An easy-to-manufacture USB Type-C connector and its manufacturing method

Abstract

The application belongs to the technical field of connectors, and in particular to a USB Type-C connector easy to produce and a production method. The application places a metal sheet between the first tongue and the second tongue before secondary injection molding, and uses the first positioning column and the second positioning column to be inserted into the first set of positioning holes and the second set of positioning holes of the metal sheet in a staggered manner to form cross interlocking, so that the superimposed body obtains reliable pre-positioning, and terminal deviation and plastic deformation are reduced from the source. Subsequently, an insulating base is integrally formed around the combination by secondary injection molding, forming a stepped portion and a plug-in portion, so that in-mold consolidation is used instead of traditional manual or automatic machine assembly, the production process is significantly shortened, and the degree of automation and dimensional consistency is improved; the annular gap between the waist-shaped sleeve body of the shell and the plug-in portion provides an accurate accommodation space for the standard Type-C male head, overall improves the product yield, reduces the manufacturing cost, and is suitable for mass production of USB Type-C connectors.

Description

Technical Field

[0001] This invention relates to the field of connector technology, specifically to an easy-to-manufacture USB Type-C connector and its manufacturing method. Background Technology

[0002] As the current mainstream interface standard, the manufacturing process of USB Type-C connectors directly affects product quality and production efficiency. Internally, they typically include two rows of terminals, insulators, a metal shield, and a housing. In traditional structures, the upper and lower rows of terminals are molded with their corresponding insulators, then stacked with the metal shield, and finally secured by the housing. The positioning between the insulator and the metal shield usually employs a simple post-hole alignment structure, with the relative positions of the stacked components maintained by the clamping force of the housing.

[0003] Therefore, we propose an easy-to-manufacture USB Type-C connector and manufacturing method to solve the above problems. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides an easy-to-manufacture USB Type-C connector and its manufacturing method, solving the problems mentioned in the background art regarding insufficient positioning constraints between the insulator and the metal sheet in traditional structures, which easily lead to relative displacement after stacking, affecting the terminal position accuracy; and the difficulty in balancing assembly convenience and structural stability in the fit between the outer shell and the internal insulator.

[0005] (II) Technical Solution To achieve the above objectives, the present invention specifically adopts the following technical solution: An easy-to-manufacture USB Type-C connector and its manufacturing method, comprising: Terminal assembly, including upper row of terminals, lower row of terminals, and upper and lower insulators respectively injection molded onto the upper row of terminals and the lower row of terminals in one step; A metal sheet is sandwiched between the upper insulator and the lower insulator; An insulating base is formed by secondary injection molding onto the assembly of the terminal assembly and the metal sheet, thus fixing the three together as one unit; The housing is fitted over the outside of the insulating base.

[0006] Furthermore, the upper insulator has a first base and a first tongue extending forward from the first base, the contact section of the upper row of terminals is embedded in the first tongue and the contact surface is exposed; the lower insulator has a second base and a second tongue extending forward from the second base, the contact section of the lower row of terminals is embedded in the second tongue and the contact surface is exposed; the metal sheet is clamped between the first tongue and the second tongue.

[0007] Furthermore, the metal sheet is provided with a first set of positioning holes and a second set of positioning holes; the bottom of the first tongue is provided with three first positioning posts, and the top of the second tongue is provided with three second positioning posts; two of the three first positioning posts are inserted into two holes of the first set of positioning holes, and the other is inserted into one hole of the second set of positioning holes; two of the three second positioning posts are inserted into two holes of the second set of positioning holes, and the other is inserted into one hole of the first set of positioning holes, forming an alternating positioning.

[0008] Furthermore, the insulating base at least covers the first tongue and the second tongue, and forms a stepped portion close to the first base and the second base, and a plug portion extending forward from the overlapping area of ​​the first tongue and the second tongue. The upper and lower surfaces of the plug portion expose the contact surfaces of the corresponding terminals, and a plurality of grooves are respectively provided on the upper and lower surfaces of the plug portion.

[0009] Furthermore, each of the two front ends of the metal sheet has an integrally extended latching arm, which extends out from the insulating base and protrudes from both sides of the plug-in portion.

[0010] Furthermore, the housing includes an inner shell and an outer shell, wherein the inner shell is annularly fitted at the junction of the stepped portion and the insertion portion and avoids the groove.

[0011] Furthermore, the outer shell has a waist-shaped sleeve that fits around the outer periphery of the stepped portion and extends forward to cover the insertion portion. A gap is left between the insertion portion and the inner wall surface of the outer shell. The inner wall of the outer shell is provided with snap-fit ​​parts that correspond to and engage with each groove.

[0012] Furthermore, the rear end of the housing is integrally formed with an upper bent piece and a lower bent piece. The upper bent piece extends rearward from the top of the rear end of the housing and passes around the top surface of the first base to one side. The lower bent piece extends rearward from the bottom of the rear end of the housing and passes around the bottom surface of the second base to the same side.

[0013] Furthermore, both ends of the upper row of terminals and both ends of the lower row of terminals are provided with strip connecting pieces to connect each row of terminals into one piece before secondary injection molding; after the insulating base is formed, each strip connecting piece is cut off, making each terminal independent of each other.

[0014] A method for manufacturing an easy-to-produce USB Type-C connector includes the following steps: S1. An upper row terminal assembly and a lower row terminal assembly are respectively manufactured by injection molding. The upper row terminal assembly includes an upper row of terminals and an upper insulator for holding the upper row of terminals. The lower row terminal assembly includes a lower row of terminals and a lower insulator for holding the lower row of terminals. S2. A metal sheet is sandwiched between the upper insulator and the lower insulator and positioned to form a composite body; S3. Perform secondary injection molding on the composite to form an insulating base, wherein the insulating base covers and fixes the terminal assembly and the metal sheet into one piece; S4. Cut off the strip connecting piece at the end of each terminal to separate the terminals from each other; S5. Assemble the housing on the insulating base.

[0015] (III) Beneficial Effects Compared with the prior art, the present invention provides a USB Type-C connector and manufacturing method that are easy to produce, and has the following beneficial effects: This invention involves placing a metal sheet between the first and second tongues before secondary injection molding, and using the first and second positioning posts to interlock in the first and second sets of positioning holes on the metal sheet, ensuring reliable pre-positioning of the assembly and reducing terminal misalignment and plastic deformation at the source. Subsequently, an insulating base is integrally molded around the assembly through secondary injection molding, forming a stepped portion and a plug-in portion. This in-mold consolidation replaces traditional manual or automated assembly, significantly shortening the production process and improving automation and dimensional consistency. The annular gap between the waist-shaped sleeve and the plug-in portion provides precise space for the standard Type-C male connector, improving overall product yield, reducing manufacturing costs, and making it suitable for mass automated production of USB Type-C connectors. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the finished product structure of the terminal assembly, metal sheet, insulating base, and housing of the present invention. Figure 2 This is a side view of the finished product structure of the terminal assembly, metal sheet, insulating base, and housing of the present invention. Figure 3 This is a schematic diagram of the upper and lower row of terminals of the present invention; Figure 4 This is a schematic diagram of the upper and lower insulator structures of the present invention; Figure 5 This is a schematic diagram of the stacking process of the terminal assembly and the metal sheet of the present invention; Figure 6 This is a schematic diagram of the stacking process of the terminal assembly and the metal sheet of the present invention; Figure 7 This is a schematic diagram of the terminal assembly and metal sheet stacked together according to the present invention; Figure 8 This is a schematic diagram of the insulating base structure of the present invention; Figure 9 This is a schematic diagram of the secondary molding state of the insulating base and terminal assembly of the present invention; Figure 10 This is a schematic diagram of the assembly of the insulating base and the housing of the present invention.

[0017] In the diagram: 1. Terminal assembly; 11. Upper row of terminals; 12. Lower row of terminals; 13. Upper insulator; 14. Lower insulator; 15. First base; 151. First guide post; 16. First tongue; 161. First positioning post; 17. Second base; 171. Second guide post; 18. Second tongue; 181. Second positioning post; 2. Metal sheet; 21. First set of positioning holes; 22. Second set of positioning holes; 3. Insulating base; 31. Stepped portion; 32. Insertion portion; 33. Groove; 34. Snap-on arm; 4. Housing; 41. Inner shell; 42. Outer shell; 43. Snap-on component; 44. Upper bending piece; 45. Lower bending piece; 5. Strip connecting piece. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example like Figure 1-10 As shown, one embodiment of the present invention provides an easy-to-manufacture USB Type-C connector, comprising: Terminal assembly 1 includes an upper row of terminals 11, a lower row of terminals 12, and an upper insulator 13 and a lower insulator 14 respectively injection molded onto the upper row of terminals 11 and the lower row of terminals 12 in one step; Metal sheet 2 is sandwiched between the upper insulator 13 and the lower insulator 14; The insulating base 3 is formed by secondary injection molding onto the assembly of the terminal assembly 1 and the metal sheet 2, thus fixing the three together as one. The housing 4 is fitted over the outside of the insulating base 3.

[0020] like Figure 1-10 As shown, in some embodiments, the upper insulator 13 has a first base 15 and a first tongue 16 extending forward from the first base 15, and the contact section of the upper row of terminals 11 is embedded in the first tongue 16 with the contact surface exposed; the lower insulator 14 has a second base 17 and a second tongue 18 extending forward from the second base 17, and the contact section of the lower row of terminals 12 is embedded in the second tongue 18 with the contact surface exposed; the metal sheet 2 is clamped between the first tongue 16 and the second tongue 18.

[0021] During injection molding, the upper insulator 13 and the lower insulator 14 respectively hold the upper row of terminals 11 and the lower row of terminals 12. The first base 15 of the upper insulator 13 and the second base 17 of the lower insulator 14 provide structural support and assembly reference for the terminal assembly 1. The first tongue 16 and the second tongue 18 respectively carry the contact sections of the corresponding terminals, extending forward, with the terminal contact surfaces exposed from the tongue surfaces. The metal sheet 2 is clamped between the first tongue 16 and the second tongue 18, and in the stacked state, it serves to isolate the upper and lower rows of terminals 12, provide electromagnetic shielding, and enhance structural strength. This clamping structure completes mechanical positioning before secondary injection molding, providing a stable internal skeleton for the subsequent molding of the insulating base 3.

[0022] The upper insulator 13 and the lower insulator 14 respectively hold the corresponding terminals and form independent tongues, so that the upper and lower rows of terminals 12 are accurately pre-positioned before being stacked. The metal sheet 2 is sandwiched between the two tongues, which not only achieves the shielding function, but also enhances the structural strength of the tongue stacking area as a rigid interlayer. This structure enables the terminals, insulators and metal sheet 2 to form a stable stack before secondary injection molding, effectively avoiding component displacement during subsequent injection molding and improving molding accuracy.

[0023] like Figure 1-10 As shown, in some embodiments, the metal sheet 2 has a first set of positioning holes 21 and a second set of positioning holes 22; the bottom of the first tongue 16 has three first positioning posts 161 protruding, and the top of the second tongue 18 has three second positioning posts 181 protruding; two of the three first positioning posts 161 are inserted into two holes of the first set of positioning holes 21, and the other is inserted into one hole of the second set of positioning holes 22; two of the three second positioning posts 181 are inserted into two holes of the second set of positioning holes 22, and the other is inserted into one hole of the first set of positioning holes 21, forming an alternating positioning.

[0024] The metal sheet 2 has a first set of positioning holes 21 and a second set of positioning holes 22. Three first positioning posts 161 protrude from the bottom of the first tongue 16, and three second positioning posts 181 protrude from the top of the second tongue 18. During stacking, not all first positioning posts 161 are inserted into the first set of positioning holes 21; instead, two are inserted into the first set of positioning holes 21 and the other into the second set of positioning holes 22. Similarly, two second positioning posts 181 are inserted into the second set of positioning holes 22 and the other into the first set of positioning holes 21. This staggered insertion method creates a cross-interlocking positioning relationship between the first tongue 16 and the metal sheet 2, and between the second tongue 18 and the metal sheet 2. The staggered distribution of the single set of positioning posts couples the upper and lower insulators 14 into a single unit through the metal sheet 2, restricting relative displacement in three directions.

[0025] The staggered fit of the positioning pins and positioning holes improves the traditional one-to-one positioning into cross-interlocking positioning, which significantly enhances the anti-displacement capability of the composite before secondary injection molding. The upper and lower insulators 14 are mutually constrained by the metal sheet 2, which effectively overcomes the misalignment problem caused by vibration or uneven clamping force in the stacking process. This structure reduces defects such as terminal misalignment and plastic deformation from the root, and improves the consistency and reliability of the stacking positioning.

[0026] like Figure 1-10 As shown, in some embodiments, the insulating base 3 at least covers the first tongue 16 and the second tongue 18, and forms a stepped portion 31 near the first base 15 and the second base 17, and a plug portion 32 extending forward from the overlapping area of ​​the first tongue 16 and the second tongue 18. The upper and lower surfaces of the plug portion 32 expose the contact surfaces of the corresponding terminals, and a plurality of grooves 33 are respectively provided on the upper and lower surfaces of the plug portion 32.

[0027] The insulating base 3 is formed by secondary injection molding, covering the periphery of the first tongue 16 and the second tongue 18, creating a stepped portion 31 adjacent to the first base 15 and the second base 17, and a plug-in portion 32 extending forward from the overlapping area of ​​the tongues. The outer dimensions of the stepped portion 31 are larger than those of the plug-in portion 32, forming a distinct axial stepped surface on the insulating base 3, providing a stop reference and axial constraint for the sleeve of the housing 4. The upper and lower surfaces of the plug-in portion 32 expose the contact surfaces of the corresponding terminals to ensure electrical connection function; the multiple grooves 33 provided on the surface of the plug-in portion 32 serve as the locking and positioning structure of the housing 4, and are integrally formed during the molding of the insulating base 3.

[0028] The integral molding of the step portion 31 and the insertion portion 32 eliminates the need for a separate positioning component for assembling the housing 4 in the traditional process, simplifying the structure. The step portion 31 provides a clear axial stop surface, ensuring accurate positioning of the housing 4 during assembly and preventing axial movement. The groove 33 is directly formed on the surface of the insertion portion 32 during secondary injection molding, forming a stable mechanical lock with the subsequent housing 4 snap-fit ​​component 43, preventing the housing 4 from loosening, and avoiding the need for additional groove processing.

[0029] like Figure 1-10 As shown, in some embodiments, the metal sheet 2 has a latching arm 34 extending integrally from both sides of its front end. The latching arm 34 extends out from the insulating base 3 and protrudes from both sides of the plug-in portion 32.

[0030] The metal sheet 2 extends integrally from both sides of its front end to form latching arms 34. During secondary injection molding, the latching arms 34 are embedded inside the insulating base 3 and protrude from both sides of the insertion portion 32, appearing as elastic cantilevered arms exposed on the sides of the insertion portion 32. When mated with the connector, the latching arms 34 utilize the elastic deformation capability of the metal sheet 2 to form a locking engagement with the mating end, providing insertion and extraction force and maintaining a stable mating state. The metal sheet 2 has three functions: shielding, reinforcement, and locking, and is integrally molded without the need for additional elastic latching components.

[0031] The metal sheet 2 integrates a locking function, eliminating the need for separate assembly of elastic hooks in traditional connectors; the latch arm 34 extends from the metal sheet 2 body, has high strength and good elasticity consistency, and its insertion and removal life and holding force are superior to those of plastic latch structures; the latch arm 34 is covered and fixed by the insulating base 3 during secondary injection molding, with only the functional part exposed, and the root is firmly fixed, making it less prone to loosening or breakage due to repeated insertion and removal.

[0032] like Figure 1-10 As shown, in some embodiments, the housing 4 includes an inner shell 41 and an outer shell 42, wherein the inner shell 41 is annularly fitted at the junction of the stepped portion 31 and the insertion portion 32 and avoids the groove 33.

[0033] The inner shell 41 is an annular component, fitted onto the junction of the stepped portion 31 and the plug portion 32 of the insulating base 3, providing circumferential coverage and reinforcement to this transition area. The inner shell 41 is positioned to avoid the groove 33 on the surface of the plug portion 32, thus not affecting the engagement between the outer shell 42 and the plug portion 32. As an inner component of the shell 4, the inner shell 41 fits tightly against the junction of the stepped portion 31 and the plug portion 32, serving a dual function of structural reinforcement and electromagnetic shielding.

[0034] The inner shell 41 is fixed at the junction of the stepped portion 31 and the plug portion 32, which effectively enhances the mechanical strength of the area with abrupt change in cross section and reduces the risk of the insulating base 3 breaking at the root during insertion and removal. The inner shell 41 forms a metal shielding layer around the junction, which reduces electromagnetic leakage caused by material discontinuity and improves signal transmission integrity. The inner shell 41 is installed independently of the outer shell 42 and avoids the groove 33, so it does not affect the snap-fit ​​assembly of the outer shell 42 and has good structural compatibility.

[0035] like Figure 1-10 As shown, in some embodiments, the outer shell 42 has a waist-shaped sleeve that is fitted around the outer periphery of the stepped portion 31 and extends forward to cover the insertion portion 32. A gap is left between the insertion portion 32 and the inner wall surface of the outer shell 42. The inner wall of the outer shell 42 is provided with snap-fit ​​members 43 that correspond to and engage with each groove 33.

[0036] The outer shell 42 has an oblong sleeve that fits around the outer periphery of the stepped portion 31 and extends forward to cover the plug portion 32. The outer dimensions of the stepped portion 31 are larger than those of the plug portion 32. Therefore, when the oblong sleeve is fitted onto the stepped portion 31, it forms a contact fit with the stepped portion 31, while an annular gap is left between the inner wall surface of the oblong sleeve and the outer surface of the plug portion 32. The radial dimension of this gap matches the thickness of the metal shell 42 of the standard Type-C male connector. When the male connector is inserted, its metal shell 4 enters this gap and makes contact with the outer surface of the plug portion 32 and the inner wall surface of the oblong sleeve, respectively, forming a complete mating circuit. The outer dimensions of the oblong sleeve conform to the standard Type-C interface specification. The inner wall of the outer shell 42 is provided with snap-fit ​​pieces 43 that correspond one-to-one with the grooves 33 on the surface of the plug portion 32. After the snap-fit ​​pieces 43 are engaged with the grooves 33, they achieve axial and circumferential positioning of the outer shell 42 and the insulating base 3, ensuring that the gap between the oblong sleeve and the plug portion 32 remains stable during assembly and use.

[0037] The annular gap between the waist-shaped sleeve and the insertion part 32 provides a precise accommodating space for the metal shell 4 of the standard Type-C male connector, ensuring that the male connector shell 42 can smoothly enter and form a reliable grounding contact during insertion, meeting the standardized mating requirements of the Type-C interface; the contact fit between the waist-shaped sleeve and the step part 31 realizes the radial positioning of the rear end of the shell 42, and the engagement of the snap-fit ​​part 43 and the groove 33 fixes the axial and circumferential position of the front end of the shell 42. The dual positioning at the front and rear makes the shell 42 stable as a whole, and it will not loosen or deflect due to repeated insertion and removal; during assembly, the shell 42 only needs to be pushed axially into the step part 31 to complete the fixation, without the need for welding or bonding, making the process simple and efficient.

[0038] like Figure 1-10 As shown, in some embodiments, the rear end of the housing 42 is integrally formed with an upper bent piece 44 and a lower bent piece 45. The upper bent piece 44 extends rearward from the top of the rear end of the housing 42 and passes around the top surface of the first base 15 to one side. The lower bent piece 45 extends rearward from the bottom of the rear end of the housing 42 and passes around the bottom surface of the second base 17 to the same side.

[0039] An upper bent piece 44 is integrally formed at the top rear end of the outer casing 42, and a lower bent piece 45 is integrally formed at the bottom. The upper bent piece 44 extends rearward from the top rear end of the outer casing 42, passes around the top surface of the first base 15, and extends to one end face. The lower bent piece 45 extends rearward from the bottom rear end of the outer casing 42, passes around the bottom surface of the second base 17, and extends to the same end face. Both bent pieces extend directly from the body of the outer casing 42 without secondary connection, and form laterally arranged welded fixing feet after passing around the end face of the insulator.

[0040] The bent piece extends integrally from the outer shell 42 body without welding or riveting connection points, resulting in high structural strength and good electrical conductivity. The upper and lower bent pieces 45 are arranged on the same side around the end face of the insulator, forming a centralized welding foot layout, which facilitates surface mount welding with the circuit board. The bent piece also axially tightens and fixes the outer shell 42, the insulator and internal components, preventing the shell 4 from coming out axially under the action of insertion and extraction force, thus improving the reliability of the overall structure.

[0041] like Figure 1-10 As shown, in some embodiments, both ends of the upper row of terminals 11 and both ends of the lower row of terminals 12 are provided with strip connecting pieces 5, so as to connect each row of terminals into one piece before secondary injection molding; after the insulating base 3 is formed, each strip connecting piece 5 is cut off, so that each terminal is independent of each other.

[0042] Both ends of the upper row of terminals 11 and both ends of the lower row of terminals 12 have strip connecting pieces 5 during stamping. Each strip connecting piece 5 has at least two connecting holes, which are used to precisely fix the terminal assembly 1 into the mold during a single injection molding process. Each row of terminals is connected into a single strip frame via its connecting pieces at both ends, maintaining the spacing and flatness between terminals during a single injection molding process. After the upper insulator 13 and lower insulator 14 are injection molded separately, the connecting pieces remain, ensuring the terminal position accuracy of the two terminal assemblies 1 during the stacking and secondary injection molding processes. After the secondary injection molding is completed and the insulating base 3 has solidified all components into a single unit, the connecting pieces are then removed, making each terminal in the same row electrically independent.

[0043] The material strip connecting piece 5 maintains the precise spacing between terminals during a single injection molding and stacking process, effectively controlling the cumulative dimensional error. The retention of the connecting piece ensures that the terminal assembly 1 maintains overall rigidity during transfer and stacking positioning, reducing the risk of terminal bending and deformation. The cutting process is only performed after the insulating base 3 is formed. At this time, all components have been solidified, and the cutting will not affect the terminal position, ensuring that each terminal is independent and accurately positioned after molding, thus improving product consistency and yield.

[0044] like Figure 1-10 As shown, in some embodiments, at least one first guide post 151 protrudes from the bottom surface of the first base 15, and at least one second guide post 171 protrudes from the top surface of the second base 17. The first guide post 151 and the second guide post 171 are staggered from each other in the overlapping direction. When the upper insulator 13 and the lower insulator 14 are overlapped, the first guide post 151 extends into the corresponding hole of the first guide post 151 on the top surface of the second base 17, and the second guide post 171 extends into the corresponding hole of the second guide post 171 on the bottom surface of the first base 15. Through the staggered insertion and cooperation of the two sets of guide posts, the first base 15 and the second base 17 are constrained in the lateral and longitudinal directions.

[0045] The first base 15 and the second base 17 serve as the supporting bodies for the terminal assembly 1. Their opposing surfaces, when stacked, form an additional mechanical interlock through the staggered arrangement of the first guide post 151 and the second guide post 171. This guide post structure is independent of the staggered positioning system of the positioning posts and positioning holes of the metal sheet 2 in the tongue region. It provides auxiliary positioning at the rear end of the stacked body, working in conjunction with the front tongue positioning to precisely constrain the entire terminal assembly 1 from both the front and rear regions before secondary injection molding. This further restricts the relative rotation and misalignment between the two sets of insulators. The base guide post and the tongue positioning post form a front and rear dual-zone positioning, which significantly enhances the overall resistance to displacement and torsion of the composite body, ensuring that the terminal assembly 1 maintains a stable relative position during the insertion of the secondary injection mold; the staggered design of the guide post avoids misinstallation that may occur due to symmetrical arrangement, has a foolproof effect, and at the same time enhances the bonding strength of the base area, further reducing product defects caused by insulator displacement during injection molding.

[0046] A method for manufacturing an easy-to-produce USB Type-C connector includes the following steps: S1. An upper row of terminals 11 and a lower row of terminals 12 are respectively manufactured by injection molding. The upper row of terminals 11 includes an upper row of terminals 11 and an upper insulator 13 for holding the upper row of terminals 11. The lower row of terminals 12 includes a lower row of terminals 12 and a lower insulator 14 for holding the lower row of terminals 12. The upper row of terminals 11 and the lower row of terminals 12 are manufactured by injection molding in one step, so that the terminals and insulators are initially fixed in the mold, forming two independent components with positioning structures.

[0047] S2. A metal sheet 2 is sandwiched between the upper insulator 13 and the lower insulator 14 and positioned to form a composite body; The metal sheet 2 is sandwiched between the upper insulator 13 and the lower insulator 14. Precise positioning is achieved by the staggered cooperation between the tongue positioning post and the positioning hole of the metal sheet 2, forming a stable composite body. This composite body can be completed outside the mold.

[0048] S3. Perform secondary injection molding on the composite to form an insulating base 3, wherein the insulating base 3 covers and fixes the terminal assembly 1 and the metal sheet 2 into a whole. The composite is placed into a secondary injection mold, and an insulating base 3 is formed on the periphery of the tongue by in-mold injection molding. The upper and lower terminal components 1 and the metal sheet 2 are covered and solidified in one go, and in-mold molding replaces the traditional manual or automatic machine assembly.

[0049] S4. Cut off the strip connecting piece 5 at the end of each terminal to separate the terminals from each other; After the insulating base 3 is formed, the material strip connecting piece 5 at the end of the terminal is cut off to separate the terminals from each other. At this time, the connector body has been formed, and the cutting does not affect the internal structure.

[0050] S5. Assemble the housing 4 on the insulating base 3; assemble the inner shell 41 and the outer shell 42 on the insulating base 3 to complete the finished product assembly.

[0051] This method integrates terminal injection molding, stacking and positioning, and secondary injection molding consolidation into a continuous process, significantly shortening the manufacturing cycle compared to traditional multi-step independent processes. Stacking is completed outside the mold, while consolidation is achieved inside the mold, balancing operational convenience and molding accuracy, and reducing transfer and repetitive positioning steps. In-mold secondary injection molding replaces manual assembly, effectively eliminating human error during assembly and significantly reducing defect rates such as PIN misalignment, excess glue, and plastic deformation, thereby improving product consistency and dimensional accuracy. The cutting of the material strip connecting piece 5 is arranged after the molding of the insulating base 3, ensuring that the terminals are always constrained throughout the entire process, separating only one step before the final formation of independent circuits, thus guaranteeing the positional accuracy of each terminal. The overall process is suitable for the mass automated production of USB Type-C connectors, improving yield while reducing unit manufacturing costs.

[0052] In summary, by clamping the metal sheet 2 between the first tongue 16 and the second tongue 18 before secondary injection molding, and using the first positioning post 161 and the second positioning post 181 to interlock in the first set of positioning holes 21 and the second set of positioning holes 22 of the metal sheet 2, the composite body can be reliably pre-positioned, reducing terminal misalignment and plastic deformation at the source. Subsequently, the insulating base 3 is integrally formed on the periphery of the assembly through secondary injection molding, forming the stepped part 31 and the plug-in part 32. In-mold consolidation replaces traditional manual or automatic machine assembly, significantly shortening the production process and improving the degree of automation and dimensional consistency. The snap-fit ​​arm 34 extending integrally from the front end of the metal sheet 2 has both shielding and locking functions, eliminating the need for independent elastic snap-fit ​​components. The annular gap between the waist-shaped sleeve of the outer shell 42 and the plug-in part 32 provides precise accommodation space for the standard Type-C male connector. With the engagement of the snap-fit ​​component 43 and the groove 33 and the integrated bending piece structure, the outer shell 4 is stably assembled and reliably grounded. It improves overall product yield, reduces manufacturing costs, and is suitable for mass automated production of USB Type-C connectors.

[0053] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A USB Type-C connector that is easy to manufacture, characterized in that, include: Terminal assembly (1) includes an upper row of terminals (11), a lower row of terminals (12), and an upper insulator (13) and a lower insulator (14) respectively injection molded onto the upper row of terminals (11) and the lower row of terminals (12). A metal sheet (2) is sandwiched between the upper insulator (13) and the lower insulator (14); An insulating base (3) is formed by secondary injection molding over the assembly of the terminal assembly (1) and the metal sheet (2), thus fixing the three together as one. The housing (4) is fitted over the outside of the insulating base (3).

2. The USB Type-C connector that is easy to manufacture according to claim 1, characterized in that: The upper insulator (13) has a first base (15) and a first tongue (16) extending forward from the first base (15), the contact section of the upper row of terminals (11) is embedded in the first tongue (16) and the contact surface is exposed; the lower insulator (14) has a second base (17) and a second tongue (18) extending forward from the second base (17), the contact section of the lower row of terminals (12) is embedded in the second tongue (18) and the contact surface is exposed; the metal sheet (2) is clamped between the first tongue (16) and the second tongue (18).

3. The USB Type-C connector that is easy to manufacture according to claim 2, characterized in that: The metal sheet (2) is provided with a first set of positioning holes (21) and a second set of positioning holes (22); the bottom of the first tongue (16) is provided with three first positioning posts (161), and the top of the second tongue (18) is provided with three second positioning posts (181); two of the three first positioning posts (161) are inserted into two holes of the first set of positioning holes (21), and the other is inserted into one hole of the second set of positioning holes (22); two of the three second positioning posts (181) are inserted into two holes of the second set of positioning holes (22), and the other is inserted into one hole of the first set of positioning holes (21), forming staggered positioning.

4. The USB Type-C connector that is easy to manufacture according to claim 1, characterized in that: The insulating base (3) covers at least the first tongue (16) and the second tongue (18), and forms a stepped portion (31) near the first base (15) and the second base (17), and a plug portion (32) extending forward from the overlapping area of ​​the first tongue (16) and the second tongue (18). The upper and lower surfaces of the plug portion (32) expose the contact surfaces of the corresponding terminals, and the upper and lower surfaces of the plug portion (32) are respectively provided with a plurality of grooves (33).

5. The USB Type-C connector that is easy to manufacture according to claim 1, characterized in that: The metal sheet (2) has a buckle arm (34) extending integrally from both sides of its front end. The buckle arm (34) extends out from the insulating base (3) and protrudes from both sides of the plug part (32).

6. The USB Type-C connector that is easy to manufacture according to claim 1, characterized in that: The housing (4) includes an inner shell (41) and an outer shell (42). The inner shell (41) is annularly fitted at the junction of the stepped portion (31) and the insertion portion (32) and avoids the groove (33).

7. A USB Type-C connector that is easy to manufacture according to claim 6, characterized in that: The outer shell (42) has a waist-shaped sleeve that is fitted around the outer periphery of the stepped portion (31) and extends forward to cover the insertion portion (32). There is a gap between the insertion portion (32) and the inner wall surface of the outer shell (42). The inner wall of the outer shell (42) is provided with snap-fit ​​pieces (43) that correspond to and engage with each groove (33).

8. A USB Type-C connector that is easy to manufacture according to claim 6, characterized in that: The rear end of the outer shell (42) is integrally formed with an upper bent piece (44) and a lower bent piece (45). The upper bent piece (44) extends rearward from the top of the rear end of the outer shell (42) and passes around the top surface of the first base (15) to one side. The lower bent piece (45) extends rearward from the bottom of the rear end of the outer shell (42) and passes around the bottom surface of the second base (17) to the same side.

9. A USB Type-C connector that is easy to manufacture according to claim 1, characterized in that: Both ends of the upper row of terminals (11) and both ends of the lower row of terminals (12) are provided with strip connecting pieces (5) so that each row of terminals can be connected together before secondary injection molding; after the insulating base (3) is formed, each strip connecting piece (5) is cut off so that each terminal is independent of each other.

10. A method for manufacturing a USB Type-C connector based on any one of claims 1-9 that is easy to manufacture, characterized in that, Includes the following steps: S1. An upper row terminal (11) assembly and a lower row terminal (12) assembly are respectively manufactured by injection molding. The upper row terminal (11) assembly includes an upper row terminal (11) and an upper insulator (13) for holding the upper row terminal (11). The lower row terminal (12) assembly includes a lower row terminal (12) and a lower insulator (14) for holding the lower row terminal (12). S2. A metal sheet (2) is sandwiched between the upper insulator (13) and the lower insulator (14) and positioned to form a composite body; S3. The composite body is subjected to secondary injection molding to form an insulating base (3), which covers and fixes the terminal assembly (1) and the metal sheet (2) into one piece; S4. Cut off the strip connecting piece (5) at the end of each terminal to separate the terminals from each other; S5. Assemble the housing (4) on the insulating base (3).

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