USB-C Plug Connector Assembly Simplification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly process for USB type-C electrical plug connectors is complex and time-consuming, leading to a high likelihood of defect production due to the numerous components and intricate assembly steps.
Innovation Solution
A simplified electrical plug connector design comprising a metallic shell, first and second insulated housings, and terminal modules, where the terminal modules are combined with their respective housings to form one-piece components through injection molding, reducing the number of components and simplifying assembly, while also providing a waterproof function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (primary plastic core, secondary plastic cores, terminal modules, hook members) are used to ensure functional requirements, then the connector achieves required electrical and mechanical performance, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple separate components (primary plastic core, secondary plastic cores, and terminal modules) into an integrated structure where the terminal modules are directly assembled into the plastic cores, reducing the number of discrete parts and simplifying the overall assembly process while maintaining electrical and mechanical performance
Solution Approach 2:
The connector is divided into functional modules (terminal modules with specific terminal types arranged in rows) that can be independently manufactured and then systematically assembled into the plastic core structure, enabling modular production that simplifies both manufacturing and assembly
2Ease of operation
If numerous components are assembled through intricate steps to meet functional requirements, then the connector achieves proper terminal arrangement and connection, but the production time increases and defect rate rises
Solution Approach 1:
Terminal modules are pre-assembled with their respective plastic cores before final integration, allowing for preliminary positioning and connection verification that simplifies the final assembly step and reduces the likelihood of defects during main assembly
Solution Approach 2:
Terminal modules are nested within the plastic core structure, with upper-row and lower-row terminal modules positioned in designated cavities of the primary and secondary plastic cores, creating a compact integrated assembly that reduces the number of external fastening operations required
Data Source
AI summary
An electrical plug connector includes a metallic shell, a first insulated housing, a second insulated housing, a first terminal module, and a second terminal module. The first terminal module includes the first terminals and the first assembling block combined with each other to form a one-piece member, and then the first insulated housing is further combined with the first terminal module. The second terminal module includes the second terminals and the second assembling block combined with each other to form a one-piece member, and then the second insulated housing is further combined with the second terminal module. The four-piece component is assembled into the metallic shell. Accordingly, the number of the components for manufacturing the connector can be reduced, thereby simplifying the assembling procedure for the connector.