Segmented Insulating Core for Reversible USB Type-C Connector
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Solution Overview
Problem
The existing USB Type-C electrical plug connectors have a complex and costly assembly process due to the annular structured insulating plastic core with terminal grooves on the outer surface, which requires additional Mylar film for protection and increases manufacturing complexity.
Innovation Solution
The design features a metallic shell with a first and second terminal module, each with insulated members, conductive strips, and terminal grooves on the inner surfaces, allowing for a dual orientation USB Type-C connector with no need for Mylar film, using different molds for assembly and featuring flexible contact portions for reversible pin assignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece annular insulating plastic core with terminal grooves extending to the outer surface is used, then the connector structure is simplified, but additional Mylar film is required to cover the terminal grooves and prevent terminal contact with the outer shell, increasing component cost and assembly complexity
Solution Approach 1:
The insulating core is divided into two separate half-shell structures (first insulating half-shell and second insulating half-shell) that are assembled together. The terminal grooves are formed only on the inner surfaces of these half-shells, not extending to the outer assembly surface, eliminating the need for additional protective films while maintaining structural simplicity and reducing assembly complexity.
2Ease of operation
If terminal grooves extend to the outer surface of the insulating core, then terminal positioning is simplified, but the front ends of terminals are exposed and require Mylar film coverage to prevent contact with the outer shell, increasing component count and cost
Solution Approach 1:
By segmenting the insulating core into two half-shells with terminal grooves formed only on inner surfaces, the design achieves easy terminal positioning within the grooves while the outer assembly surface remains closed and exposed-free, eliminating the need for additional Mylar film protective components.
3Reliability
If a conventional annular insulating core with Mylar film coverage is used, then terminal protection is ensured, but the manufacturing cost increases due to additional components and assembly steps
Solution Approach 1:
The segmented half-shell design integrates terminal protection directly into the structure by forming terminal grooves only on inner surfaces, ensuring terminals are positioned and protected without requiring separate Mylar film components, thereby reducing manufacturing cost while maintaining reliability.
Solution Approach 2:
The protective function previously requiring a separate Mylar film layer is merged into the insulating core structure itself through the closed outer surface design of the assembled half-shells, eliminating the need for additional protective components and reducing overall manufacturing cost.
Data Source
AI summary
An electrical plug connector includes a first terminal module and a second terminal module disposed inside a metallic shell. The first terminal module includes a first insulated member and first plug terminals, a first combining portion, and a first conductive strip assembled on the first insulated member. The second terminal module includes a second insulated member and second plug terminals, a second combining portion, and a second conductive strip assembled on the second insulated member. The first terminal module and the second terminal module are formed by different plastic injection molds, and therefore the assembly of the first plug terminals, the second plug terminals, the first combining portion, and the second combining portion on the first insulated member and the second insulated member becomes easy. No additional Mylar film is utilized because no terminal groove appears on the outer surface of the first insulated member and the second insulated member.