USB-C Plug Connector Insert-Molding Design
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Solution Overview
Problem
The manufacturing time and cost of conventional USB type-C electrical plug connectors are increased due to the small sized terminals and close terminal spacing, which makes it difficult to combine them with the plastic core using one-time insert-molding.
Innovation Solution
An electrical plug connector design featuring a metallic shell with an insulated housing that includes a base portion, tubular portion, and mating room, where plug terminals with flexible contact portions and extending portions are assembled via insert-molding, allowing for reduced manufacturing time and cost by forming a single unit with cut portions that can be separated, and flexible contact portions that bend within grooves during mating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If terminals are made small and spaced closely to reduce connector size, then device compactness is improved, but manufacturing complexity and cost increase due to inability to use one-time insert-molding
Solution Approach 1:
The connector is divided into modular components: a plastic core with integrated tubular portion, separate upper and lower terminal assemblies, and a metallic shell. Each module can be manufactured independently using appropriate processes, then assembled together. This segmentation allows small terminals to be precisely manufactured and positioned without requiring complex one-time insert-molding of the entire assembly.
Solution Approach 2:
The tubular portion is integrated into the plastic core, and terminal assemblies are nested within the plastic core structure. The metallic shell encloses the entire assembly. This nested structure allows compact arrangement of small terminals while maintaining manufacturing simplicity through hierarchical assembly of pre-manufactured components.
2Adaptability or versatility
If terminals are assembled separately on the plastic core due to small size and close spacing, then manufacturing flexibility is improved, but manufacturing time and cost increase
Solution Approach 1:
The plastic core with integrated tubular portion is pre-manufactured with precise positioning features before terminal assembly. This preliminary preparation of the core structure enables rapid subsequent assembly of terminal units, reducing overall manufacturing time while maintaining the flexibility to assemble terminals separately if needed.
Solution Approach 2:
The tubular portion is merged with the plastic core into a single integrated component manufactured by injection molding. This combination eliminates separate manufacturing steps for the tubular portion and core, improving productivity while maintaining the modular advantage of separate terminal assembly when required.
3Volume of moving object
If conventional USB type-C connector design is used with small terminals, then connector compactness is achieved, but terminal positioning precision becomes difficult to maintain
Solution Approach 1:
The terminal assemblies incorporate self-positioning features such as positioning protrusions that fit into corresponding recesses in the plastic core. This self-service positioning mechanism ensures precise terminal alignment during assembly without requiring complex external fixtures or post-assembly adjustment, maintaining high positioning precision despite compact dimensions.
Data Source
AI summary
An electrical plug connector includes a metallic shell, an insulated housing, and a plurality of plug terminals. The insulated housing is received in the metallic shell. The insulated housing includes a first groove and a plurality of second grooves. The plug terminals are held in the insulated housing in a single row manner. Each of the plug terminals includes a flexible contact portion, a body portion, and a plurality of cut portions. The flexible contact portion is extending backward from the body portion in the front-to-rear direction and protruded from the insulated housing. The cut portions are at the body portion and correspond to the first groove, and the flexible contact portions respectively correspond to the second grooves.