USB Type-C Connector Reinforced Mating Strength
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Solution Overview
Problem
Existing USB type C connectors lack sufficient strength due to their traditional insert-molded terminal modules, which are not reinforced adequately for robust mating performance.
Innovation Solution
A USB type C connector design featuring a metallic base insert-molded with an insulative base, incorporating an internal PCB within a frame structure, secured by a die-casting metallic shield and an insulator, forming a reinforced mating portion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an internal PCB is attached to the insulative housing in a cantilevered manner, then the manufacturing process is simplified, but the interior strength during mating is insufficient
Solution Approach 1:
The patent employs a composite structure combining metallic base material with insulative housing material. The metallic base insert provides structural reinforcement while the insulative housing maintains electrical isolation. This composite approach allows the internal PCB to be securely attached with enhanced strength during mating operations, resolving the contradiction between manufacturing simplicity and structural strength.
2Device complexity
If a traditional insert-molded terminal module is used, then the structure is simple, but the mating portion lacks sufficient reinforcement
Solution Approach 1:
The connector is segmented into distinct functional components: a metallic base insert for structural strength, an insulative housing for electrical isolation, and an internal PCB for electrical connections. This segmentation allows each component to be optimized for its specific function while collectively providing reinforced mating strength, resolving the contradiction between structural simplicity and mating reinforcement.
Solution Approach 2:
The patent combines metallic and insulative materials in a composite structure where the metallic base insert provides the necessary reinforcement for the mating portion. This composite approach maintains reasonable structural complexity while significantly enhancing the strength of the mating portion compared to traditional single-material insert-molded designs.
3Strength
If multiple components are assembled to form the connector, then the structural integrity is enhanced, but the manufacturing complexity increases
Solution Approach 1:
The patent merges multiple components into an integrated assembly where the metallic base insert is embedded within the insulative housing, and the internal PCB is securely attached to form a unified structure. The insulator applied upon the front region secures both the internal PCB and basic unit together. This merging approach enhances structural integrity while managing manufacturing complexity through coordinated assembly processes.
Data Source
AI summary
An electrical connector having a metallic base insert-molded with an insulative base to initially form a basic unit and successively with an internal PCB inserted in a frame structure of the metallic base to form an intermediate assembly with the reinforced mating portion thereof. An insulator is applied upon a front region of the intermediate assembly to secure the internal PCB and the basic unit together and commonly form a sub-assembly. A die-casting metallic shield encloses the sub-assembly and secured to the metallic base to commonly form the final receptacle connector.