Plug Connector Two-Level Terminal Staggering for USB 3.0 Soldering
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Solution Overview
Problem
USB 3.0 connectors face challenges in transmitting high-frequency signals due to electromagnetic interference and unstable impedance, and the soldering process is complicated by the interference of terminals and the flow of hot-melt adhesive into terminal holes, affecting signal transmission efficiency.
Innovation Solution
A plug connector design featuring an insulative housing with first and second terminals arranged in two levels, a positioning bracket with a zigzag boundary to prevent adhesive flow, and a metal shell assembly that stabilizes the soldering process and maintains impedance by separating soldering segments and preventing short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If terminals are arranged in rows for USB 3.0 connector compatibility, then connector compatibility is achieved, but soldering becomes difficult due to terminal interference
Solution Approach 1:
The patent transitions from a planar row arrangement of terminals to a three-dimensional configuration where soldering portions are positioned at different heights (two levels) on the positioning bracket. This vertical dimension separation allows terminals to maintain their row arrangement for USB 3.0 compatibility while enabling easier soldering access by staggering the soldering portions vertically, thus resolving the interference issue during soldering operations.
2Ease of manufacture
If hot-melt adhesive is used to mount the positioning bracket on the insulative housing, then mounting is simplified, but adhesive flows into terminal holes affecting signal transmission
Solution Approach 1:
The positioning bracket incorporates a zigzag boundary structure at its mounting interface with the insulative housing. This local geometric feature creates adhesive barriers that selectively control the flow of hot-melt adhesive, allowing it to bond the bracket securely while preventing it from flowing into the terminal holes. The zigzag pattern provides different properties in different locations: bonding capability at the interface and flow restriction at the terminal hole perimeters.
3Productivity
If terminals are positioned close together for high-density connection, then connection density increases, but electromagnetic interference increases and impedance becomes unstable
Solution Approach 1:
The positioning bracket divides the terminals into distinct groups or sections, each mounted on separate portions of the bracket structure. This segmentation physically separates adjacent terminals and their associated signal paths, reducing electromagnetic coupling and interference between them. By compartmentalizing the terminal arrangements, the bracket maintains high connection density while preserving impedance stability through reduced electromagnetic interaction between neighboring terminals.
Data Source
AI summary
A plug connector has an insulative housing, a plurality of first terminals, a plurality of second terminals and a positioning bracket. The terminals are mounted in the insulative housing and each terminal has a soldering portion. The positioning bracket is mounted on the insulative housing and has a positioning protrusion having a top surface and a bottom surface respectively holding the soldering portions on two levels. The soldering portions are arranged in two levels to facilitate soldering wires to the soldering portions.