USB Type-C Connector Terminal Integration for Cost Reduction
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Solution Overview
Problem
Conventional USB Type-C electrical connectors have high manufacturing costs due to complex processes and lack of metal buckling portions, leading to abrasion and inadequate ground connections when mated with other connectors.
Innovation Solution
The electrical connector design features an insulating housing with a terminal assembly that includes ground, power, and detecting terminals, where the terminals are integrated using injection molding, eliminating the need for a center shielding plate and reducing manufacturing costs by simplifying the structure and adding insertion and withdrawal resistance functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple separate terminals and a center shielding plate are used in conventional connectors, then the connector can provide multiple functions (charging, data transfer, grounding), but the manufacturing cost increases and the structure becomes more complex
Solution Approach 1:
The patent combines multiple separate terminals (ground terminals, power terminals, detecting terminals) and the center shielding plate into a single integrated terminal assembly. This assembly is formed as one piece through injection molding, merging multiple functional components into a unified structure that provides grounding, power transmission, and detection functions simultaneously, thereby reducing structural complexity while maintaining versatility
Solution Approach 2:
The integrated terminal assembly serves multiple functions: it provides ground connections through dedicated ground terminals, power transmission through power terminals, and connection status detection through detecting terminals. Additionally, the assembly replaces the traditional center shielding plate, providing structural support and guiding insertion while maintaining all electrical functions, thus achieving multi-functionality in a single component
2Adaptability or versatility
If multiple separate terminals and a center shielding plate are used in conventional connectors, then the connector can provide multiple functions, but the manufacturing cost increases due to multiple processes
Solution Approach 1:
The patent merges multiple separate terminals and the center shielding plate into a single integrated terminal assembly that is manufactured in one piece through injection molding. This eliminates the need for separate manufacturing processes for each terminal and the shielding plate, as well as reducing assembly steps, thereby significantly lowering manufacturing cost while maintaining all required functions
Solution Approach 2:
The injection molding process automatically forms the integrated terminal assembly with all necessary structural features and terminal configurations in a single operation. The mold design incorporates all terminal geometries and arrangements, allowing the complex multi-functional structure to be self-formed without requiring multiple machining or assembly operations, thus reducing manufacturing cost
3Device complexity
If the tongue portion lacks metal buckling portions, then the structure is simpler, but the plastic portions undergo abrasion after multiple buckling operations
Solution Approach 1:
The patent integrates metal buckling portions directly into the terminal assembly by forming them as integral parts of the injected structure. These metal portions are embedded within the plastic housing of the terminal assembly, combining the durability of metal with the structural integrity of the plastic housing, thereby preventing abrasion during repeated buckling operations while maintaining overall structural simplicity
Solution Approach 2:
The terminal assembly employs a composite structure where metal buckling portions are integrated into the plastic housing. This composite design combines the wear resistance and strength of metal with the insulating and structural properties of plastic, creating a durable buckling interface that resists abrasion during repeated connector mating operations
4Device complexity
If the tongue portion lacks metal buckling portions, then the structure is simpler, but ground connection between connectors cannot be established
Solution Approach 1:
The patent combines ground terminals with metal buckling portions within the integrated terminal assembly. The metal buckling portions serve dual functions: providing mechanical strength and guidance during insertion, and establishing ground electrical connections when the connectors are mated. This merging eliminates the need for separate ground connections while ensuring reliable electrical connectivity
Solution Approach 2:
The metal buckling portions in the terminal assembly perform multiple functions simultaneously: they provide mechanical guidance during insertion, structural support for the tongue portion, and establish ground electrical connections between mated connectors. This multi-functionality ensures reliable ground connection while maintaining structural simplicity
Data Source
AI summary
An electrical connector includes an insulating housing and a terminal assembly. The insulating housing has a base body. A front surface of the base body extends frontward to form a stepping portion. A front surface of the stepping portion extends frontward to form a tongue portion. The terminal assembly includes at least two ground terminals, at least two power terminals and at least two detecting terminals fastened to the insulating housing. The at least two ground terminals are mounted to two outermost portions of two opposite sides of the tongue portion. The at least two power terminals are mounted to the two opposite sides of the tongue portion. The at least two detecting terminals are disposed in a middle of the tongue portion, and the at least two power terminals surround the at least two detecting terminals.