Integrally-Molded Grounding Structure for USB Type-C Connectors
Solution Overview
Problem
Conventional USB Type-C electrical connectors are prone to damage from mishandling and have complex, high-cost manufacturing processes due to the need for precise assembly and multiple molds, leading to inefficiencies and high maintenance costs.
Innovation Solution
An electrical connector design featuring an integrally-molded structure with misaligned grounding terminals and members, allowing for simplified manufacturing using a single mold set and reducing production costs while maintaining compliance with terminal pitch standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional USB Type-C electrical connectors are designed with separate grounding terminals and grounding members requiring precise assembly, then the connector can meet terminal pitch standards, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines the grounding terminal and grounding member into a single integrally-molded structure, eliminating the need for separate assembly operations. This integration maintains the required misalignment between grounding and signal terminals while simplifying the manufacturing process and reducing assembly complexity.
Solution Approach 2:
The integrally-molded structure serves multiple functions simultaneously: it provides both grounding terminals and grounding members, maintains proper pitch alignment, and prevents improper insertion. This multi-functionality reduces the number of separate components and assembly steps required.
2Manufacturing precision
If conventional connectors require multiple pressing molds for different terminals, then precise terminal positioning can be achieved, but production efficiency decreases and costs increase
Solution Approach 1:
The patent consolidates multiple terminal types (grounding terminals and grounding members) into a single integrally-molded structure that can be produced in one pressing operation. This eliminates the need for multiple pressing molds and operations, thereby improving production efficiency while maintaining positioning accuracy.
Solution Approach 2:
The integral molding process pre-establishes the correct positioning and misalignment relationships between grounding terminals and grounding members during a single manufacturing step, eliminating the need for subsequent assembly and adjustment operations.
3Ease of manufacture
If grounding terminals and grounding members are precisely aligned in conventional designs, then assembly is simplified, but the connector may not meet pitch standards when connected
Solution Approach 1:
The patent intentionally introduces asymmetry by misaligning the grounding terminals and grounding members within the integrally-molded structure. This asymmetric design ensures that when the connector is mated with another connector, the correct pitch standards are met while the integral molding keeps the manufacturing process simple.
4Ease of repair
If conventional connectors use separate components for grounding terminals and grounding members, then component replacement is possible, but repair processes become complicated and costly
Solution Approach 1:
By integrating grounding terminals and grounding members into a single molded structure, the patent simplifies the overall connector assembly, reducing the number of parts that need to be handled during repair or replacement operations.
Data Source
AI summary
An electrical connector including an insulating body, a plurality of terminals, and at least one grounding member is provided. The terminals and the grounding member are disposed in the insulating body. At least one grounding terminal among the terminals and the grounding member next to the grounding terminal form an integrally-molded structure. A portion of the grounding terminal and a portion of the grounding member are misaligned from each other along an arrangement direction of the terminals.