High integration assembly process for AC adapter with foldable prongs

An AC (Alternating Current) adapter for powering an Information Handling System (IHS), the AC adapter comprising:

• an AC/DC converter;
• an AC cord, wherein the AC cord is connected to the AC/DC converter at a first end and connected to an AC plug at a second end;
• and
• the AC plug comprising:
• a cover comprising a plurality of slots;
• a PCB (printed circuit board) connecting the AC plug to the AC cord;
• wherein the PCB comprises a plurality of contact pads;
• a plurality of spring mounted terminals, wherein a first end of each of the spring mounted terminals is positioned on one of the plurality of contact pads, and wherein the spring mounted terminals are positioned based on an alignment of the second end of each of the spring mounted terminals with an alignment structure of the cover;
• and
• a plurality of prongs conforming to receptacles of an AC outlet, wherein:
• in an extended position, the plurality of prongs are insertable in the receptacles of the AC outlet and each of the plurality of prongs contacts a respective spring mounted terminal that is coupled to the PCB;
• and
• in a retracted position, the plurality of prongs are recessed in the plurality of slots of the cover and each of the plurality of prongs does not contact the respective spring mounted terminals.

A method of assembling an AC (Alternating Current) plug for providing power via a power circuit, the method comprising:

• positioning an inner side of a cover for the AC plug in an upwards orientation, wherein the inner side of the cover comprises structures for receiving a PCB (printed circuit board) and for receiving a plurality of spring mounted terminals, and wherein the cover comprises a plurality of slots;
• securing a plurality of foldable prongs to the inner side of the cover, wherein the prongs protrude from the outer side of the cover in an extended position, and wherein the prongs are recessed within the slots in a retracted position;
• positioning the PCB on the cover, wherein the PCB comprises a plurality of contact pads connecting the PCB to the power circuit;
• positioning the plurality of spring mounted terminals on the inner side of the cover, wherein a first end of each spring mounted terminal is positioned on a contact pad of the PCB;
• positioning a cap on the spring mounted terminals, the PCB and the cover, wherein assembly holes of the cap, the PCB and the cover are aligned;
• and
• fastening the cap to the cover, wherein the first end of each spring mounted terminal is secured against a respective positioned contact pad.