USB-C Connector Tongue Assembly to Prevent Terminal Burrs
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Solution Overview
Problem
The formation of burrs on the extending portions of terminals in USB Type-C connectors during the injection molding process due to friction with molds, leading to manufacturing defects.
Innovation Solution
The design incorporates a surrounding portion with recessed fastening grooves and additional molds to secure the terminals, reducing friction and preventing burr formation by using a fifth mold to stabilize the terminals during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple molds are used to directly clamp the terminals in the injection molding process, then the terminals can be fastened securely, but friction between the extending portions and molds increases causing burr formation
Solution Approach 1:
The invention divides the fastening function into two separate stages: first, the molds clamp the tongue assembly to secure it during molding; second, the extending portions are inserted into elastic resetting components that provide individual fastening for each terminal. This segmentation prevents the extending portions from swaying during molding while eliminating direct friction between the molds and extending portions, thus preventing burr formation.
Solution Approach 2:
The invention introduces elastic resetting components as an intermediary between the molds and the terminals. These components receive the extending portions and provide the fastening force, acting as a mediator that eliminates direct contact between the molds and the extending portions. This intermediary mechanism secures the terminals without causing friction-induced burrs on their surfaces.
2Adaptability or versatility
If the extending portions are in a suspended state during molding, then the terminals can be positioned freely, but they sway longitudinally and laterally increasing friction with molds
Solution Approach 1:
The invention performs preliminary fastening by inserting the extending portions into elastic resetting components before the injection molding process begins. This preliminary action secures the terminals in fixed positions, preventing any swaying during molding. The terminals maintain their required positions without direct mold clamping, eliminating the suspended state that causes friction and burr formation.
Solution Approach 2:
The elastic resetting components provide beforehand cushioning by absorbing positioning adjustments and securing the extending portions in stable positions before molding occurs. This cushioning mechanism prevents sudden movements or swaying during the molding process, eliminating the conditions that lead to friction and burr generation on the terminal surfaces.
3Ease of manufacture
If the molds directly clamp the terminals, then fastening is achieved, but burrs are caused at friction positions between extending portions and molds
Solution Approach 1:
The elastic resetting components serve as an intermediary mechanism that simplifies the fastening process. Instead of complex direct mold clamping of individual terminals, the extending portions are simply inserted into the elastic components which automatically provide fastening through their elastic properties. This intermediary mechanism achieves secure fastening without direct mold-terminal contact, eliminating burr formation while maintaining ease of manufacture.
Solution Approach 2:
The elastic resetting components provide self-service fastening by automatically securing the extending portions through their elastic deformation and recovery characteristics. When the extending portions are inserted, the elastic components deform to accommodate them and then exert restoring force to secure them firmly. This self-service mechanism eliminates the need for complex external fastening systems while preventing burr formation through the absence of direct mold friction.
Data Source
AI summary
An electrical connector includes a shielding shell, a tongue assembly and a plurality of the terminals. The shielding shell has an accommodating space. The tongue assembly is disposed in the accommodating space. Two opposite sides of a rear surface of the tongue assembly extend rearward to form two connecting portions, respectively. Rear ends of the two connecting portions extend towards each other to form a surrounding portion extending downward. A rear surface of the surrounding portion is recessed frontward to form a fastening groove. The plurality of the terminals are mounted in the tongue assembly. Each terminal has an extending portion. Middles of rear surfaces of the extending portions of the plurality of the terminals are exposed outside of a middle of the surrounding portion by the fastening groove.