Power pack

Claim 2

A power pack for use with a small electrical appliance to to reduce line voltage and provide a low operating voltage, said power pack comprising a transformer subassembly enclosed within a case and cover assembly from which project primary terminals for plugging into a wall outlet and a secondary line cord or terminals for connection to the appliance, said transformer subassembly including a bobbin molded for electrical insulating material, primary and secondary windings on the bobbin, secondary soldering lugs anchored to the bobbin and connected to the secondary winding and the secondary line cord, primary terminals carried in channels formed in the bobbin connected to the primary winding, a laminated iron core fastened to the bobbin and surrounding the windings, insulating flanges integrally formed on the bobbin for insulating the laminated core from the primary terminals and the secondary lugs, locating holes in said laminated core, said case and cover assembly including transformer locating pins for engaging said laminated core locating holes to orient the transformer subassembly within the case and cover assembly, said cover including openings for the primary terminals to project therethrough, and means on the cover coacting with the bobbin to lock the terminals in the channels and inhibit movement thereof.

Claim 3

The combination as defined in claim 1, wherein support means within the case and on the cover coact with the locating pins to prevent movement of the transformer subassembly relative the casing.

Claim 4

The combination as defined in claim 2, wherein said primary terminals include prongs that engage the wall outlet and anchor portions extending at right angles to the prongs for anchoring the terminals in the channels.

Claim 5

The combination as defined in claim 1, wherein said cover means includes primary terminal locking pins engaging the bobbin at the primary terminals to squeeze the channels in which the primary terminals are located.

Claim 6

The combination as defined in claim 1, wherein said cover means includes primary terminal locking pins engaging the bobbin and the terminals to lock the terminals to the bobbin.

Claim 7

The combination as defined in claim 1, wherein said channels are defined by opposed walls and said terminal locking means including primary terminal locking pins such that when the cover is in closed position relative the case said locking pins engage one of the channel walls to move it toward the other channel wall and frictionally grip the terminals therein.

Claim 8

The combination as defined in claim 1, wherein the cover is sonically welded to the case.

Claim 9

The combination as defined in claim 1, wherein the cover is glued to the case.

Claim 10

The combination as defined in claim 3, wherein the cover is sonically welded to The case.

Claim 11

The combination as defined in claim 3, wherein said channels are defined by opposed front and back walls, said front wall and said terminal anchor portion having aligned holes, and said terminal locking means including primary terminal locking pins such that when the cover is in closed position relative the case said locking pins enter the holes of said channel walls and anchor portions to lock the terminals in place on the bobbin.

Claim 12

A power pack for use with a small electrical appliance to reduce line voltage and provide a low operating voltage, said power pack comprising a transformer subassembly enclosed within a case and cover assembly from which project primary terminals for plugging into a wall outlet and a secondary line cord or terminals for connection to the appliance, said transformer subassembly including a bobbin molded of electrical insulating material, primary and secondary windings on the bobbin, secondary soldering lugs and anchored to the bobbin and connected to the secondary winding and the secondary line cord, primary terminals carried in channels formed in the bobbin connected to the primary winding, a laminated iron core fastened to the bobbin and surrounding the windings, insulating flanges integrally formed on the bobbin for insulating the laminated core from the primary terminals and the secondary lugs, locating holes in said laminated core, said case and cover assembly including means coacting with said laminated core locating holes to orient the subassembly within the case and cover assembly, said cover including openings for the primary terminals to project therethrough, and means on the cover coacting with the bobbin to lock the terminals in the channels and inhibit movement thereof.

Claim 13

A power pack for use with a small electrical appliance to reduce line voltage and provide a low operating voltage, said power pack comprising a transformer subassembly enclosed within a case and cover assembly from which project primary terminals for plugging into a wall outlet and a secondary line cord or terminals for connection to the appliance, said transformer subassembly including a bobbin molded of electrical insulating material, primary and secondary windings on the bobbin, secondary soldering lugs and anchored to the bobbin and connected to the secondary winding and the secondary line cord, primary terminals carried in channels formed in the bobbin connected to the primary winding, a laminated iron core fastened to the bobbin and surrounding the windings, insulating flanges integrally formed on the bobbin for insulating the laminated core from the primary terminals and the secondary lugs, locating holes in said laminated core, said case and cover assembly including means coacting with said laminated core locating holes to orient the subassembly within the case and cover assembly, said cover including openings for the primary terminals to project therethrough, and means on the cover coacting with the bobbin to lock the terminals in the channels and inhibit movement thereof.

Claim 14

The combination as defined in claim 11, wherein said subassembly orienting means includes locating pins extending from the case and cover.

Claim 15

The combination as defined in claim 11, wherein said subassembly orienting means includes rivets extending through said case and cover and which also locks the cover and case together.

Claim 16

The combination as defined in claim 11, wherein said subassembly orienting means includes rivet holes in the case and cover, and rivets extending through the holes and the laminated core locating holes to orient the subassembly and lock the cover and case together.

Claim 17

A power pack for use with a small electrical appliance to reduce line voltage and provide a low operating voltage, said power pack comprising a case and cover assembly and a transformer subassembly enclosed within the case and cover assembly, said transformer subassemby including a one-piece bobbin molded of electrical insulating materials having a body and a plurality of winding and electrical insulating flanges, primary and secondary windings on the bobbin body within the winding flanges, a laminated iron core fastened to the bobbin and surrounding the windings, secondary soldering lugs, one of said winding flanges including means receiving and anchoring said secondary soldering lugs to the bobbin, a secondary line cord, means connecting said secondary line cord and said secondary winding to said lugs, opening means in the case and cover assembly through which said cord projects, one of said electrical insulating flanges insulating the secondary lugs from the laminated core, primary terminals having prongs extending through opening means in the case and cover assembly for engaging in an electrical outlet and anchoring portions within the case and cover assembly extending substantially at right angles to the prongs, another of said electrical insulating flanges, having L-shaped channels receiving said anchoring portions and a part of said prongs of the primary terminals and insulating said primary terminals from the laminated core, each said channel including a first portion coextensive with the primary terminal prong and receiving part of said prong and a second portion at right angles to the first portion receiving the primary terminaL anchoring portion whereby pull forces exerted on the prong during disengagement of same from an electrical outlet are transmitted through said anchoring portion of the primary terminal and second portion of the channel to the bobbin of the transformer subassembly, means on the transformer subassembly coacting with means on the case and cover assembly to orient the subassembly within the case and cover assembly, and means on the case and cover assembly coacting with the bobbin to lock the primary terminals in the channels and inhibit movement thereof.

Claim 18

A power pack for use with a small electrical appliance to reduce line voltage and provide a low operating voltage, said power pack comprising a case and cover assembly and a transformer subassembly enclosed within the case and cover assembly, said transformer subassemby including a one-piece bobbin molded of electrical insulating materials having a body and a plurality of winding and electrical insulating flanges, primary and secondary windings on the bobbin body within the winding flanges, a laminated iron core fastened to the bobbin and surrounding the windings, secondary soldering lugs, one of said winding flanges including means receiving and anchoring said secondary soldering lugs to the bobbin, a secondary line cord, means connecting said secondary line cord and said secondary winding to said lugs, opening means in the case and cover assembly through which said cord projects, one of said electrical insulating flanges insulating the secondary lugs from the laminated core, primary terminals having prongs extending through opening means in the case and cover assembly for engaging in an electrical outlet and anchoring portions within the case and cover assembly extending substantially at right angles to the prongs, another of said electrical insulating flanges, having L-shaped channels receiving said anchoring portions and a part of said prongs of the primary terminals and insulating said primary terminals from the laminated core, each said channel including a first portion coextensive with the primary terminal prong and receiving part of said prong and a second portion at right angles to the first portion receiving the primary terminaL anchoring portion whereby pull forces exerted on the prong during disengagement of same from an electrical outlet are transmitted through said anchoring portion of the primary terminal and second portion of the channel to the bobbin of the transformer subassembly, means on the transformer subassembly coacting with means on the case and cover assembly to orient the subassembly within the case and cover assembly, and means on the case and cover assembly coacting with the bobbin to lock the primary terminals in the channels and inhibit movement thereof.

Claim 19

The power pack defined in claim 15, wherein the primary terminals are oriented relative the laminated core such that the prongs extend substantially at right angles to the core.