Integrated sealed electrical connector

Abstract

To provide an integrated sealed electrical connector that enables a securely sealed hybrid connector capable of reliable mating / mounting within a small space.SOLUTION: A connector includes a housing holding conductive elements in a row. The housing has a body, a tongue extending from the body in a mating direction, and a bracket extending from a side of the body. Each conductive element has a mating portion held by the tongue. A frame is partially embedded in and partially disposed outside the housing to mount to a board. The frame and bracket have aligned holes configured for receiving a screw to mount to the board. Some conductive elements are configured for transmitting power and have a uniform thickness, and others are configured for transmitting signals and have a smaller thickness at the mating portion. Front and rear seals are attached to rough surfaces of the housing and conductive elements, respectively.SELECTED DRAWING: Figure 8

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to and the benefit of Chinese Patent Application No. 202322241812.2, filed on August 18, 2023. This application also claims priority to and the benefit of Chinese Patent Application No. 202311045011.7, filed on August 18, 2023. This application also claims priority to and the benefit of Chinese Patent Application No. 202321801117.0, filed on July 10, 2023. The contents of these applications are incorporated herein by reference in their entireties.

[0002] FIELD OF THEINVENTION TECHNICAL FIELD This application relates to interconnection systems, such as those that include electrical connectors configured to interconnect electronic assemblies. [Background technology]

[0003] Electrical connectors are used in many electronic systems. It is generally easier and more cost effective to manufacture systems as separate electronic subassemblies, such as Printed Circuit Boards (PCBs), which can be joined together with electrical connectors. Having separable connectors allows components of an electronic system made by different manufacturers to be easily assembled. Separable connectors also allow components to be easily swapped out after the system is assembled, either to replace defective components or to upgrade the system with higher performance components.

[0004] A well-known configuration for joining several electronic subassemblies is to have one printed circuit board act as a backplane. A well-known backplane is a PCB to which many connectors may be attached. Conductive traces in the backplane may be electrically connected to signal conductors in the connectors, thereby allowing signals to be routed between the connectors. Other printed circuit boards, called "daughterboards," "daughtercards," or "midboards," may be connected through the backplane. For example, connectors may also be attached on the daughtercards. The connectors mounted on the daughtercards may plug into connectors mounted on the backplane. In this way, signals may be routed between the daughtercards through the connectors and the backplane. The daughtercards may be plugged into the backplane at a right angle. Thus, connectors used in these applications may include right-angle bends and are often referred to as "right-angle connectors."

[0005] Connectors may also be used in other configurations for interconnecting electronic assemblies. In some cases, one or more printed circuit boards are connected to another printed circuit board, called a "motherboard," which carries electronic components and interconnects the daughterboards. In such configurations, the printed circuit boards connected to the motherboard may be called daughterboards. Daughterboards are often smaller than the motherboard and may be aligned parallel to the motherboard. Connectors used in this configuration are often called "stacking connectors" or "mezzanine connectors." In other systems, the daughterboards may be perpendicular to the motherboard.

[0006] Connectors may also be used in computers where the motherboard may have a processor and a bus configured to pass data between the processor and peripheral devices such as a printer or memory device. The connectors may be mounted to the motherboard and connected to the bus. The mating interfaces of these connectors may often be exposed through openings in the housing for the computer such that a connector attached to the peripheral device via a cable may be inserted into the connector on the motherboard. This configuration allows the peripheral device to be easily connected to the computer.

[0007] To increase the availability of peripheral devices, buses and connectors used to physically connect peripheral devices over the bus may be standardized. Thus, there may be a large number of peripheral devices available from a large number of manufacturers. Any of these products may be used in a computer having a bus that complies with the standard, so long as the product complies with the standard. An example of such a standard is the Universal Serial Bus (USB), which is commonly used in computers. The standard has undergone multiple revisions to adapt over time to the higher performance expected of computers. For example, portable electronic devices often include a USB Type-C connector for various purposes, such as charging and / or exchanging data with another electronic device by connecting the USB connector with a USB plug connector.

[0008] Some USB connectors are water resistant. These connectors may include a seal that blocks water from outside the computer's housing from entering the computer's housing through an opening left for the connector. Summary of the Invention

[0009] Aspects of the present disclosure relate to an integrally sealed electrical connector.

[0010] Some embodiments relate to a terminal assembly that may include a plurality of first terminals aligned in a row, each of the plurality of first terminals having the same thickness in a vertical direction perpendicular to the row direction along a length of the first terminal, and a plurality of second terminals aligned in the row with the plurality of first terminals, each of the plurality of second terminals including a portion having a smaller thickness in the vertical direction than a remainder of the second terminal.

[0011] Optionally, the plurality of first terminals are configured to transmit power and the plurality of second terminals are configured to transmit signals.

[0012] Optionally, the terminal assembly is configured according to the USB-C standard, and each of the plurality of first terminals is configured to carry a current in the range of 5 A to 10 A, and each of the plurality of second terminals is configured to transmit signals at a speed in the range of 5 Gbps to 80 Gbps per second.

[0013] Optionally, each of the plurality of first terminals has a first thickness in the range of 0.1 mm to 0.35 mm, and for each of the plurality of second terminals, a thinner portion has a thickness in the range of 0.01 mm to 0.10 mm, and a remaining portion of the second terminal has a thickness in the range of 0.1 mm to 0.25 mm.

[0014] Optionally, each of the plurality of second terminals includes a mating portion configured for mating with another component, the mating portion of the second terminal including a portion having a reduced thickness.

[0015] Optionally, each of the plurality of second terminals includes a tail portion opposite the mating portion and configured for surface mounting to a substrate.

[0016] Optionally, each of the plurality of first terminals and the plurality of second terminals includes a plating layer of one or more of platinum, rhodium-ruthenium, and palladium.

[0017] Optionally, each of the plurality of first terminals and the plurality of second terminals includes a roughened portion adjacent the tail portion, the roughened portion of the respective terminal having a higher surface roughness than other portions of the respective terminal such that a sealing member can be attached to the roughened portion of the terminal.

[0018] Some embodiments relate to an electrical connector that may include a housing including a body, a tongue extending from the body in a mating direction, and a bracket extending from a side portion of the body, a plurality of conductive elements held in a row by the housing, each of the plurality of conductive elements including a mating portion held by the tongue of the housing and a tail portion extending from the housing, and a frame including a first portion embedded in the body of the housing, a second portion disposed outside the housing, and a third portion embedded in the bracket of the housing.

[0019] Optionally, the housing includes a groove disposed between the body and the tongue and having a surface with a higher roughness than other portions of the housing, and the sealing member is attached to a surface of the housing groove.

[0020] Optionally, the groove is disposed along a peripheral portion of the housing.

[0021] Optionally, the bracket is a first bracket extending from a first side portion of the body of the housing, and the housing includes a second bracket extending from a second side portion of the body of the housing opposite the first side portion, and the sealing member is disposed between the first bracket and the second bracket.

[0022] Optionally, the first bracket and the second bracket each include a hole, and the third portion of the frame includes a hole aligned with the holes in the first bracket and the second bracket.

[0023] Optionally, the sealing member is a first sealing member, the body of the housing includes a cavity, and the electrical connector includes a second sealing member disposed within the cavity of the body of the housing and attached to a portion of the plurality of conductive elements passing through the cavity of the body of the housing.

[0024] Optionally, portions of the plurality of conductive elements that pass through the cavity of the body of the housing have a surface having a higher roughness than other portions of the respective conductive elements.

[0025] Optionally, the plurality of conductive elements include a first terminal each having a uniform thickness along its length and a second terminal having a smaller thickness at the mating portion than at the tail portion.

[0026] Some embodiments relate to a method for manufacturing an electrical connector, which may include providing a plurality of conductive elements, molding an assembly housing over at least a portion of the plurality of conductive elements, disposing a frame on the assembly housing, and molding a connector housing over a portion of the frame.

[0027] Optionally, the plurality of conductive elements is a first plurality of conductive elements aligned in a first row, and the method includes arranging a second plurality of conductive elements in a second row parallel to the first row, and then disposing the frame on the assembly housing.

[0028] Optionally, the connector housing includes a groove about a circumferential circumference of the connector housing, the method including roughening a surface of the housing groove and forming a sealing member in the housing groove.

[0029] Optionally, the sealing member is a front sealing member and the housing includes a cavity through which the plurality of conductive elements pass, and the method includes forming a rear sealing member within the cavity of the housing and around the plurality of conductive elements passing through the cavity.

[0030] Some embodiments relate to a terminal assembly that may include first terminals having a first thickness and configured to transmit power and second terminals configured to transmit signals, where at least a portion of each second terminal is configured to have a second thickness that is less than the first thickness.

[0031] Optionally, the first thickness is in the range of 0.1 mm to 0.35 mm.

[0032] Optionally, the second terminal is configured to have a thinned portion that has been subjected to a thinning process, the thinned portion having a thickness as the second thickness, the second terminal is configured to have a thickness in the range of 0.1 mm to 0.25 mm in a portion other than the thinned portion, and the thinned portion is configured to have a thinned thickness in the range of 0.01 mm to 0.10 mm.

[0033] Optionally, the first terminal includes a mating portion and a tail portion, the second terminal includes a mating portion and a tail portion, the mating portion of the second terminal includes a reduced-metal portion, and the mating portion of the first terminal is configured to have a uniform thickness.

[0034] Optionally, the first terminal is configured to be capable of carrying a current in the range of 5 A to 10 A, and the second terminal is configured to be capable of transmitting signals at speeds in the range of 5 Gbps to 80 Gbps per second.

[0035] Optionally, each of the first terminal and the second terminal is provided with a corrosion-resistant plating layer, and the material of the plating layer may be any one of platinum, rhodium-ruthenium, and palladium.

[0036] Some embodiments relate to an electrical connector, which may include a housing and a terminal assembly, in which a plurality of first terminals and a plurality of second terminals are provided to form two rows of terminals arranged one above the other in a height direction of the electrical connector, and a housing is sleeve-connected to the outside of the two rows of terminals to secure the two rows of terminals.

[0037] Optionally, the terminals in one of the two rows of terminals are configured as conductive elements of a first row formed by some of the plurality of first terminals and some of the plurality of second terminals, and the terminals in the other of the two rows of terminals are configured as conductive elements of a second row formed by other terminals of the plurality of first terminals and other terminals of the plurality of second terminals, the conductive elements of the first row and the conductive elements of the second row being arranged opposite each other in the height direction of the electrical connector.

[0038] Optionally, at least some of the plurality of second terminals forming the conductive elements of the first row and at least some of the plurality of second terminals forming the conductive elements of the second row are configured to have a reduced-wall portion that has been subjected to a thinning process, and the second terminals forming the conductive elements of the first row and having the reduced-wall portion and the second terminals forming the conductive elements of the second row and having the reduced-wall portion are aligned with each other in the height direction.

[0039] Optionally, the terminal assembly includes a shield positioned between the first row of conductive elements and the second row of conductive elements, the shield being spaced a predetermined distance in the height direction from the first row of conductive elements and the second row of conductive elements, respectively.

[0040] Optionally, the housing includes a terminal assembly housing defining a housing portion for accommodating the first terminal and the second terminal, and a tail portion of the first terminal and a tail portion of the second terminal are molded into the housing portion of the terminal assembly housing by injection molding.

[0041] Optionally, the shield is molded into the housing portion of the terminal assembly housing by injection molding together with the tail portions of the first and second terminals forming the first and second rows of conductive elements.

[0042] Optionally, the electrical connector further comprises a first sealing member, a groove being provided along a peripheral portion of the housing, the first sealing member being provided within the groove.

[0043] Optionally, the electrical connector further comprises a second sealing member, the housing being provided with a cavity having a hole depth direction perpendicular to the top surface of the terminal assembly, the second sealing member being provided inside the cavity.

[0044] Optionally, the housing is provided with a first roughened surface portion at the bottom of the groove for enhancing adhesion between the first sealing member and the housing, and the terminal assembly is provided with a second roughened surface portion in an area where the cavity is projected onto the terminal assembly in the depth direction of the hole for enhancing adhesion between the second sealing member and the terminal assembly.

[0045] Optionally, the first sealing member is an elastically deformable member, and the first sealing member is configured to elastically deform and form an interference fit with the mounting portion of the electronic device when the first sealing member contacts a mounting portion of the electronic device adapted for the electrical connector.

[0046] Optionally, the first sealing member is configured to have an annular shape that extends continuously circumferentially around the mating end of the housing, the first sealing member being configured to have a mounting surface that forms a positive fit with a groove in the housing.

[0047] Optionally, the second sealing member is configured to have a substantially square shape, the second sealing member being configured to have a mounting surface that forms a positive fit with the cavity of the housing.

[0048] Optionally, the electrical connector further comprises a frame having a first portion embedded within the housing, a second portion disposed outside the housing, and a third portion formed by extending from both sides of the first portion, the housing having a bracket formed thereon extending from both sides thereof, and the third portion of the frame being embedded within the bracket.

[0049] Optionally, a receiving portion for receiving the first portion is provided near a tail end of the terminal assembly housing such that the frame is positioned in a predetermined position relative to the terminal assembly housing and the terminal assembly.

[0050] Optionally, a cavity is formed in a central portion of the housing connecting the bracket, and a corresponding one of the first terminal and the second terminal is exposed through the cavity before the second sealing member is arranged in the cavity.

[0051] Optionally, the mating portion of the housing has a groove formed therein at a predetermined location from the central portion.

[0052] Some embodiments relate to a method for manufacturing an electrical connector. The method includes step 01) of providing a plurality of first terminals and a plurality of second terminals, forming a first row of conductive elements with some of the plurality of first terminals and some of the plurality of second terminals, and forming a second row of conductive elements with other of the plurality of first terminals and other of the plurality of second terminals; step 02) of providing a shield; step 03) of placing the first row of conductive elements and the shield in a first injection mold and performing a first injection molding to form a first molded member; step 04) of assembling the second row of conductive elements on the first molded member and positioning the second row of conductive elements in a predetermined position relative to the first molded member; and step 05) of providing a frame, positioning the frame in a predetermined position relative to the first molded member and the second row of conductive elements, placing the frame, the second row of conductive elements, and the first molded member in a second injection mold and performing a second injection molding to form a second molded member, the second molded member including a housing.

[0053] Optionally, in step 03), mounting slots for assembling the second row of conductive elements are integrally molded on a side of the first molded member opposite a side of the shield on which the first row of conductive elements are located.

[0054] Optionally, the mounting slots include a plurality of first slots proximate a mating end side of the first molded member, a plurality of third slots proximate a tail end side of the first molded member, and a plurality of second slots disposed between the plurality of first slots and the plurality of third slots in the mating direction of the electrical connector, each of the plurality of first slots, each of the plurality of second slots, and each of the plurality of third slots being aligned with one another in a one-to-one correspondence in the mating direction of the electrical connector to receive and position a corresponding one of the terminals forming the second row of conductive elements.

[0055] Optionally, the first molded member formed in step 03) includes a terminal assembly housing, and the accommodating portion is provided on a side of the terminal assembly housing, on which the first row of conductive elements are arranged, proximate a tail end of the first molded member.

[0056] Optionally, in step 05), providing the frame includes constructing a frame having a first portion as a central portion of the frame, a second portion extending from the first portion toward the tail end of the electrical connector in the mating direction, and a third portion extending from both sides of the first portion in the width direction of the electrical connector along the height direction of the electrical connector, the third portion being formed with an L-shaped step having a leg parallel to the first portion, and the second portion being accommodated in the accommodating portion to position the frame in a predetermined position relative to the first molding member and the conductive elements of the second row assembled together in step 04).

[0057] Optionally, in step 05), while performing a second injection molding to form a second molded part, a support portion is formed near the tail end of the housing, a groove is formed on a mating side of the support portion at a predetermined distance from the support portion, and a cavity is formed on two opposing surfaces of the support portion in a height direction of the electrical connector.

[0058] Optionally, the method further comprises roughening the electrical connector, the groove, and the cavity to form a roughened portion.

[0059] Optionally, the method further includes applying an adhesive to the roughened portion of the groove and / or the roughened portion of the cavity to form a first sealing member in the groove and / or a second sealing member in the cavity.

[0060] Optionally, in step 03), the conductive elements of the first row are spaced apart from the shield in a height direction of the electrical connector.

[0061] Optionally, in step 04), the conductive elements of the second row are positioned at a predetermined position relative to the first molding member such that the conductive elements of the second row are spaced apart from the conductive elements of the first row in a height direction of the electrical connector and the shield is positioned between the conductive elements of the first row and the conductive elements of the second row.

[0062] These techniques may be used alone or in any suitable combination.The foregoing summary is provided by way of illustration and is not intended to be limiting. [Brief description of the drawings]

[0063] The accompanying drawings may not be drawn to scale. In the drawings, each of the same or nearly identical components illustrated in various figures may be represented by a like numeral. For clarity, not every component may be labeled in every drawing. The drawings are as follows: [Figure 1] 7 is a perspective view of a row of terminals of the electrical connector of FIG. 6 according to some embodiments. [Diagram 2] 2 is a schematic side view of a terminal of the row of terminals of FIG. 1 according to some embodiments. [Diagram 3] 2 is a perspective view of a first terminal and a second terminal of the row of terminals of FIG. 1 according to some embodiments. [Figure 4] 7 is a perspective view of a terminal assembly with a shield disposed between two rows of terminals of the electrical connector of FIG. 6 with the terminal assembly housing hidden according to some embodiments. [Diagram 5] FIG. 13 is a bottom view of an electrical connector according to some embodiments. [Figure 6] 6 is a top perspective view of the electrical connector of FIG. 5 according to some embodiments. [Figure 7] 7 is a bottom perspective view of the electrical connector of FIG. 6 according to some embodiments. [Figure 8] 7 is a partially exploded perspective view of the electrical connector of FIG. 6 according to some embodiments. [Figure 9] 6 is a perspective view of the electrical connector of FIG. 5 with the connector housing hidden, showing the terminal assembly housing and frame according to some embodiments. [Figure 10A] 7 is a top view of the electrical connector of FIG. 6 showing the first roughened portion and the second roughened portion according to some embodiments. [Figure 10B] 7 is a bottom view of the electrical connector of FIG. 6 showing the first roughened portion and the second roughened portion according to some embodiments. [Figure 11] 7 is a bottom perspective view of a first row of terminals of the electrical connector of FIG. 6 illustrating step 03) of a method of manufacturing an electrical connector according to some embodiments. [Figure 12] 7 is a schematic bottom perspective view of the first and second rows of terminals of the electrical connector of FIG. 6 illustrating step 04) of a method of manufacturing an electrical connector according to some embodiments. [Figure 13] 13 is another bottom perspective view of the first and second rows of terminals of FIG. 12 illustrating step 04) of a method of manufacturing an electrical connector according to some embodiments. [Figure 14] 7 is a top perspective view of the electrical connector of FIG. 6 illustrating step 05) of a method of manufacturing the electrical connector according to some embodiments. [Figure 15] 7 is a top perspective view of the electrical connector of FIG. 6, illustrating a method 06) of manufacturing the electrical connector according to some embodiments. [Figure 16] 7 is a side view of one second terminal in a first row of terminals (A) and one second terminal in a second row of terminals (B) of the electrical connector of FIG. 6 according to some embodiments.

[0064] Reference numbers: 1-electrical connector, 10-first terminal, 20-second terminal, 21-thinned portion, 100-terminal assembly, 101-first row of conductive elements, 102-second row of conductive elements, 110-shield, 200-housing, 210-groove, 220-cavity, 230-first roughened portion, 240-second roughened portion, 250-bracket, 260-terminal assembly housing, 261-first slot, 262-second slot, 263-third slot, 264-receiving portion, 270-support portion, 300-first sealing member, 400-second sealing member, 500-frame, 510-first portion, 520-second portion, 530-third portion. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0065] The present inventors have recognized and understood techniques for making improved electrical connectors that are improved in one or more ways, including that they are simple and cost-effective to manufacture, rugged, can withstand environmental conditions, and are suitable for use with high power peripheral devices. These techniques may be applied in some embodiments to connectors in the USB-C form factor.

[0066] Such electrical connectors may have integrated seals and / or may have both thicker terminals for high power transmission (e.g., 5-10A) and thinner terminals for high speed signal transmission (e.g., 5-80Gbps). The strength of the connector may be enhanced by having a single integral component (e.g., metal frame) that acts as both the outer shell and the board holder, which is partially embedded within the connector housing. The connector may be water resistant by having sealing members (e.g., formed by a liquid injection molding (LIM) process) at both the front and rear of the connector. The sealing members may be attached to a surface of the housing / terminals that has been treated to have a higher surface roughness than other portions of the housing / terminals. The sealing members may be formed from liquid silicone. Such a configuration may provide a hybrid connector with reduced height but a mechanically reliable structure and achieving an IPX8 immersion test rating.

[0067] Some aspects of the present disclosure relate to a method of manufacturing an electrical connector. The method may include molding an assembly housing around a lower row of terminals and a shield, assembling an upper row of terminals onto the assembly housing, disposing a metal frame in place, and then molding the connector housing thereon. The method may further include roughening selected areas of the housing and terminals, for example with a laser, such that the selected areas may have a surface roughness in the range of VDI 24 to VDI 39, and simultaneously disposing a front LIM and a back LIM. Such a configuration may simplify the manufacturing process and reduce costs.

[0068] According to aspects of the disclosure, a connector may include a housing that holds the conductive elements in an aligned manner. The housing may have a body, a tongue extending from the body in a mating direction, and a bracket extending from a side portion of the body. Each conductive element may have a mating portion that is held by the tongue. The frame may be partially embedded in the housing and partially disposed outside the housing for mounting to, for example, a board. The frame and bracket may have aligned holes configured to receive screws for mounting to, for example, a board. Some conductive elements may be configured to transmit power and have a uniform thickness, while other conductive elements may be configured to transmit signals and may have a smaller thickness in the mating portion than the remainder of the conductive elements. The front and rear seals may be attached to roughened surfaces of the housing and conductive elements, respectively. Such techniques may enable a securely sealed hybrid connector capable of reliable mating / mounting in small spaces.

[0069] According to an aspect of the disclosure, in the terminal assembly provided in the present application, a first terminal configured to transmit power may have a first thickness, and a second terminal configured to transmit a signal may have a second thickness that is smaller than the first thickness. For example, a portion of the second terminal may have a second thickness that is smaller than the first thickness of the first terminal. As another example, the second terminal may be thinner compared to a conventional signal terminal. Such a technique may enable a connector for high-speed transmission and alleviate problems with existing USB Type-C terminal structures.

[0070] Next, the terminal assemblies provided by some embodiments of the present application will be described in detail with reference to the drawings. For clarity and simplicity of description, X, Y, and Z directions may be used in the drawings to indicate a horizontal direction X, a mating direction Y, and a vertical direction Z, respectively. The horizontal direction X, the mating direction Y, and the vertical direction Z may be perpendicular to each other. The horizontal direction X may refer to the width direction of the electrical connector of the present application. The mating direction Y may refer to the connection direction of the electrical connector to another matched electrical connector, for example, the mating direction in which the electrical connector is mated with a corresponding matched electrical connector. The vertical direction Z may refer to the height direction (e.g., thickness direction) of the electrical connector.

[0071] According to some embodiments of the present application, for example to accommodate high speed signal transmission in a USB Type-C connector, as shown in FIGS. 1 and 2 , a connector terminal assembly 100 may include first terminals 10 having a first thickness and configured to transmit power, and second terminals 20 configured to transmit signals, where at least a portion of each of the second terminals 20 has a second thickness that is less than the first thickness.

[0072] For example, the first terminal 10 functions as a terminal for transmitting power, e.g., a current terminal, and the second terminal 20 functions as a terminal for transmitting a signal, e.g., a signal terminal. The first terminal 10 has a thickness that is a first thickness. The first thickness is in the range of 0.1 mm to 0.35 mm and enables the first terminal 10 to carry a current in the range of 5 A to 10 A.

[0073] The second terminal 20 functions as a terminal for transmitting signals. In the illustrated exemplary embodiment, after the second terminal 20 is subjected to a thinning process, the second terminal 20 has a thickness that is thinner at some positions than at other positions, and a thin portion 21 is formed. The thin portion 21 has a thickness that is a second thickness. The second terminal 20 has a thickness of 0.1 mm to 0.25 mm at a portion other than the thin portion, and the thin portion 21 has a smaller thickness in the range of 0.01 mm to 0.10 mm, allowing the second terminal 20 to transmit signals at high speeds of 5 G to 80 G per second. For example, the thin portion has a thickness of 0.01 mm to 0.10 mm that is smaller than the thickness of the remaining portion of the second terminal.

[0074] 3, the first terminal 10 may include a mating portion 11 and a tail portion 12. The second terminal 20 may include a mating portion 22 and a tail portion 23. The mating portion 22 of the second terminal 20 has a thinned portion 21 having a thickness h that is less than a thickness H of the remaining portions of the mating portion 22 of the second terminal 20. The mating portion 11 of the first terminal has a uniform thickness along its length.

[0075] Each of the first terminal and the second terminal has a thickness that is the thickness of each of the first terminal and the second terminal in a vertical direction, eg, a height direction Z of the electrical connector.

[0076] In some embodiments, the thinned portion 21 of the second terminal 20 is formed by a stamping process, such as a stamping forming process. It should be understood that a stamping process is a manufacturing technique in which pressure is applied to a panel metal or non-metal by a stamping equipment (press) and a tool (die) to cause separation or plastic deformation, thus resulting in a product with a specific shape, size and performance requirements.

[0077] It should be understood that the term "mating," as used in the description of this application, may refer to the end of a connector that faces a mating connector when the connector is connected to a corresponding mating connector, while the term "tail" may refer to the end of a connector that faces away from the mating connector when the connector is connected to a corresponding mating connector. For example, "mating" and "tail" may refer to opposite ends of a connector in a mating orientation, respectively.

[0078] In some embodiments, as shown in FIG. 4, the terminal assembly 100 includes a plurality of first terminals 10 and a plurality of second terminals 20 arranged side by side in a row. In the illustrated exemplary embodiment, the terminal assembly 100 includes two rows of terminals, each row including a plurality of first terminals 10 and a plurality of second terminals 20. As shown in FIG. 4, the terminals in the first row of the two rows of terminals may include both the first terminals 10 and the second terminals 20. The terminals in the second row of the two rows of terminals may also include both the first terminals 10 and the second terminals 20. In some embodiments, corresponding first terminals 10 and second terminals 20 forming either of the two rows of terminals may be arranged in an array.

[0079] In accordance with an exemplary embodiment of the present application, as shown in FIG. 5 , the terminal assembly includes a total of two rows of terminals, e.g., row A of terminals and row B of terminals spaced apart across a thickness of the terminal assembly in FIG. 5 , with the rows of terminals located in the upper position in FIG. 5 being identified from right to left as A1, A2, A3, A4, A5, A6, A7, A8, A9, A10, A11, and A12, and the rows of terminals located in the lower position in FIG. 5 being identified from left to right as B1, B2, B3, B4, B5, B6, B7, B8, B9, B10, B11, and B12.

[0080] In the illustrated exemplary embodiment, each of the terminal row A and the terminal row B includes a first terminal 10 and a second terminal 20, which are arranged side by side to form a terminal row. The terminals A4, A5, A6, A9 and B4, B5, B6, B9 as the first terminals 10 have a thickness of 0.1 mm to 0.35 mm to provide a rated current of 5 A to 10 A. The terminals A1, A2, A3, A7, A8, A10, A11, A12 and B1, B2, B3, B7, B8, B10, B11, B12 as the second terminals 20 have a thickness of 0.1 mm to 0.25 mm to provide high-speed signal transmission of 5 G to 80 G.

[0081] As shown in FIG. 2, in some embodiments, the second terminals 20 may be initially formed with a terminal material thickness ranging from 0.10 mm to 0.25 mm. To better meet high frequency structural requirements, the second terminals 20 may be thinned with a thinning depth of 0.01 mm to 0.10 mm. In an optional exemplary embodiment, four of the second terminals 20 may be thinned. Referring to FIG. 1, A2, A3, A10, and A11 of the terminals in row A of the second terminals 20 are thinned.

[0082] In the illustrated exemplary embodiment, the terminals in row A and row B are aligned with each other in the vertical direction Z (height direction of the terminal assembly). In an optional exemplary embodiment, the second terminals 20 of the terminals in row A that have been thinned are aligned with the second terminals 20 of the terminals in row B that have been thinned in the vertical direction Z. In the illustrated exemplary embodiment, in response to the thinning of the second terminals 20 of the terminals in row A, B2, B3, B10, and B11 of the second terminals 20 of the terminals in row B, the terminals A2, A3, A10, and A11 are aligned with the B11, B10, B3, and B2, respectively, in the vertical direction Z. In some embodiments, the recess formed by thinning the second terminal in the terminals of row A and the recess formed by thinning the second terminal in the terminals of row B are provided opposite to each other in the vertical direction Z. With reference to Fig. 16, as an example, the recess formed by thinning the terminal A2 in the terminals of row A is provided opposite to the terminal in row B in the vertical direction Z, and the recess formed by thinning the terminal B11 in the terminals of row B is provided opposite to the terminal in row A in the vertical direction Z.

[0083] Optionally, the first terminal 10 and the second terminal 20 are provided with a corrosion-resistant plating layer, and the material of the plating layer is any one of platinum, rhodium-ruthenium, and palladium. For example, the terminal surfaces of the first terminal 10 and the second terminal 20 are treated with a special plating layer, such as a platinum plating layer, a rhodium-ruthenium plating layer, or a palladium plating layer, to fulfill the corrosion-resistant effect.

[0084] In some embodiments, the surfaces of the first terminal 10 and the second terminal 20 are treated with platinum, rhodium-ruthenium, and palladium by electroplating to form corresponding plating layers, thereby forming uniform, dense, and well-bonded metal surfaces while improving the corrosion resistance of the corresponding terminals.

[0085] With the terminal assembly 100 provided by the exemplary embodiment of the present application, the first terminal 10 for transmitting power has a thickness as a first thickness, and the second terminal 20 for transmitting a signal has a thickness as a second thickness smaller than the first thickness. For example, a portion of the second terminal 20 has a thickness smaller than the thickness of the first terminal 10, and the second terminal 20 is thinner compared with the conventional signal terminal, and can meet the requirement of high-speed transmission, alleviating the technical problem existing in the prior art that the USB Type-C terminal structure cannot meet the high-speed signal transmission.

[0086] 5 and 6, according to another aspect of an embodiment of the present application, an electrical connector 1 is provided, which may be applicable to 5G cellular phones, tablet PCs, adapters, communication devices, network devices, routing and notebook PCs, electronic cigarettes, etc. As an example, the electrical connector 1 may be a USB Type-C connector.

[0087] In the illustrated exemplary embodiment, the electrical connector 1 according to the present application may include a housing and a terminal assembly. The terminal assembly may be the terminal assembly 100 as described above in the previous embodiment. As described in the previous embodiment, in the terminal assembly 100, the first terminals 10 and the second terminals 20 are both provided in plurality to form two rows of terminals arranged one above the other. In the illustrated exemplary embodiment, the housing 200 of the electrical connector 1 is sleeve-connected to the outside of the two rows of terminals to fix the two rows of terminals.

[0088] For example, the electrical connector 1 includes a terminal assembly 100 and a housing 200, the housing 200 being sleeved over at least a portion of an outer portion of the terminal assembly 100, the terminal assembly 100 including a plurality of first terminals 10 and a plurality of second terminals 20, the first terminals 10 and the second terminals 20 being formed to have an elongated strip shape. As shown in Fig. 4, some of the first terminals 10 and the second terminals 20 are arranged to form a row of the terminal group, e.g., the conductive elements 101 of the first row, and other of the first terminals 10 and the second terminals 20 are arranged to form another row of the terminal group, e.g., the conductive elements 102 of the second row.

[0089] According to an exemplary embodiment of the present application, the terminals of one of the two rows of terminals are configured as a first row of conductive elements 101 formed by some of the plurality of first terminals 10 and some of the plurality of second terminals 20, and the terminals of the other of the two rows of terminals are configured as a second row of conductive elements 102 formed by other terminals of the plurality of first terminals 10 and other terminals of the plurality of second terminals 20.

[0090] In the illustrated exemplary embodiment, the first row of conductive elements 101 and the second row of conductive elements 102 are spaced apart from each other in the thickness direction Z of the electrical connector 1, and a plastic member as the housing 200 is molded on the outside of the first row of conductive elements 101 and the second row of conductive elements 102.

[0091] In some embodiments, the first row of conductive elements 101 and the second row of conductive elements 102 are arranged opposite one another. In some embodiments, the first terminal 10 may include a mating portion 11 and a tail portion 12. The second terminal 20 may include a mating portion 22 and a tail portion 23.

[0092] In some embodiments, the terminal assembly 100 includes an insulating terminal assembly housing and a plurality of first terminals 10 and a plurality of second terminals 20 integrally molded with the insulating terminal assembly housing. Some of the first terminals 10 and some of the second terminals 20 are aligned in a horizontal direction X to form a first row of conductive elements 101, and other terminals of the first terminals 10 and other terminals of the second terminals 20 are aligned in a horizontal direction X to form a second row of conductive elements 102. The conductive elements 101 in the first row and the conductive elements 102 in the second row have thin-walled portions that have been thinned by a thinning process, and the conductive elements 101 in the first row and the conductive elements 102 in the second row are arranged opposite each other in the thickness direction Z of the electrical connector 1 such that at least a portion of the second terminals 20 forming the conductive elements 101 in the first row and at least a portion of the second terminals 20 forming the conductive elements 102 in the second row have thin-walled portions that have been thinned, and the conductive elements 101 in the first row and the second terminals 20 having thin-walled portions forming the conductive elements 102 in the second row are aligned vertically with each other along the height direction Z.

[0093] 4, the terminal assembly 100 further includes a shield 110 provided between the first row of conductive elements 101 and the second row of conductive elements 102 in the thickness direction Z of the electrical connector 1. The shield 110 is spaced a predetermined distance from the first row of conductive elements 101 and the second row of conductive elements 102 in the height direction Z of the electrical connector 1. The shield 110 is configured to shield signal interference between the two rows of conductive terminals.

[0094] In some embodiments, housing 200 includes a terminal assembly housing 260, which may be defined by portions for accommodating first terminal 10 and second terminal 20. Each of mating portion 11 of first terminal 10 and mating portion 22 of second terminal 20 of terminal assembly 100 is molded into a housing portion of terminal assembly housing 260 by injection molding.

[0095] In some embodiments, the shield 110 may be molded into the housing portion of the terminal assembly housing by injection molding together with the tail portion 12 of the first terminal 10 and / or the tail portion 23 of the second terminal 20 to form a unitary member.

[0096] In some embodiments, the shield 110 may be formed as a plate. Optionally, the shield 110 formed as a plate may be provided between and parallel to the first and second rows of conductive elements 101, 102, respectively.

[0097] 6 to 8, the electrical connector 1 includes a first sealing member 300. A groove 210 is provided along the circumferential direction of the housing 200, and the first sealing member 300 is provided inside the groove 210.

[0098] For example, the groove 210 is disposed along a peripheral portion of the housing 200. The first sealing member 300 is formed in the groove 210 by a LIM process (liquid injection molding), and the first sealing member 300 fills the groove 210 to achieve the effect of a front seal of the electrical connector 1.

[0099] In an exemplary embodiment according to the present application, groove 210 is provided in an area of ​​housing 200 proximate the tail portions of the terminals forming first row 101 and second row 102 of conductive elements.

[0100] In some embodiments, the groove 210 is roughened to form a roughened portion by roughening the bottom of the groove 210 by laser engraving (also known as laser machining) or electrical discharge machining (see FIGS. 10A-10B). The so-called "groove bottom" of the groove 210 includes the surfaces of the bottom wall and the two side walls connected to the bottom wall that make up the groove. For example, the groove surface of the groove 210 may be embossed or knurled to form the roughened portion.

[0101] In some embodiments, the first sealing member 300 may be formed by: placing a roughened portion of the groove 210 to be machined in an adhesive forming tool that matches the first sealing member 300 in a predetermined size and shape, and applying adhesive to the roughened portion in a circumferential direction of the housing 200. In some examples, the adhesive is applied in the adhesive forming tool by one of a time-pressurized application method, a piston pump application method, or a screw metering pump application method.

[0102] Optionally, the adhesive forming tool contains an adhesive, which may be selected from one of a UV adhesive, a silicone, and an epoxy resin adhesive.

[0103] In an exemplary embodiment according to the present application, the electrical connector 1 further includes a second sealing member 400, and the housing 200 is provided with a cavity 220 having a hole depth direction perpendicular to the top surface of the terminal assembly 100, and the second sealing member 400 is provided within the cavity 220.

[0104] For example, the cavity 220 is provided throughout the housing 200. For example, the cavity 220 is provided on both sides of the housing 200, two cavities 220 are provided opposite each other, the terminal assembly 100 is located between the two cavities 220, the second sealing member 400 is formed in the cavity 220 by the LIM process, and the cavity 220 is sealed by the second sealing member 400 to realize the rear sealing effect of the electrical connector.

[0105] 6-8, in some embodiments of the present application, the housing 200 may include a support portion 270 formed near a tail end of the housing 200. The support portion 270 may be configured as a stop portion for stopping excessive movement of the electrical connector 1 in the mating direction Y when the electrical connector 1 is mated with a matched corresponding electrical connector.

[0106] In the illustrated exemplary embodiment, the cavities 220 are provided on two opposing surfaces of the support portion 270 in the thickness direction Z of the electrical connector 1. If the second sealing member 400 is not provided, a part of the tail portions of the terminals forming the first row of conductive elements 101 and the second row of conductive elements 102 may be visible from the outside of the electrical connector 1 through the cavities 200.

[0107] In the illustrated exemplary embodiment, the groove 210 is provided at a predetermined distance from the support portion 270 and is located on the mating side of the support portion 270, so that when the electrical connector 1 is mated with a matched corresponding electrical connector in the mating direction Y, the first sealing member 300 provided in the groove 210 first comes into contact with the engaging portion of the matched corresponding electrical connector to realize a forward sealing effect of the electrical connector 1.

[0108] For example, the inner surface of cavity 220, like groove 210, may be roughened by either laser engraving (also called laser machining) or electrical discharge machining to form a roughened portion, or the outer surface of groove 210 may be embossed or knurled to form a roughened portion.

[0109] In some embodiments, the second sealing member 400 is formed by: using an adhesive forming tool that matches the second sealing member 400 in terms of a predetermined size and shape, placing the roughened portion of the groove 220 to be machined on the adhesive forming tool, and applying an adhesive to the roughened portion of the inner periphery of the cavity 220.

[0110] In some embodiments, the rough surface portion 22 includes a pattern formed by at least one of a diagonal line pattern, a grid pattern, or a predetermined symbol pattern. For example, the predetermined symbol pattern includes at least one of a Union Jack shape, an H shape, or an X shape.

[0111] In some embodiments, first sealing member 300 is configured to have an annular shape that extends continuously circumferentially around an outer periphery of housing 200 proximate support portion 270. Optionally, sealing member 300 is configured to have a mounting surface that forms a positive fit with a groove.

[0112] In some embodiments, the cavity 220 may be configured to have a square opening cross-sectional shape, and therefore the second sealing member 400 is configured to have a mounting surface that has a substantially square shape and forms a positive fit with the cavity 220.

[0113] It should be understood that the term "positive fit" as used in this application may refer to a close fitting relationship in which two mating components abut one another in terms of shape and position.

[0114] In some embodiments, the first sealing member 300 and / or the second sealing member 400 may be an elastically deformable member. The first sealing member 300 and the second sealing member 400 are configured to elastically deform when the first sealing member 300 and the second sealing member 400 are in contact with a mounting portion of a corresponding electronic device (e.g., a part of the shell of a connector of the electronic device) to which they are fitted, and form an interference fit with the mounting portion of the electronic device in a direction perpendicular to the mating direction Y. In one embodiment, the sealing member may be made of an ultraviolet curing adhesive (UV adhesive), silicone, or epoxy resin adhesive. The ultraviolet curing adhesive is quickly cured by ultraviolet irradiation to become an elastic adhesive film, and is characterized by high adhesive strength, vibration resistance, high temperature resistance, good durability, etc.

[0115] With the electrical connector 1 according to the exemplary embodiments of the present application, particularly in embodiments in which roughened surface portions are formed in the grooves 210 and / or cavities 220, the roughened surface portions increase the surface roughness of the contact surfaces between the sealing members 300, 400 and the corresponding grooves 210, cavities 220 of the housing 200, thereby improving the adhesion of the sealing members to the housing and ensuring the sealing performance of the electrical connector 1.

[0116] The above technical solution can provide a very close attachment between the first and / or second sealing members and the housing, and the outer side wall of the housing of the connector provided with the roughened portion has a higher surface roughness than that of the other portion of the housing, thereby greatly improving the adhesion between the first and / or second sealing members and the roughened portion of the main housing and reducing the risk of the sealing members falling off. Thus, when the connector is mounted on the mounting portion of the electronic device, a seamless seal is generated between the connector and the mounting portion of the electronic device, and the risk of water vapor / dust entering the inside of the electronic device can be reduced.

[0117] Optionally, as shown in FIG. 6 , in order to enhance the adhesion of the first sealing member 300 and the second sealing member 400 to the housing 200, the housing 200 is provided with a first rough surface portion 230 at the bottom of the groove 210, and the terminal assembly 100 is provided with a second rough surface portion 240 in an area where the cavity 220 is projected onto the terminal assembly 100 in the depth direction of the hole, and the first rough surface portion 230 and the second rough surface portion 240 are formed by laser processing to enhance the surface roughness, enhance the adhesion of the first sealing member 300 and the second sealing member 400, and meet the waterproof requirement.

[0118] In some embodiments, the seals may include a front seal member and a rear seal member. The adhesion of the LIM may be increased by roughening the mounting surface, such as with a laser. Such a configuration may enable the connector to meet IPX8 immersion testing.

[0119] In some embodiments according to the present application, as shown in Figs. 6 to 8, the electrical connector 1 may further include a frame 500. The frame 500 may be configured to increase the strength of the housing 200. The frame 500 has a first portion 510 embedded in the support portion 270 of the housing 200, a second portion 520 disposed on the outside of the housing 200, and a third portion 530 formed by extending from both sides of the first portion 510. In the width direction X of the electrical connector 1, the bracket 250 is formed by extending from both sides of the support portion 270 of the housing 200. The bracket 250 may have a threaded hole. The third frame portion 530 of the frame 500 is embedded in the bracket 250.

[0120] It should be noted that the first portion 510, the second portion 520, and the third portion 530 are connected to each other. For example, the first portion 510, the second portion 520, and the third portion 530 may be integrally formed, such as by being stamped from a single sheet. For example, the first portion 510 is embedded in the housing 200 using insert molding, the third portion 530 is embedded in the bracket 250 using insert molding, and the second portion 520 is disposed on the housing 200, which increases the strength of the product, improves drop resistance, and simplifies the manufacturing of the product.

[0121] With the electrical connector 1 provided by the exemplary embodiment of the present application, the first sealing member 300 and the second sealing member 400 are integrally molded by using LIM, which meets the waterproof requirements of the electrical connector and brings about a simpler process; furthermore, the first rough surface portion 230 and the second rough surface portion 240 are formed using laser processing to increase the surface roughness and increase the adhesive force of the sealing members to meet the waterproof requirements; and the first and third portions of the frame 500 are embedded in the housing 200 to improve the strength of the housing 200.

[0122] An embodiment according to yet another aspect of the present application provides a method for manufacturing the electrical connector 1.

[0123] According to an exemplary embodiment of the present application, a method for manufacturing an electrical connector 1 may include step 01 of providing a plurality of first terminals 10 and a plurality of second terminals 20, and forming a first row of conductive elements 101 (lower row of terminals) and a second row of conductive elements 102 (upper row of terminals) by the plurality of first terminals 10 and the plurality of second terminals 20, respectively.

[0124] In some embodiments, in step 01), a plurality of first terminals 10 and a plurality of second terminals 20 are arranged in a row such that each row includes first terminals 10 and second terminals 20 arranged in an array.

[0125] In some embodiments, referring to Figures 1 and 4, step 01) may include forming a first row of conductive elements 101 by arranging some of the plurality of first terminals 10 and some of the plurality of second terminals 20 in an array, and forming a second row of conductive elements 102 by arranging other terminals of the plurality of first terminals 10 and other terminals of the plurality of second terminals 20 in an array.

[0126] The method may include a step 02) of providing a shield (110).

[0127] In some embodiments, step 02) may include providing a shield 110 formed as a plate.

[0128] The method may include step 03) of placing a first row of conductive elements 101 (lower row of terminals) and a shield 110 (middle shield plate) in a first injection mold and forming a first injection molded product to form a first molded member M1, where the first row of conductive elements 101 and the shield 110 are spaced apart from each other in a thickness direction Z of the electrical connector 1, as shown in FIG. 11 .

[0129] 11 and 12, in some embodiments, in step 03), mounting slots for assembling the second row of conductive elements 102 may be integrally molded on a side of the first molded member M1 opposite to the side of the shield 110 on which the first row of conductive elements 101 are located. FIG. 11 shows the state of the first molded member M1 before the second row of conductive elements 102 are assembled. FIG. 12 shows the state of the first molded member M1 after the second row of conductive elements 102 are assembled to the first molded member M1.

[0130] In the illustrated exemplary embodiment, the first molded member M1 includes a terminal assembly housing 260 formed by injection molding around the first row of conductive elements 101 (the lower row of terminals) and the shield 110 (the middle shield plate). The terminal assembly housing 260 is configured to have mounting slots for assembling the second row of conductive elements 102 on a side of the first molded member M1 opposite the side of the shield 110 that positions the first row of conductive elements 101.

[0131] 11, the mounting slots may include a plurality of first slots 261 near the mating end side of the terminal assembly 100 ( / first molding member M1), a plurality of third slots 263 near the tail end side of the terminal assembly 100 ( / first molding member M1), and a plurality of second slots 262 provided between the plurality of first slots 261 and the plurality of third slots 263 along the mating direction Y of the electrical connector 1. The first slots 261, the second slots 262, and the third slots 263 may have the same number, and the corresponding first slots 261, the second slots 262, and the third slots 263 aligned with each other in the mating direction Y of the electrical connector 1 are used to receive and position one of the terminals forming the conductive elements 102 of the second row.

[0132] The method may include step 04) of assembling the second row of conductive elements 102 onto the first molding member M1, as shown in FIG. 12, and positioning the second row of conductive elements (upper row terminals) relative to the first molding member M1 such that the second row of conductive elements 102 are spaced apart from the first row of conductive elements 101 in the height direction Z of the electrical connector 1, and the shield 110 is located between the first row of conductive elements 101 and the second row of conductive elements 102.

[0133] The method may include step 05) of placing the first row of conductive elements (upper row of terminals) and the first molding member M1 in a second injection molding mold, providing a frame 500 as a reinforcing member, positioning the frame 500 in a predetermined position relative to the first molding member M1 and the second row of conductive elements 102 assembled in step 04), and then performing a second injection molding (over-injection molding) using the assembled reinforcing member (frame 500), the second row of conductive elements 102, and the first molding member M1 as a mold core to form the second molding member M2, as shown in FIG.

[0134] According to an exemplary embodiment of the present application, the second molded member M2 is formed by assembling together the first molded member M1, the second row of conductive elements 102, and the frame 500, and over-injection molding the frame 500. The second molded member M2 includes the housing 200. By two-step injection molding, the frame 500 is embedded inside the housing 200, thereby providing greater rigidity to the electrical connector.

[0135] In the illustrated exemplary embodiment, the frame 500 as a reinforcing member may be configured to have, as shown in FIG. 8 , a first portion 510 as a central portion of the frame 500, a second portion 520 extending from the first portion 510 toward the tail end of the electrical connector 1 in the mating direction Y of the electrical connector 1, and a third portion 530 protruding from both sides of the first portion 510 toward the conductive elements 102 of the second row along the thickness direction Z of the electrical connector 1 in the width direction X of the electrical connector 1, the third portion 530 having an L-shaped step portion formed therein and having legs parallel to the first portion 510.

[0136] In some embodiments, in step 03), an accommodating portion 264 (see FIG. 8) for accommodating the second portion 520 of the frame 500 may be provided on the side of the terminal assembly housing 260 on which the first row of conductive elements 101 are provided, near the tail end of the first molded member M1 while forming the first molded member M1 in order to position the frame 500 in a predetermined position relative to the first molded member M1 and the second row of conductive elements 102 assembled together in step 04).

[0137] In some embodiments, during performing the secondary injection molding (over-injection molding) to form the second molded member M2, the first portion 510 of the frame 500 may be embedded in the housing 200 formed by the second molded member M2 by molding, and the second portion 520 is exposed to the outside of the housing 200. The third portion 530 of the frame 500 may be embedded in the housing 200 formed by the second molded member M2 by molding to form the bracket 250 of the electrical connector 1.

[0138] In some embodiments, while performing a secondary injection molding (over-injection molding) to form the second molded member M2, the support portion 270 may be formed by molding near the tail end of the housing 200. The first portion 510 of the frame 500 is embedded in the support portion 270 of the housing 200.

[0139] In some embodiments, while performing secondary injection molding (over-injection molding) to form the second molded member M2, the groove 210 may be formed on the mating end side of the support portion 270 of the housing 200 at a predetermined distance from the support portion 270, as shown in FIG. 14.

[0140] In some embodiments, as shown in FIG. 14, during secondary injection molding (over-injection molding) to form the second molded member M2, the cavity 220 may be formed on two opposing surfaces of the support portion 270 of the housing 200 in the thickness direction Z of the electrical connector 1.

[0141] Optionally, the groove surface of groove 210 and the inner surface of cavity 220 may be roughened by laser engraving (also called laser processing), or electrical discharge processing, or embossing or knurling to form a roughened portion. In an exemplary embodiment, as shown in Figures 10A-10B, a first roughened portion 230 may be formed on the groove surface of groove 210. A second roughened portion 240 may be provided in a region where cavity 220 is projected in the depth direction of the hole in terminal assembly 100.

[0142] The method may include step 06) of applying an adhesive to the first rough surface portion 230 and the second rough surface portion 240, respectively, and curing the adhesive to form a first sealing member 300 and a second sealing member 400 on the first rough surface portion 230 and the second rough surface portion 240, respectively, as shown in Figures 10 and 15.

[0143] It should be understood that the method for manufacturing the electrical connector of the present application is not limited to the method described in the above specific embodiments, and the individual steps described entail only a non-exhaustive list and do not have a specific order, and the order of the steps can be adjusted by those skilled in the art according to actual needs.

[0144] Various aspects are described in this disclosure, including but not limited to the following aspects.

[0145] Aspect 1. A terminal assembly (e.g., 100), the terminal assembly comprising a first terminal (e.g., 10) having a first thickness and configured to transmit power, and a second terminal (e.g., 20) configured to transmit a signal, wherein at least a portion of each second terminal (e.g., 20) is configured to have a second thickness that is less than the first thickness.

[0146] Aspect 2. The terminal assembly of Aspect 1 or any other aspect, wherein the first thickness is in the range of 0.1 mm to 0.35 mm.

[0147] Aspect 3. The terminal assembly of aspect 1 or any other aspect, wherein the second terminal (e.g., 20) is configured to have a thinned portion (e.g., 21) that has been subjected to a thinning process, the thinned portion (e.g., 21) is configured to have a thickness as a second thickness, the second terminal (e.g., 20) is configured to have a thickness in the range of 0.1 mm to 0.25 mm at a portion other than the thinned portion (e.g., 21), and the thinned portion (e.g., 21) is configured to have a smaller thickness in the range of 0.01 mm to 0.10 mm.

[0148] Aspect 4. The terminal assembly of Aspect 3 or any other aspect, wherein the first terminal (e.g., 10) includes a mating portion (e.g., 11) and a tail portion (e.g., 12), the second terminal (e.g., 20) includes a mating portion (e.g., 22) and a tail portion (e.g., 23), the mating portion (e.g., 22) of the second terminal (e.g., 20) includes a thinned portion (e.g., 21), and the mating portion (e.g., 11) of the first terminal (e.g., 10) is configured to have a uniform thickness.

[0149] Aspect 5. The terminal assembly of aspect 1 or any other aspect, wherein the first terminal (e.g., 10) is configured to be capable of carrying a current in the range of 5 A to 10 A and the second terminal (e.g., 20) is configured to be capable of transmitting signals at speeds in the range of 5 Gbps to 80 Gbps per second.

[0150] Aspect 6. A terminal assembly as described in aspect 1 or any other aspect, wherein each of the first terminal (e.g., 10) and the second terminal (e.g., 20) is provided with a corrosion-resistant plating layer, and the material of the plating layer is any one of platinum, rhodium-ruthenium, and palladium.

[0151] Embodiment 7. An electrical connector comprising a housing (e.g., 200) and a terminal assembly (e.g., 100) according to any one of embodiments 1 to 6 or any other embodiment, wherein a plurality of first terminals (e.g., 10) and a plurality of second terminals (e.g., 20) are provided to form two rows of terminals arranged one above the other in the height direction (Z) of the electrical connector, and the housing (e.g., 200) is sleeve-connected to the outside of the two rows of terminals to fix the two rows of terminals.

[0152] Aspect 8. An electrical connector as described in aspect 7 or any other aspect, wherein one of the two rows of terminals is configured as a first row of conductive elements (e.g., 101) formed by some of the plurality of first terminals (e.g., 10) and some of the plurality of second terminals (e.g., 20), and the other of the two rows of terminals is configured as a second row of conductive elements (e.g., 102) formed by other of the plurality of first terminals (e.g., 10) and other of the plurality of second terminals (e.g., 20), and the first row of conductive elements (e.g., 101) and the second row of conductive elements (e.g., 102) are arranged opposite each other in the height direction of the electrical connector.

[0153] Aspect 9. An electrical connector as described in aspect 8 or any other aspect, wherein at least some of the plurality of second terminals forming the conductive elements of the first row (e.g., 101) and at least some of the plurality of second terminals forming the conductive elements of the second row (e.g., 102) are configured to have thin-walled portions that have been thinned, and the second terminals having thin-walled portions forming the conductive elements of the first row (e.g., 101) and the second terminals having thin-walled portions forming the conductive elements of the second row (e.g., 102) are aligned with each other in the height direction.

[0154] Aspect 10. An electrical connector as described in aspect 8 or 9 or any other aspect, wherein the terminal assembly (e.g., 100) comprises a shield (e.g., 110) positioned between a first row of conductive elements (e.g., 101) and a second row of conductive elements (e.g., 102), and the shield (e.g., 110) is spaced apart in the height direction from the first row of conductive elements (e.g., 101) and the second row of conductive elements (e.g., 102), respectively, by a predetermined distance.

[0155] Embodiment 11. The electrical connector of any one of embodiments 7-9 or any other embodiment, wherein the housing (e.g., 200) includes a terminal assembly housing (e.g., 260), the terminal assembly housing (e.g., 260) defines a housing portion for accommodating a first terminal (e.g., 10) and a second terminal (e.g., 20), and the tail portion (e.g., 12) of the first terminal (e.g., 10) and the tail portion (e.g., 23) of the second terminal (e.g., 20) are molded into the housing portion of the terminal assembly housing (e.g., 260) by injection molding.

[0156] Example 12. An electrical connector as described in Example 11 or any other example, wherein the shield (e.g., 106) is molded into the housing portion of the terminal assembly housing (260) by injection molding together with the tail portion (e.g., 12) of the first terminal and the tail portion (e.g., 23) of the second terminal (e.g., 20) that form the first row of conductive elements and the second row of conductive elements.

[0157] Aspect 13. The electrical connector of aspect 7 or any other aspect, further comprising a first sealing member (e.g., 300), wherein a groove (e.g., 210) is provided along a peripheral portion of the housing (e.g., 200), and the first sealing member (e.g., 300) is provided inside the groove (e.g., 210).

[0158] Aspect 14: The electrical connector further comprises a second sealing member (e.g., 400), wherein the housing (e.g., 200) has a cavity (e.g., 220) having a hole depth direction perpendicular to the top surface of the terminal assembly (e.g., 100), and the second sealing member (e.g., 400) is provided inside the cavity (e.g., 220), the electrical connector being as described in Aspect 13 or any other aspect.

[0159] Aspect 15. An electrical connector as described in Aspect 14 or any other aspect, wherein the housing (e.g., 200) has a first roughened portion (e.g., 230) at the bottom of the groove (e.g., 210) for increasing the adhesive strength between the first sealing member (e.g., 300) and the housing (e.g., 200), and the terminal assembly (e.g., 100) has a second roughened portion (e.g., 240) in an area where the cavity (e.g., 220) is projected in the depth direction of the hole on the terminal assembly (e.g., 100) for increasing the adhesive strength between the second sealing member (e.g., 400) and the terminal assembly (e.g., 100).

[0160] Example 16. The electrical connector of Example 13 or any other example, wherein the first sealing member (e.g., 300) is an elastically deformable member, and the first sealing member (e.g., 300) is configured to elastically deform and form an interference fit with the mounting portion of the electronic device when the first sealing member (e.g., 300) contacts a mounting portion of an electronic device adapted to the electrical connector.

[0161] Aspect 17. An electrical connector as described in Aspect 13 or any other aspect, wherein the first sealing member (e.g., 300) is configured to have an annular shape that extends continuously circumferentially around the mating end of the housing (e.g., 200), and the first sealing member (e.g., 300) is configured to have a mounting surface that forms a positive fit with the groove (e.g., 210) of the housing (e.g., 200).

[0162] Example 18. An electrical connector as described in Example 14 or any other example, wherein the second sealing member (e.g., 400) is configured to have a substantially square shape, and the second sealing member (e.g., 400) is configured to have a mounting surface that forms a positive fit with the cavity of the housing (e.g., 200).

[0163] Aspect 19. The electrical connector of aspect 14 or any other aspect, further comprising a frame (e.g., 500), the frame (e.g., 500) including a first portion (e.g., 510) embedded in the housing (e.g., 200), a second portion (e.g., 520) disposed outside the housing (e.g., 200), and a third portion (e.g., 530) formed by extending from both sides of the first portion (e.g., 510), the housing (e.g., 200) being formed with a bracket (e.g., 250) extending from both sides thereof, the third portion (e.g., 530) of the frame (e.g., 500) being embedded in the bracket (e.g., 250).

[0164] Aspect 20. An electrical connector as described in aspect 19 or any other aspect, characterized in that the accommodating portion (e.g., 264) for accommodating the first portion (e.g., 510) is provided near an end of the terminal assembly housing (e.g., 260) so that the frame (e.g., 500) is positioned in a predetermined position relative to the terminal assembly housing (e.g., 260) and the terminal assembly (e.g., 100).

[0165] Example 21. An electrical connector as described in Example 19 or any other example, wherein a cavity (e.g., 220) is formed in a central portion of the housing (e.g., 200) that connects the bracket (e.g., 250), and corresponding terminals of the first terminal (e.g., 10) and the second terminal (e.g., 20) are exposed through the cavity (e.g., 220) before the second sealing member (e.g., 400) is arranged in the cavity (e.g., 220).

[0166] Aspect 22. An electrical connector as described in aspect 21 or any other aspect, wherein the mating portion of the housing (e.g., 200) has a groove (e.g., 210) formed at a predetermined position from the central portion.

[0167] Aspect 23. A method for manufacturing an electrical connector according to any one of aspects 7-22 or any other aspect, the method including: providing a plurality of first terminals (e.g., 10) and a plurality of second terminals (e.g., 20); forming a first row of conductive elements (e.g., 101) with some of the plurality of first terminals (e.g., 10) and some of the plurality of second terminals (e.g., 20); forming a second row of conductive elements (e.g., 102) with other terminals of the plurality of first terminals (e.g., 10) and other terminals of the plurality of second terminals (e.g., 20); providing a shield (e.g., 110); and placing the first row of conductive elements (e.g., 101) and the shield (e.g., 110) in a first injection mold and performing a first injection molding. 03) assembling the second row of conductive elements (e.g., 102) on the first molded member (e.g., M1) to position the second row of conductive elements (e.g., 102) in a predetermined position relative to the first molded member (e.g., M1); and 05) providing a frame (e.g., 500), positioning the frame (e.g., 500) in a predetermined position relative to the first molded member (e.g., M1) and the second row of conductive elements (e.g., 102), placing the frame (e.g., 500), the second row of conductive elements (e.g., 102), and the first molded member (e.g., M1) in a second injection mold, and performing a second injection molding to form a second molded member (e.g., M2) including a housing (e.g., 200).

[0168] A method according to embodiment 23 or any other embodiment, wherein in step 03) mounting slots for assembling the second row of conductive elements (e.g., 102) are integrally molded in a side portion of the first molding member (e.g., M1) opposite the side portion of the shield (e.g., 110) that positions the first row of conductive elements (e.g., 101).

[0169] Aspect 25. The method of aspect 24 or any other aspect, wherein the mounting slots include a plurality of first slots (e.g., 261) near the mating end side of the first molding member (e.g., M1), a plurality of third slots (e.g., 263) near the rear end side of the first molding member (e.g., M1), and a plurality of second slots (e.g., 262) provided between the plurality of first slots (e.g., 261) and the plurality of third slots (e.g., 263) in the mating direction (Y) of the electrical connector (e.g., 1), and each of the plurality of first slots (e.g., 261), each of the plurality of second slots (e.g., 262), and each of the plurality of third slots (e.g., 263) are aligned with each other in a one-to-one correspondence in the mating direction (Y) of the electrical connector (e.g., 1) to receive and position a corresponding one of the terminals forming the second row of conductive elements (e.g., 102).

[0170] A method according to Aspect 23 or any other aspect, wherein the first molded member (e.g., M1) formed in Aspect 26. Step 03) includes a terminal assembly housing (e.g., 260), and the accommodating portion (e.g., 264) is provided on a side of the terminal assembly housing (e.g., 260), and a first row of conductive elements (e.g., 101) are arranged on the terminal assembly housing and are close to the tail end of the first molded member (e.g., M1).

[0171] In step 05 of embodiment 27, providing the frame (e.g., 500) includes dividing the frame (e.g., 500) into a first portion (e.g., 510) as a central portion of the frame (e.g., 500), a second portion (e.g., 520) extending from the first portion (e.g., 510) toward the tail end of the electrical connector (e.g., 1) in the mating direction (Y), and a second portion (e.g., 520) extending from both sides of the width direction (X) of the electrical connector (e.g., 1) of the first portion (e.g., 510) in the height direction (Z) of the electrical connector (e.g., 1). and a third portion (e.g., 530) having an L-shaped step with legs parallel to the first portion (e.g., 510), and the second portion (e.g., 520) is received in the receiving portion (e.g., 264) to position the frame (e.g., 500) in a predetermined position relative to the first molding member (e.g., M1) and the second row of conductive elements (e.g., 102) assembled together in step 04). The method of embodiment 26 or any other embodiment,

[0172] A method according to Aspect 23 or any other aspect, wherein in step 05), during performing a second injection molding to form a second molded member (e.g., M2), a support portion (e.g., 270) is formed near the tail end of the housing (e.g., 200), a groove (e.g., 210) is formed on a mating side of the support portion (e.g., 270) at a predetermined distance from the support portion (e.g., 270), and a cavity (e.g., 220) is formed on two opposing surfaces of the support portion (e.g., 270) in the height direction (Z) of the electrical connector (e.g., 1).

[0173] Example 29. The method of example 28 or any other example, wherein the method further includes roughening the electrical connector, the groove (e.g., 210), and the cavity (e.g., 220) to form a roughened portion.

[0174] Embodiment 30. The method of embodiment 29 or any other embodiment, wherein the method further includes applying an adhesive to the roughened portion of the groove and / or the roughened portion of the cavity to form a first sealing member (e.g., 300) in the groove and / or a second sealing member (e.g., 400) in the cavity.

[0175] Aspect 31. The method of aspect 23 or any other aspect, wherein in step 03), the conductive elements (e.g., 101) of the first row are spaced apart from the shield (e.g., 110) in the height direction (Z) of the electrical connector (e.g., 1).

[0176] A method according to claim 31, wherein in step 04) the second row of conductive elements (e.g., 102) are positioned at a predetermined position relative to the first molding member (e.g., M1) such that the second row of conductive elements is spaced from the first row of conductive elements (e.g., 101) in the height direction (Z) of the electrical connector (e.g., 1) and the shield (e.g., 110) is located between the first row of conductive elements (e.g., 101) and the second row of conductive elements (e.g., 102).

[0177] A terminal assembly (e.g., 100) comprises a plurality of first terminals (e.g., 10) aligned in a row direction, each of the plurality of first terminals having the same thickness in a vertical direction perpendicular to the row direction along the length of the first terminal, and a plurality of second terminals (e.g., 20) aligned in the row direction with the plurality of first terminals, each of the plurality of second terminals including a portion (e.g., 21) having a smaller thickness in the vertical direction than the remainder of the second terminal.

[0178] Example 34. The terminal assembly of example 33 or any other example, wherein the plurality of first terminals are configured to transmit power and the plurality of second terminals are configured to transmit signals.

[0179] Aspect 35. The terminal assembly of aspect 34 or any other aspect, wherein the terminal assembly is configured according to the USB-C standard, wherein each of the plurality of first terminals is configured to carry a current in the range of 5 A to 10 A, and each of the plurality of second terminals is configured to transmit signals at a speed in the range of 5 Gbps to 80 Gbps per second.

[0180] Aspect 36. A terminal assembly as described in aspect 33 or any other aspect, wherein each of the plurality of first terminals has a first thickness in the range of 0.1 mm to 0.35 mm, and for each of the plurality of second terminals, a thinner portion has a thickness in the range of 0.01 mm to 0.10 mm, and a remaining portion of the second terminal has a thickness in the range of 0.1 mm to 0.25 mm.

[0181] Example 37. The terminal assembly of example 33 or any other example, wherein each of the plurality of second terminals includes a mating portion configured to mate with another component, and the mating portion of the second terminal includes a portion having a smaller thickness.

[0182] Example 38. The terminal assembly of example 37 or any other example, wherein each of the plurality of second terminals includes a tail portion opposite the mating portion and configured for surface mounting to a substrate.

[0183] Aspect 39. A terminal assembly as described in aspect 38 or any other aspect, wherein each of the plurality of first terminals and the plurality of second terminals includes one or more plating layers of platinum, rhodium-ruthenium, and palladium.

[0184] Example 40. A terminal assembly as described in example 38 or any other example, wherein each of the plurality of first terminals and the plurality of second terminals includes a roughened portion (e.g., 240) adjacent to the tail portion, and the roughened portion of each terminal has a higher surface roughness than other portions of each terminal such that a sealing member can be attached to the roughened portion of the terminal.

[0185] Aspect 41. An electrical connector comprises a housing including a body, a tongue extending from the body in a mating direction, and a bracket extending from a side portion of the body, a plurality of conductive elements held in a row by the housing, each of the plurality of conductive elements including a mating portion held by the tongue of the housing and a tail portion extending from the housing, and a frame (e.g., 500) including a first portion (e.g., 510) embedded in the body of the housing, a second portion (e.g., 520) disposed outside the housing, and a third portion (e.g., 530) embedded in a bracket (e.g., 250) of the housing.

[0186] Aspect 42. An electrical connector as described in aspect 41 or any other aspect, wherein the housing includes a groove (e.g., 210) disposed between the body and the tongue and having a surface having a higher roughness than other portions of the housing, and the sealing member (e.g., 400) is attached to the surface of the groove of the housing.

[0187] Embodiment 43. The electrical connector of embodiment 42 or any other embodiment, wherein the groove is disposed along a peripheral portion of the housing.

[0188] Aspect 44. The electrical connector of Aspect 42 or any other aspect, wherein the bracket is a first bracket extending from a first side portion of the housing body, the housing includes a second bracket extending from a second side portion of the housing body opposite the first side portion, and the sealing member is disposed between the first bracket and the second bracket.

[0189] Example 45. The electrical connector of example 44 or any other example, wherein each of the first bracket and the second bracket includes a hole, and the third portion of the frame includes a hole aligned with the holes of the first bracket and the second bracket.

[0190] Example 46. The electrical connector of Example 42 or any other example, wherein the sealing member is a first sealing member, the housing body includes a cavity (e.g., 220), and the electrical connector includes a second sealing member (e.g., 300) disposed within the cavity of the housing body and attached to a portion of the plurality of conductive elements passing through the cavity of the housing body.

[0191] Aspect 47. An electrical connector as described in aspect 42 or any other aspect, wherein the portions of the plurality of conductive elements that pass through the cavity of the body of the housing have a surface having a higher roughness than other portions of each conductive element.

[0192] Example 48. An electrical connector as described in example 41 or any other example, wherein the plurality of conductive elements each include a first terminal (e.g., 10) having a uniform thickness along its length and a second terminal (e.g., 20) having a smaller thickness at the mating portion than at the tail portion.

[0193] Aspect 49. A method for manufacturing an electrical connector, comprising: providing a plurality of conductive elements; molding an assembly housing (e.g., 260) over at least a portion of the plurality of conductive elements (e.g., 10, 20); disposing a frame (e.g., 500) on the assembly housing; and molding a connector housing (e.g., 200) over a portion of the frame.

[0194] Aspect 50. The method of aspect 49 or any other aspect, wherein the plurality of conductive elements is a first plurality of conductive elements aligned in a first row, and the method includes arranging a second plurality of conductive elements in a second row parallel to the first row, and then disposing the frame on the assembly housing.

[0195] Aspect 51. The method of aspect 49 or any other aspect, wherein the connector housing includes a groove (e.g., 210) around a circumferential circumference of the connector housing, and the method includes roughening a surface of the housing groove and forming a sealing member (e.g., 400) within the housing groove.

[0196] Aspect 52. The method of aspect 51 or any other aspect, wherein the sealing member is a front sealing member, the housing includes a cavity (e.g., 220) through which the multiple conductive elements pass, and the method includes forming a rear sealing member (e.g., 300) within the cavity of the housing and around the multiple conductive elements passing through the cavity.

[0197] Although several aspects of several embodiments have been described above, it should be understood that various changes, modifications, and improvements will be readily conceived by those skilled in the art. Such changes, modifications, and improvements are intended to be part of this disclosure and are intended to be within the spirit and scope of the present invention. Although the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be understood by those skilled in the art.

[0198] As an example, many of the inventive aspects have been described above with reference to right-angle connectors, but it should be understood that aspects of the present disclosure are not limited to right-angle connectors. Any of the inventive features, whether alone or in combination with one or more other inventive features, may also be used with other types of electrical connectors, such as vertical connectors.

[0199] Moreover, although several advantages of the invention may be noted, it should be understood that not all embodiments of the invention include all described advantages. Some embodiments may not implement any feature described as advantageous. Accordingly, the foregoing description and drawings are by way of example only.

[0200] Also, the described techniques may be embodied as a method, at least one example of which is provided. The operations performed as part of a method may be ordered in any suitable manner. Thus, while shown as sequential operations in the illustrative embodiments, embodiments may be constructed in which operations are performed in an order different from that illustrated, which may include performing some operations simultaneously.

[0201] All definitions, as defined and used, should be understood to take precedence over dictionary definitions, definitions in documents incorporated by reference, and / or ordinary meanings of the defined terms.

[0202] In describing the present disclosure, the orientations and positional relationships indicated by orientation terms such as "front", "rear", "upper", "lower", "left", "right", "transverse direction", "vertical direction", "perpendicular", "horizontal", "top", "bottom", etc., should be understood to be shown based on the accompanying drawings in order to facilitate and simplify the description of the present disclosure. Unless stated to the contrary, these orientation terms do not indicate or imply that a particular device or element must be specifically located, constructed, and operated in a specific direction, and therefore should not be understood as limitations on the present disclosure. The orientation terms "inside" and "outside" refer to the inside and outside relative to the contour of each component itself.

[0203] For ease of description, spatially relative terms such as "on," "above," "on an upper surface of," and "upper" may be used to describe the spatial relationship between one or more components or features and other components or features illustrated in the accompanying drawings. It should be understood that spatially relative terms not only include the orientation of the components illustrated in the accompanying drawings, but also include different orientations during use or operation.

[0204] It should be noted that the terms used herein are for the purpose of describing particular embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, the singular term includes the plural term unless otherwise indicated. In addition, when the terms "including" and / or "comprising" are used herein, they should also be understood to indicate the presence of features, steps, operations, parts, components, and / or combinations thereof.

[0205] The indefinite articles "a" and "an," as used in the specification and claims, unless clearly indicated to the contrary, should be understood to mean "at least one."

[0206] The phrase "and / or" as used in the specification and claims should be understood to mean "either or both" of the elements so conjoined, e.g., elements that may be present conjunctively or disjunctively. Multiple elements listed with "and / or" should be interpreted in the same manner, e.g., "one or more" of the elements so conjoined. Other elements other than the elements specifically identified by the "and / or" clause may optionally be present, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to "A and / or B," when used in conjunction with open-ended language such as "comprising," may refer in one embodiment to only A (optionally including elements other than B), in another embodiment to only B (optionally including elements other than A), in yet another embodiment to both A and B (optionally including other elements), etc.

[0207] When used in the present specification and claims, "or" should be understood to have the same meaning as "and / or" defined above. For example, when separating items in a list, "or" or "and / or" shall be interpreted as being inclusive, e.g., including at least one of, but also including more than one, and optionally including additional unlisted items, of a number of elements or a list of elements. Only terms clearly indicating the opposite, such as "only one of" or "exactly one of," or, when used in the claims, "consisting of," refer to the inclusion of exactly one element of a number of elements or a list of elements. In general, when used, the term "or" shall be interpreted as indicating exclusive alternatives (i.e., "one or the other but not both") only when preceded by terms of exclusivity, such as "either," "one of," "only one of," or "exactly one of." As used in the claims, "consisting essentially of" shall have its ordinary meaning as used in the field of patent law.

[0208] As used herein and in the claims, the phrase "at least one" in reference to a list of one or more elements should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed in the list of elements, and not excluding any combination of elements in the list of elements. This definition also allows for elements other than those specifically identified in the list of elements to which the phrase "at least one" refers, whether related or unrelated to those specifically identified elements, may optionally be present. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently, "at least one of A and / or B") may refer in one embodiment to at least one, optionally including two or more, i.e., A without the presence of B (and optionally including elements other than B); in another embodiment, to at least one, optionally including two or more, i.e., B without the presence of A (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including two or more, i.e., A, and at least one, optionally including two or more, i.e., B (and optionally including other elements);

[0209] In the claims, as well as in the above specification, all transitional phrases such as "comprising," "including," "carrying," "having," "containing," "involving," "holding," "composed of," and the like, are to be understood to be open-ended, e.g., meant to include but not be limited to. For example, a process, method, system, product, or device that includes a series of steps or units need not be limited to the explicitly recited steps or units, but instead may include other steps or units that are not explicitly recited or that are inherent to those processes, methods, products, or devices. Only the transitional phrases "consisting of" and "consisting essentially of" are intended to be closed or semi-closed transitional phrases, respectively.

[0210] The claims should not be read as limited to the described order or elements unless stated to that effect. It is understood that various changes in form and details can be made by those skilled in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the following claims and equivalents are claimed.

[0211] As in the specification above, in the claims, the use of sequence terms such as "first," "second," "third," etc. does not, in and of itself, imply any priority, precedence, or ordering of one element relative to another, or the temporal order in which method operations are performed, but is merely used as a label to distinguish one element having a particular name from another element having the same name (in the absence of the use of sequence terms) in order to distinguish the elements.

Claims

1. a plurality of first terminals aligned in a row direction; the plurality of first terminals and the plurality of second terminals aligned in the row direction; each of the plurality of first terminals has a same thickness along a length of the first terminal in a vertical direction perpendicular to the row direction; a terminal assembly, wherein each of the plurality of second terminals has a portion having a smaller thickness in the vertical direction than a remainder of the second terminal.

2. the plurality of first terminals are configured to transmit power; The terminal assembly of claim 1 , wherein the plurality of second terminals are configured to transmit a signal.

3. The terminal assembly is configured in accordance with the USB-C standard; each of the plurality of first terminals is configured to carry a current in the range of 5 A to 10 A; The terminal assembly of claim 2 , wherein each of the plurality of second terminals is configured to transmit signals at a speed in the range of 5 Gbps to 80 Gbps per second.

4. each of the plurality of first terminals has a first thickness in a range of 0.1 mm to 0.35 mm; For each of the plurality of second terminals, the thinner portion has a thickness in the range of 0.01 mm to 0.10 mm; The terminal assembly of claim 1 , wherein a remaining portion of the second terminal has a thickness in the range of 0.1 mm to 0.25 mm.

5. 2. The terminal assembly of claim 1, wherein each of the plurality of second terminals includes a mating portion configured to mate with another component, the mating portion of the second terminal including the portion with the reduced thickness.

6. The terminal assembly of claim 5 , wherein each of the plurality of second terminals includes a tail portion opposite the mating portion and configured for surface mounting to a substrate.

7. The terminal assembly of claim 6 , wherein each of the plurality of first terminals and the plurality of second terminals includes a plating layer of one or more of platinum, rhodium-ruthenium, and palladium.

8. 7. The terminal assembly of claim 6, wherein each of the plurality of first terminals and the plurality of second terminals includes a roughened portion adjacent the tail portion, the roughened portion of each terminal having a higher surface roughness than other portions of each terminal such that a sealing member can be attached to the roughened portion of the terminal.

9. a housing including a main body, a tongue portion extending from the main body in a mating direction, and a bracket extending from a side portion of the main body; a plurality of conductive elements held in a row by the housing, each of the plurality of conductive elements including a mating portion held by the tongue of the housing and a tail portion extending from the housing; a frame including a first portion embedded in the body of the housing, a second portion disposed on the outside of the housing, and a third portion embedded in the bracket of the housing; An electrical connector comprising:

10. the housing includes a groove disposed between the body and the tongue, the groove having a surface with a higher roughness than other portions of the housing; 10. The electrical connector of claim 9, wherein the surface of the groove of the housing has a sealing member attached thereto.

11. The electrical connector of claim 10 , wherein the groove is disposed along a peripheral portion of the housing.

12. the bracket being a first bracket extending from a first side portion of the body of the housing; the housing includes a second bracket extending from a second side of the body of the housing opposite the first side; The electrical connector of claim 10 , wherein the sealing member is disposed between the first bracket and the second bracket.

13. each of the first bracket and the second bracket includes a hole; The electrical connector of claim 12 , wherein the third portion of the frame includes holes aligned with the holes in the first bracket and the second bracket.

14. the sealing member is a first sealing member, the body of the housing includes a cavity; 11. The electrical connector of claim 10, further comprising a second sealing member disposed within the cavity of the body of the housing and attached to a portion of the plurality of conductive elements that pass through the cavity of the body of the housing.

15. 11. The electrical connector of claim 10, wherein the portions of the plurality of conductive elements that pass through the cavity of the body of the housing have a surface having a higher roughness than other portions of the respective conductive elements.

16. 10. The electrical connector of claim 9, wherein the plurality of conductive elements include a first terminal each having a uniform thickness along its length and a second terminal each having a smaller thickness at the mating portion than at the tail portion.

17. 1. A method for manufacturing an electrical connector, comprising: Providing a plurality of conductive elements; molding an assembly housing over at least a portion of the plurality of conductive elements; disposing a frame on the assembly housing; molding a connector housing over a portion of the frame; A method comprising:

18. the plurality of conductive elements being a first plurality of conductive elements aligned in a first row; The method of claim 17 , wherein the method includes arranging a second plurality of conductive elements in a second row parallel to the first row and then disposing the frame over the assembly housing.

19. The connector housing includes a groove around a circumferential periphery of the connector housing, The method comprises: roughening a surface of the groove of the housing; and forming a sealing member in the groove of the housing.

20. the sealing member is a front sealing member, the housing includes a cavity through which the plurality of conductive elements pass; 20. The method of claim 19, wherein the method includes forming a rear sealing member within the cavity of the housing and around the plurality of conductive elements passing through the cavity.

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