USB Type-C Plug Connector with Wire Organizer
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Solution Overview
Problem
The assembly of USB type-C electrical plug connectors is complicated and costly due to the separation of upper and lower plug terminals, which requires intricate soldering and alignment of wires, increasing the risk of short circuits.
Innovation Solution
The design incorporates a metallic shell, insulated housing, plug terminals with flexible contact portions, and a wire organizer with tooth portions that puncture wires for electrical conduction, allowing for one-time assembly and eliminating the need for soldering, enabling reversible USB Type-C connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If upper and lower plug terminals are separated and assembled individually, then the connector can provide reversible USB Type-C connectivity, but the assembly difficulty and cost increase
Solution Approach 1:
The patent combines the upper and lower plug terminals into a single integrated terminal structure. The terminal includes both upper and lower contact portions that are formed as one piece, eliminating the need for separate assembly operations. This integration maintains the reversible connectivity function while significantly simplifying the manufacturing process.
Solution Approach 2:
The integrated terminal is designed with distinct upper and lower contact portions that are segmented in function but unified in structure. The terminal body includes separate contact regions for upper and lower connections, allowing each to perform its specific function while being manufactured as a single component.
2Reliability
If traditional soldering methods are used to connect wires to plug terminals, then reliable electrical connections can be achieved, but the soldering process becomes complicated and time-consuming
Solution Approach 1:
The patent replaces the traditional soldering process with a mechanical insertion method. Wires are inserted into wire grooves and secured by insertion fixing structures, eliminating the need for thermal soldering operations. This mechanical connection method maintains electrical reliability while dramatically improving assembly speed and productivity.
Solution Approach 2:
The wire organizer and insertion fixing structures are designed to automatically secure wires in their proper positions during assembly. The structure includes self-aligning features that guide wires into correct positions and provide automatic retention, reducing the need for complex manual positioning and securing operations.
3Reliability
If wires are aligned with plug terminals during assembly, then correct electrical connections can be established, but the alignment requirement increases assembly complexity
Solution Approach 1:
The patent introduces a wire organizer as an intermediary component between the wires and the plug terminals. The wire organizer includes wire grooves that pre-position and align wires with the corresponding terminal contacts. This intermediary structure automatically performs the alignment function, eliminating the need for complex manual alignment procedures.
Solution Approach 2:
The wire organizer is designed to pre-align and pre-position wires before they reach the terminal connection points. The wire grooves and guiding structures prepare the wires in the correct orientation and position in advance, so that the final connection step is simplified and does not require complex alignment operations.
4Reliability
If soldering wires to plug terminals is performed, then electrical connections can be made, but the risk of short circuits increases due to contact between soldering wires and terminals
Solution Approach 1:
The patent replaces the soldering process with a mechanical insertion and fixing system. Wires are inserted into grooves and secured by retention structures, completely eliminating the use of soldering wires and the associated short circuit risks. The mechanical connection provides reliable electrical contact without the harmful effects of traditional soldering.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution simplifies the assembly process, reduces costs, and ensures reliable electrical connections by using flexible contact portions and tooth portions for wire puncture, thereby avoiding the complexities of traditional soldering and enhancing the usability of USB Type-C connectors.
Implementation Method 1
a plurality of tooth portions that puncture the wires for electrical conduction
Data Source
AI summary
An electrical plug connector includes a metallic shell, an insulated housing, a plurality of plug terminals, a plurality of tooth portions, and a wire organizer. The insulated housing is received in the metallic shell. The plug terminals are held at the insulated housing. Each of the power terminal and the ground terminal of the plug terminals includes a clamping structure. Each of the tooth portions is extending from rear of the corresponding plug terminal. The wire organizer is assembled to the insulated housing. Each of the tooth portions is inserted into the corresponding wire groove of the wire organizer to connect to a corresponding wire when the wires held in the wire organizer are pressed against the tooth portions. Each power and ground terminals may include either a single one or a pair of flexible contact portions.