. The electric appliance of claim 1, wherein the first component
has a maximum heating temperature higher than the second
component.
8. The electric appliance of claim 1, wherein the partition wall
includes an adhesive portion attached to the step portion.
9. The electric appliance of claim 1, wherein the partition wall
has a smaller thickness than the case.
10. The electric appliance of claim 1, wherein the partition
includes a reinforcing portion crossing a central portion of one
surface of the partition wall.
11. The electric appliance of claim 1, wherein a central portion of
the partition wall has the convex curved surface.
12. The electric appliance of claim 1, wherein a central portion of
the partition wall protrudes to form a step.
13. An adapter comprising: a case including a first space and a
second space; a heating component disposed in the first space; a
partition wall disposed between the first space and the second
space in the case to separate the first space and the second space
from each other and has a hole, a potting pattern provided in the
first space and consist of a resin material; a connection portion
extends from the second space to the first space through the hole
and electrically connected to the heating component; and a packing
member interposed between the hole and the connection portion.
14. The adapter of claim 13, wherein the potting pattern covers one
surface of the partition wall.
15. The adapter of claim 13, wherein the second space is filled
with air.
16. The adapter of claim 13, wherein a filling pattern including a
foaming agent is formed in the second space.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn. 119
to Korean Patent Application No. 10-2020-0166351, filed on Dec. 2,
2020, in the Korean Intellectual Property Office, the disclosure of
which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] The following disclosure relates to an electric appliance,
and more particularly, to an electric appliance or an adapter
including a partition wall preventing a fluid, provided for the
heat radiation and heat dissipation of a component installed in its
case, from being deviated from a predetermined region.
BACKGROUND
[0003] It is a trend that an electric appliance has a smaller size,
lighter weight and larger capacity day by day. In particular, there
is a high demand for a charger charging a mobile device to have a
smaller size, lighter weight and larger capacity. Hereinafter, the
electric appliance is described based on the charger which is its
representative example. However, a scope of the present disclosure
is not limited to the charger.
[0004] In recent years, the mobile device has larger capacity and
consumes more power, and a battery which is a power source of the
mobile device is thus required to have increased capacity and
shorter charging time. When an output capacity of the charger is
increased to satisfy this demand, its maximum heating temperature
may be increased. In general, the electric appliance may use a case
as a heat sink to dissipate its internal heat to the outside,
thereby lowering a temperature of its internal component. However,
for the electric appliance in which a user may touch its case such
as the charger, the case that the user may touch is required to
maintain its surface temperature lower to a predetermined level
(e.g., 50 degrees) or less to prevent a low-temperature burn of the
user. There may thus be a restriction on using the case as the heat
sink.
[0005] A conventional charger may have a size large enough to
dissipate the heat by using a natural convection phenomenon in the
charger. However, in this conventional charger, an internal
component of the charger may be continuously exposed to an
excessively-high temperature, and the component continuously
exposed to the excessively-high temperature for a long time may
have a short lifespan, malfunction or damage. Moreover, when the
charger has a larger capacity and a smaller size, it may cause an
increased amount of the heat generated in the internal component, a
reduced distance between the internal components, and a narrower
space between the internal component and the case. Here, a problem
of the excessively-high temperature in the charger may become more
serious, and it may thus be difficult to allow the charger to
achieve the larger capacity and the smaller size.
[0006] In addition, when the smaller-sized charger has the case
filled with a fluid having high thermal conductivity to dissipate
the heat, it may be difficult to insert a fluid injection nozzle
into the case due to the narrower separation space among the
component, a substrate and the case. In this case, it may be
difficult to evenly inject the fluid, and an air pocket may easily
occur in a space among the component, the substrate and the fluid,
thus reducing heat radiation performance.
[0007] In addition, in order to solve the above problem, the fluid
having high thermal conductivity may first be injected into the
case in which the component and the substrate are yet to be
assembled to each other, and the component and substrate may then
be inserted into the case to be assembled to each other. In this
case, a portion in which an electrical terminal, the component and
the substrate, disposed in the case, are in contact with one
another may be immersed in the fluid. Alternately, the component
and the substrate may be assembled to each other in a state of
being stained with the fluid thereon. The portion in which the
component, the substrate and the terminal are in contact with one
another may thus have poor contact due to the fluid.
[0008] In addition, when filled up with the fluid having high
thermal conductivity, the charger may easily dissipate the heat,
but may have increased weight.
[0009] In addition, when the case of the charger has a single
internal space, the fluid may fill even a region which does not
relatively need to be filled with the fluid having thermal
conductivity, such as a region where neither the component nor the
substrate is disposed in the charger, thereby making the charger
difficult to have the lighter weight.
[0010] In addition, in order to satisfy a standard of no failure
when dropped from a predetermined height, it is required for the
charger to have the lighter weight and to have the internal
component and the substrate, protected from falling impact.
However, the charger may be required to further have a support
member fixing and protecting the component and the substrate, and
may thus be difficult to have the reduced size and weight.
[0011] In addition, as the charger has the smaller size, it is
difficult to secure a separation distance between the components
for securing electrical insulation between the components disposed
in the charger.
SUMMARY
[0012] An exemplary embodiment of the present disclosure is
directed to providing an electric appliance having a smaller size
and a reduced overall weight by preventing a fluid from flowing
into a space unrelated to a heating component in a state where the
fluid fills its case, and a method of manufacturing the same.
[0013] In one general aspect, an electric appliance includes: a
case including a first space and a second space communicated to
each other; a first component disposed in the first space; a second
component disposed in the second space; a connection portion
electrically connecting the first component and the second
component to each other, and extending from the second space to the
first space; a potting pattern including a resin material and
formed in the first space; a partition wall disposed between the
first space and the second space in the case to separate the first
space and the second space from each other; and a step portion
formed on a boundary line between the first space and the second
space by a difference in a width of the case in the first space
between a width of the case in the second space, wherein the
partition wall is disposed on the step portion, either a guide
portion or a partition-wall guide portion is formed on at least one
of the step portion and the partition wall, the guide portion being
formed by making one surface of the step portion to be recessed and
the partition-wall guide portion being formed by making a
predetermined region of the partition-wall to be recessed inward,
and the connection portion is disposed between the step portion and
the partition wall, by being disposed in at least one of the guide
portion and the partition-wall guide portion.
[0014] A filling pattern having a lower specific gravity than the
potting pattern may be disposed in the second space.
[0015] The filling pattern may include a plurality of air
bubbles.
[0016] The potting pattern may have a viscosity of 50 gf/10 mm or
more and 1000 gf/10 mm or less.
[0017] The case may include an observation window formed at a
predetermined position in the first space for checking a filling
amount of the potting pattern.
[0018] The case may include a fluid level indicator formed in the
first space, the fluid level indicator having a scale shape and
indicating an appropriate fluid level of the potting pattern.
[0019] The first component may have a maximum heating temperature
higher than the second component.
[0020] The partition wall may include an adhesive portion attached
to the step portion.
[0021] The partition wall may have a smaller thickness than the
case.
[0022] The partition may include a reinforcing portion crossing a
central portion of one surface of the partition wall.
[0023] A central portion of the partition wall may have the convex
curved surface.
[0024] A central portion of the partition wall may protrude to form
a step.
[0025] In another general aspect, an adapter includes: a case
including a first space and a second space; a heating component
disposed in the first space; a partition wall disposed between the
first space and the second space in the case to separate the first
space and the second space from each other and has a hole, a
potting pattern provided in the first space and consist of a resin
material; a connection portion extends from the second space to the
first space through the hole and electrically connected to the
heating component; and a packing member interposed between the hole
and the connection portion.
[0026] The potting pattern may cover one surface of the partition
wall.
[0027] The second space may be filled with air.
[0028] A filling pattern including a foaming agent may be formed in
the second space.
[0029] Other features and aspects will be apparent from the
following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is an exploded perspective view of an electric
appliance according to the present disclosure.
[0031] FIG. 2 is a cross-sectional view of a portion taken along
x-z axes of the electric appliance according to a first exemplary
embodiment of the present disclosure.
[0032] FIG. 3 is a cross-sectional view of a portion taken along
y-z axes of the electric appliance according to a first exemplary
embodiment of the present disclosure.
[0033] FIGS. 4A to 4D are front views of a partition wall according
to the first and second exemplary embodiments and cross-sectional
views of a partition wall according to third and fourth exemplary
embodiments according to the present disclosure.
[0034] FIGS. 5A to 5D are enlarged cross-sectional views of portion
A of FIG. 3 according to various exemplary embodiments of the
present disclosure.
[0035] FIG. 6 is a cross-sectional perspective view of the electric
appliance according to an exemplary embodiment of the present
disclosure.
[0036] FIG. 7 is a cross-sectional view of the electric appliance
according to an exemplary embodiment of the present disclosure.
[0037] FIG. 8 is another cross-sectional view of the electric
appliance according to an exemplary embodiment of the present
disclosure.
DETAILED DESCRIPTION OF EMBODIMENTS
[0038] Hereinafter, the technical spirit of the present disclosure
will be described in more detail with reference to the accompanying
drawings. Terms and words used in the present specification and
claims are not to be construed as a general or dictionary meaning,
but are to be construed as meanings and concepts meeting the
technical ideas of the present disclosure based on a principle that
the inventors may appropriately define the concepts of terms in
order to describe their inventions in best mode.
[0039] Therefore, configurations described in exemplary embodiments
and the accompanying drawings of the present disclosure do not
represent all of the technical spirits of the present disclosure,
but are merely most preferable exemplary embodiments. Therefore,
the present disclosure should be construed as including all the
changes and substitutions included in the spirit and scope of the
present disclosure at the time of filing this application.
[0040] Hereinafter, the technical spirit of the present disclosure
will be described in more detail with reference to the accompanying
drawings. The accompanying drawings are only examples illustrated
in order to describe the technical idea of the present disclosure
in more detail. Therefore, the technical idea of the present
disclosure is not limited to forms of the accompanying
drawings.
[0041] Then, as shown in the drawings, the description defines a
longitudinal direction of the case as a z-(axis) direction, a
direction perpendicular to the z-(axis) direction as an x-(axis)
direction, and a direction perpendicular to z-(axis) direction and
the x-(axis) direction as a y-(axis) direction; and also defines
the z-(axis) direction as the longitudinal direction of a
substrate, the x-(axis) direction as a width direction thereof, and
the y-(axis) direction as a thickness direction thereof. In
addition, the description describes a positive direction in the
z-(axis) direction as an upper side in the longitudinal direction,
and a negative direction in the z-(axis) direction as a lower side
in the longitudinal direction.
[0042] Referring to FIGS. 1 to 3, an electric appliance according
to the present disclosure includes: a case 100 including a first
space 101 and a second space 102 communicated to each other; a
partition wall 200 which is a sheet separating the first space 101
and the second space 102 from each other; a first component 110
disposed in the first space 101; a second component 120 disposed in
the second space 102; a connection portion 300 electrically
connecting the first component 110 and the second component 120 to
each other; and a potting pattern 400 filling the first space 101
and having a viscosity greater than water.
[0043] The partition wall 200 may be a removable sheet disposed
between the first space 101 and the second space 102 to prevent the
potting pattern 400 from flowing into the second space 102 when the
potting pattern 400 is formed in the first space 101 in a state
where the first space 101 is disposed above the second space
102.
[0044] The case 100 may include the first space 101 in which the
first component 110 is disposed and the second space 102 in which
the second component 120 is disposed. The partition wall 200 may be
coupled to and detached from the case 100, and may allow the first
space 101 and the second space 102 to be separated from each other,
thereby preventing the potting pattern 400 formed in the first
space 101 from flowing into the second space 102.
[0045] Although not shown, the case 100 may include an inner case
and an outer case, and a heat shielding means may be disposed
between the inner case and the outer case to lower a surface
temperature of the outer case to prevent a low-temperature burn of
a user.
[0046] The first component 110 may include a substrate (i.e.
printed circuit board, PCB) on which a heating element such as a
switch or a transformer is mounted, and the second component 120
may include a plug and a bus bar connected to the plug. The
connection portion 300 may electrically connect the first component
110 and the second component 120 to each other. The connection
portion 300 may connect the first component 110 and the second
component 120 to each other by penetrating through the partition
wall 200. Alternatively, the connection portion 300 may connect the
first component 110 and the second component 120 to each other
without penetrating through the partition wall 200. Here, the
connection portion 300 may be, for example, a connector or a bus
bar.
[0047] The potting pattern 400 may be formed in the first space
101, and may disperse and radiate heat generated in the first
component 110. It may be preferable that at least a portion of the
first component 110 is immerged in the potting pattern 400 and then
assembled to the case 100.
[0048] The potting pattern may include a resin having thermal
conductivity, and the thermal conductivity may be about 1.5 W/mK or
more, about 2 W/mK or more, 2.5 W/mK or more, 3 W/mK or more, 3.5
W/mK or more or 4 W/mK or more.
[0049] In addition, the potting pattern may include a resin
including a filler component having excellent thermal conductivity
(1 W/mK or more). Here, the filler may include ceramic, alumina,
aluminium nitride (AIN), boron nitride (BN), silicon nitride, zinc
oxide (ZnO), silicon carbide (SiC) or beryllium oxide (BeO).
[0050] The potting pattern may include an acrylic resin, an
epoxy-based resin, a urethane-based resin, an olefin-based resin,
an ethylene-vinyl acetate copolymer (EVA)-based resin, or a
silicone-based resin. The potting pattern may also include a
thixotropic agent, a diluent, a dispersant, a surface treatment
agent, a flame retardant or a coupling agent.
[0051] The potting pattern may preferably have an elongation of
about 10% or more in consideration of impact resistance and
vibration resistance.
[0052] In addition, the potting pattern may have 400 degrees C. or
more of a 5% weight loss temperature in thermogravimetric analysis
(TGA), or a residual amount of 70 wt % or more at 800 degrees C.,
to have ensured stability at a high temperature.
[0053] The potting pattern may preferably have adhesiveness of 100
gf/10 mm or more in order not to be separated from the substrate
and/or the component mounted on the substrate.
[0054] Based on the above configuration, an electric appliance
according to the present disclosure may radiate and dissipate the
heat generated in the first component 110 mounted in the first
space 101 by filling the first space 101 with the potting pattern
400. When a portion of the first space 101, where the potting
pattern 400 is not formed, may be defined as a third space, the
third space may be filled with air.
[0055] In addition, a space filled with the potting pattern 400 may
be restricted to the first space 101 due to such a configuration of
the partition wall 200, and the second space 102 may be maintained
empty, thereby reducing an overall weight of the electric
appliance. Therefore, the electric appliance may have a center of
gravity maintained as the first space 101 to prevent the component
such as a plug connected to the second space 102 from being bent or
damaged even when dropped.
[0056] Here, the first component 110 may have a maximum heating
temperature higher than the second component 120. That is, when the
first component 110 and the second component 120 are electrically
connected to each other and then operated by the connection portion
300, the first component 110 may have the higher maximum heating
temperature than the second component 120, and may have a larger
heating area than the second component 120. Here, it is preferable
that the second component 120 is heated to a relatively low
temperature compared to the first component 110, and has no need to
radiate the heat therefrom. Accordingly, the potting pattern 400
may fill only the first space 101 to radiate and dissipate the heat
generated in the first component 110.
[0057] In addition, the potting pattern 400 may be cured to form a
potting layer. That is, the potting pattern 400 may be in a liquid
or viscosity state before filling the first space 101, and may be
cured when filling the first space 101 to form the potting layer
having predetermined strength and elasticity.
[0058] Here, the potting pattern 400 before being cured may have a
viscosity of 50 gf/10 mm or more and 1000 gf/10 mm or less.
[0059] Referring to FIG. 3, the second space 102 may have a smaller
cross-sectional area than the first space 101, thereby forming a
step portion 130 on a boundary line between the second space 102
and the first space 101, and the partition wall 200 may be seated
on the step portion 130 in a direction of the first space 101. That
is, when comparing cross-sectional areas of the first space 101 and
the second space 102, taken in a direction (i.e. x-(axis) direction
or y-(axis) direction) perpendicular to an extension direction
(i.e. z-(axis) direction) of the case 100, the cross-sectional area
of the first space 101 may be larger than that of the second space
102. The step portion 130 may be formed on the boundary line
between the first space 101 and the second space 102 by a
difference in the cross-sectional area of the first space 101
between that of the second space 102. The first component 110
installed in the first space 101 may have a larger size than the
second component 120 installed in the second space 102. To this
end, the cross-sectional area of the first space 101 and that of
the second space 102 may be formed to have different sizes from
each other, thereby making it possible for the electric appliance
of the present disclosure to reduce the overall size and weight of
the case 100.
[0060] Here, it may be preferable that the partition wall 200 is
installed on the step portion 130, a maximum cross-sectional area
of the second space 102 is smaller than a minimum cross-sectional
area of the first space 101, and the cross-sectional area of the
partition wall 200 is smaller than the minimum cross-sectional area
of the first space 101, and larger than the maximum cross-sectional
area of the second space 102.
[0061] In addition, a thickness of the partition wall 200 may be
smaller than a minimum thickness of the case 100. The case 100 is
required to protect the first component 110 and the second
component 120, respectively disposed in the first space 101 and the
second space 102, and to have predetermined strength and impact
resistance to withstand a gripping pressure of the user. On the
contrary, the partition wall 200 only needs to withstand a weight
of the potting pattern 400 or to be maintained until the potting
pattern 400 is cured. It may thus be preferable that the thickness
of the partition wall 200 is smaller than the minimum thickness of
the case 100 to reduce the weight and size of the electric
appliance.
[0062] Here, the partition wall 200 may have a lower specific
gravity than the case 100. That is, the thickness of the partition
wall 200 is smaller than the minimum thickness of the case 100, and
a specific gravity of the partition wall 200 may be lower than that
of the case 100.
[0063] In addition, flexibility of the partition wall 200 may be
greater than that of the case 100. That is, the thickness of the
partition wall 200 may be smaller than the minimum thickness of the
case 100, and simultaneously its flexibility may be greater than
that of the case 100. It is thus possible to prevent the partition
wall 200 from being cracked or damaged even if the partition wall
200 is bent in a direction of the second space 102 due to the
weight of the potting pattern 400.
[0064] Referring to FIG. 4A, when the partition wall 200 has the
greater flexibility than the case 100, the partition wall 200 may
further include a reinforcing portion 210 crossing its central
portion. That is, when the partition wall 200 has the smaller
thickness than the case 100 and has the predetermined flexibility,
the partition wall 200 may be bent in the direction of the second
space 102 due to the weight of the potting pattern 400. Here, in
order to prevent the partition wall 200 from being bent to be
separated from the step portion 130, the reinforcing portion 210
having an `X` shape may be formed on a surface of the partition
wall 200, in contact with the step portion 130.
[0065] Referring to FIG. 4B, when the partition wall 200 has the
greater flexibility than the case 100, the partition wall 200 may
include an adhesive portion 220 attached to the step portion 130.
That is, when the partition wall 200 has the smaller thickness than
the case 100 and has the predetermined flexibility, the partition
wall 200 may be bent in the direction of the second space 102 due
to the weight of the potting pattern 400. Here, in order to prevent
the partition wall 200 from being bent to be separated from the
step portion 130, the adhesive portion 220 may be formed on an edge
of the surface of the partition wall 200, in contact with the step
portion 130, thereby maintaining a coupling between the partition
wall 200 and the step portion 130.
[0066] Referring to FIG. 4C, when the partition wall 200 has the
greater flexibility than the case 100, the partition wall 200 may
have the central portion convex in a direction of the first space
101. That is, when the partition wall 200 has the smaller thickness
than the case 100 and has the predetermined flexibility, the
partition wall 200 may be bent in the direction of the second space
102 due to the weight of the potting pattern 400. Here, the central
portion of the partition wall 200 has the convex shape in the
direction of the first space 101, thereby allowing the partition
wall 200 to be bent to a minimum in the direction the second space
102.
[0067] Referring to FIG. 4D, the central portion of the partition
wall 200 may protrude toward the upper side in the longitudinal
direction (i.e. positive direction in the z-(axis) direction) of
the case 100 to form a step.
[0068] In addition, the partition wall 200 may be made of
polycarbonate having a thickness of 0.05 mm or more and 3.0 mm or
less.
[0069] In addition, the partition wall 200 may have 80 degrees C.
or more as a thermal deformation temperature.
[0070] FIG. 5A shows an exemplary embodiment of the present
disclosure, in which a left view shows a guide portion 140, and a
right view shows a structure in which the guide portion 140 and the
connection portion 300 are connected to each other. Referring to
FIG. 5A, the step portion 130 may include the guide portion 140
which is formed in a predetermined region in contact with the
partition wall 200 and through which the connection portion 300
passes. The guide portion 140 may be formed by making the
predetermined region between the partition wall 200 seated on the
step portion 130 and the step portion 130 to be recessed. Here, the
connection portion 300 connected to the first component 110 through
the guide portion 140 may enter the second space 102 without
penetrating through the partition wall 200 to be electrically
connected to the second component 120. Here, when a gap is formed
between the connection portion 300 and the guide portion 140, a
packing member such as a gasket may be disposed in the gap to
prevent the potting pattern 400 from flowing into the second space
102 through the guide portion 140.
[0071] In addition, as shown in FIG. 5A, an air bubble 400a may be
formed in the potting pattern 400.
[0072] FIG. 5B shows another exemplary embodiment of the present
disclosure, in which a left view shows a hole 230, and a right view
shows a structure in which the hole 230 and the connection portion
300 are connected to each other. Referring to FIG. 5B, the
partition wall 200 may include the hole 230 through which the
connection portion 300 passes. The hole 230 may be formed at a
position corresponding to a point where the connection portion 300
and the first component 110 are connected to each other, and the
connection portion 300 may be connected to the first component 110
and connected to the second component 120 by penetrating through
the partition wall 200. Here, when a gap is formed between the hole
230 and the connection portion 300 penetrating through the hole
230, the packing member such as the gasket may be disposed in the
gap to prevent the potting pattern 400 from flowing into the second
space 102 through the guide portion 140. More specifically, the
packing member may be interposed between the hole and the
connection portion 300 to seal the gap formed between the hole and
the connection portion 300, and the packing member may be made of a
material such as rubber, synthetic resin, absestos, or the like.
Here, when there is another structure on a path where the first
component 110 and the second component 120 are connected to each
other by the connection portion 300, a through hole or an avoidance
structure may be installed for the connection portion to pass
through or avoid the corresponding structure.
[0073] FIG. 5C shows yet another exemplary embodiment of the
present disclosure, in which a left view shows a partition-wall
guide portion 240, and a right view shows a structure in which the
partition-wall guide portion 240 and the connection portion 300 are
connected to each other. Referring to FIG. 5C, the partition wall
200 may include a partition-wall guide portion 240 formed in a
portion of the partition wall 200, and through which the connection
portion 300 passes. The partition-wall guide portion 240 may be
formed by making a predetermined region of the partition wall 200
to be recessed inward. Here, the connection portion 300 connected
to the first component 110 through the partition-wall guide portion
240 may enter the second space 102 without penetrating through the
partition wall 200 to be electrically connected to the second
component 120. Here, when a gap is formed between the connection
portion 300 and the partition-wall guide portion 240, the packing
member such as the gasket may be disposed in the gap to prevent the
potting pattern 400 from flowing into the second space 102 through
the partition-wall guide portion 240.
[0074] FIG. 5D shows yet still another exemplary embodiment of the
present disclosure, in which a left view shows the guide portion
140 and the partition-wall guide portion 240, and a right view
shows a structure in which the guide portion 140, the
partition-wall guide portion 240 and the connection portion 300 are
connected to one another. In this exemplary embodiment, a guide
structure, through which the connection portion 300 connecting the
first space and the second space to each other may pass, may be
disposed on each of the partition wall 200 and the step portion
130. According to this exemplary embodiment, the guide structure
may be simultaneously formed on both the partition wall and the
step portion. Therefore, a space through which the connection
portion may pass may be secured as much as possible, and the
connection portion may thus be formed thick. As a result, it is
possible to stably supply power to the electric appliance.
[0075] Meanwhile, at least a portion of the partition wall 200 may
be made of a transparent or translucent material. After the
partition wall 200 is inserted into the case 100, the fluid
included in the potting pattern 400 may flow into the second space
102 in a process of providing the potting pattern 400 in the first
space 101. When the partition wall 200 is made of the transparent
or translucent material, it is possible to check the inflow of the
potting pattern 400 during an assembly process, thereby preventing
production of a defective or low-quality product.
[0076] Referring to FIG. 6, the case 100 may include an observation
window 150 formed at a predetermined position in the first space
101 for checking a filling amount of the potting pattern 400. The
observation window 150 may penetrate through the inner and outer
surfaces of the predetermined position of the case 100,
corresponding to the first space 101. Through the observation
window 150, it is possible to visually check the formed height and
state of the potting pattern 400 filling the first space 101 from
the outside. Here, a transparent or translucent sheet may be
mounted on the observation window 150 to prevent the potting
pattern 400 from leaking out of the case 100.
[0077] In addition, at least a portion of the case 100 may be made
of the transparent or translucent material. When at least a portion
of the case 100 is made of the transparent or translucent material,
it is possible to check, from the outside, how high the formed
height of the potting pattern 400 is and whether the potting
pattern 400 flows into the second space 102. As a result, it is
possible to prevent the production of the defective or low-quality
product in a process of manufacturing the electric appliance.
[0078] Referring to FIG. 7, the case 100 may include a fluid level
indicator 160 formed in the first space 101, the fluid level
indicator having a scale shape and indicating an appropriate fluid
level of the potting pattern 400. The fluid level indicator 160 may
indicate the appropriate amount and maximum amount of the potting
pattern 400 to fill the first space 101. It is thus possible to
visually check whether the potting pattern 400 fills the first
space 101 more than necessary or the potting pattern 400 is formed
in an amount lower than necessary. As a result, it is possible to
prevent the production of the defective or low-quality product
during the manufacturing process.
[0079] Referring to FIG. 8, an electric appliance according to the
present disclosure may include a filling pattern 500 having a lower
specific gravity than the potting pattern 400 in the second space
102, or made of air. Here, the filling pattern 500 may include air
or a foaming agent. When the crack occurs in the partition wall
200, or the partition wall 200 is deviated from its regular
position, the potting pattern 400 filling the first space 101 may
enter the second space 102. Here, the filling pattern 500 may fill
the second space 102, thereby preventing the potting pattern 400
from entering the second space 102.
[0080] Here, the filling pattern 500 may have the lower specific
gravity than the potting pattern 400. That is, in order to prevent
the second space 102 from having an excessively increased weight by
being filled with filling pattern 500, it is preferable that the
filling pattern 500 is made of a fluid having the specific gravity
different from that of the potting pattern 400, and has an amount
less than the potting pattern 400.
[0081] In addition, the filling pattern 500 may be a foaming agent
that is spread in a form of a bubble after filling an object, and
the filling pattern 500 may thus be spread after filling the second
space 102. Here, the filling pattern 500 may be made of a material
having a plurality of porosity. That is, the filling pattern 500
may include the plurality of air bubbles 400a.
[0082] Referring to FIGS. 2 and 3, an adapter according to the
present disclosure includes: a case 100 including a first space 101
and a second space 102; a heating component disposed in the first
space 101; a connection portion 300 disposed in the second space
102 and electrically connected to the heating component; and a
partition wall 200 disposed between the first space 101 and the
second space 102 in the case 100 to separate the first space 101
and the second space 102 from each other.
[0083] In addition, the adapter may further include a potting
pattern including a resin material and formed in the first space
101, in which the potting pattern 400 covers one surface of the
partition wall 200.
[0084] A method of manufacturing an electric appliance according to
the present disclosure includes: (a) preparing a case 100 including
a first space 101 and a second space 102 to which a second
component 120 is connected, (b) disposing a connection portion 300
electrically connected to the second component 120 in the case 100,
(c) disposing a partition wall 200, which is a sheet separating the
first space 101 and the second space 102 from each other, in the
case 100, (d) filling the first space 101 with a potting pattern
400 having a viscosity greater than water, and (e) inserting the
first component 110 into the first space 101 to be electrically
connected to the connection portion 300.
[0085] For reference, when the first component 110 is disposed in
the case 100 before the potting pattern 400 is injected into the
case, it is difficult to insert a nozzle for injecting the potting
pattern 400 due to a narrower space between the first component 110
and the case 100. In addition, it may be difficult to evenly inject
the potting pattern 400 in the first space 101, and an air pocket
may easily occur, thus reducing heat radiation performance. The
present disclosure may solve the above problem by first injecting
the potting pattern 400 into the case 100 in which the first
component 110 is not inserted.
[0086] Here, in the method of manufacturing an electric appliance
according to the present disclosure, the operation (b) may further
include (b-1) filling the second space 102 with a filling pattern
500 after electrically connecting the connection portion 300 to the
second component 120.
[0087] As set forth above, the exemplary embodiments of the present
disclosure may have the following effects:
[0088] (1) The partition wall may separate the first space that is
filled with the fluid and the second space that does not need to be
filled with the fluid from each other, thereby preventing more
fluid than necessary from filling the case or from flowing into the
second space. The case of the electric appliance may thus have the
smaller size and the reduced overall weight.
[0089] (2) In addition, compared to a case where the case itself
has a partition-wall shape, it may be easier to dispose a
connection portion (i.e. bus bar) that electrically connects the
components respectively disposed in the first space and the second
space to each other through the partition wall. It is thus possible
to assemble the components to each other more easily, and to
prevent the leakage of the potting pattern more effectively.
[0090] (3) The case may have the overall center of gravity
maintained as the first space to prevent the second space in which
the plug is formed from hitting the ground when dropped. In this
manner, it is possible to prevent the plug from being bent or
damaged.
[0091] (4) The reinforcing portion may be formed on the partition
wall, or the central portion of the partition wall has a convex
shape toward the first space. It is thus possible to prevent the
partition wall from being separated, cracked or damaged by the
weight of the potting pattern.
[0092] (5) The adhesive portion may be formed on the edge of the
partition wall and attached to an inner surface of the case to
prevent the partition wall from being separated from at a
predetermined position.
[0093] The present disclosure is not limited to the abovementioned
exemplary embodiments, but may be variously applied, and may be
variously modified without departing from the gist of the present
disclosure claimed in the claims.
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