USB Connector Housing with Sandwiched Metal Plate for Grounding

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Solution Overview

Problem

Existing USB connectors lack a solid construction and are not easily manufactured, as they often require complex assembly processes and materials that are not cost-effective or durable.

Innovation Solution

An electrical connector design featuring a pair of modules with insert-molded terminals, a metal plate sandwiched between the modules, and a second housing over-molded with the modules and latches to form a subassembly, which improves grounding and manufacturing simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional assembly methods are used for USB connectors, then manufacturing flexibility is maintained, but construction solidity and grounding effectiveness are insufficient

Engineering Contradiction:

Improveconstruction solidityVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines multiple components (housing, terminals, metal plate, and latches) into a single integrated subassembly through insert molding and overmolding processes. This merging of parts achieves solid construction and improved grounding effectiveness while eliminating complex manual assembly steps, as the entire assembly is formed in one manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite material construction by integrating a metal plate within a plastic housing structure. The metal plate provides grounding and shielding functionality, while the plastic housing provides structural support and insulation. This composite approach enhances construction solidity and grounding effectiveness without requiring separate assembly operations.

Inventive Principle:

Principle #40Composite materials

2Productivity

If multiple separate components are used for USB connectors, then ease of repair is improved, but manufacturing efficiency and construction solidity deteriorate

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidnumber of parts

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the housing, terminals, metal plate, and latches into a single integrated subassembly using insert molding and overmolding techniques. This reduces the number of discrete parts from multiple separate components to one unified structure, thereby improving manufacturing efficiency and construction solidity while maintaining the functional integrity of each component.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If traditional molding processes are used, then manufacturing simplicity is maintained, but construction solidity and grounding effectiveness are insufficient

Engineering Contradiction:

Improvegrounding effectivenessVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by first forming the housing and terminals through insert molding, then embedding the metal plate and latches within the housing through overmolding. This sequential molding approach ensures proper positioning and integration of grounding components before final assembly, achieving reliable grounding effectiveness while maintaining manufacturing simplicity through a two-step process rather than multiple separate operations.

Inventive Principle:

Principle #10Preliminary action

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

The solution provides a robust and easily manufactured USB connector with enhanced grounding capabilities, ensuring reliable electrical connections and improved durability through a solid construction and efficient assembly process.

Implementation Method 1

insert molding a first housing and a row of terminals to form a module

Methodology Applied

Scientific EffectInsert molding:

Implementation Method 2

over molding a second housing with the pair of modules and the metal plate

Methodology Applied

Scientific EffectOver molding:

Data Source

PatentUS9590360B2Electrical connector having improved housing and method of making the same

Publication Date: 2017.03.07 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An electrical connector (100) includes a pair of modules (3) each including a row of terminals (31) and a first housing (32) insert molded with the terminals, a metal plate (1) sandwiched between the pair of modules, a pair of latches affixed to the metal plate, and a second housing over molded with the pair of modules, the metal plate, and the pair of latches to form a subassembly. Each terminal includes a securing portion (312) secured to the first housing, a soldering portion (313) extending rearwardly from the first housing, and a contacting beam (311) cantilevered forwardly from the first housing.