USB Connector Structural Strength and Grounding via Pressure Welding
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Solution Overview
Problem
Current USB connectors suffer from poor structural strength and grounding reliability due to unreliable welding techniques and complex structures, leading to failures and malfunctions, especially during incautious use, and they are not optimized for miniaturization and cost reduction.
Innovation Solution
A USB connector design featuring a buckle-slot structure for precise positioning of the PCB and USB head, with a metal housing pressure-welded onto a conductive layer on the PCB, eliminating the need for additional lugs and welding joints, and using a fastening member like a screw for secure assembly, ensuring structural strength and grounding reliability while shortening the USB head length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding technique is used to connect USB head and PCB, then grounding and positioning are achieved, but reliability and structural strength deteriorate due to faulty welding
Solution Approach 1:
The patent merges the grounding function and positioning function into a single integrated structure. The USB head is directly integrated with the shell element to form a unified grounding structure, eliminating the need for separate welding connections. This integration ensures both reliable grounding and strong structural connection simultaneously.
Solution Approach 2:
The patent replaces the welding mechanism (thermal/mechanical process) with a mechanical fastening system using a fastening member that passes through the shell element and USB head. This mechanical connection provides both grounding and positioning without the reliability issues of welding, while maintaining structural strength through threaded engagement.
2Reliability
If additional mechanical structure like fixed lug is used for positioning, then positioning reliability improves, but device complexity and cost increase
Solution Approach 1:
The patent combines the positioning function with the shell element itself rather than adding separate positioning structures. The shell element is designed with integrated features that provide both structural support and positioning, eliminating the need for additional fixed lugs or mechanical positioning structures.
Solution Approach 2:
The shell element serves multiple functions simultaneously: it provides structural protection, grounding connection, positioning of the USB head, and mounting for the fastening member. This multi-functionality eliminates the need for separate dedicated positioning structures, reducing overall device complexity.
3Reliability
If four weld legs are used on USB head, then grounding and positioning are achieved, but USB head length increases to 21.5mm
Solution Approach 1:
The patent extracts and eliminates the weld legs from the USB head design. Instead of extending the USB head with four weld legs for grounding and positioning, the design uses the shell element as the primary grounding structure, allowing the USB head to be shorter and more compact.
Solution Approach 2:
The grounding function previously requiring extended weld legs is merged into the shell element structure. The shell element provides grounding through its integration with the USB head and connection to the PCB, eliminating the need for extended USB head structures.
4Ease of manufacture
If USB head is made longer for welding connections, then welding is feasible, but overall rigidity decreases making it easy to bend and deform
Solution Approach 1:
The patent replaces the welding connection system with a mechanical fastening system using a fastening member. This allows for a shorter, more rigid USB head design while maintaining strong connections through threaded engagement, eliminating the need for extended structures required for welding.
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 design enhances structural strength and grounding reliability, prevents incorrect insertion, and achieves miniaturization and cost reduction by eliminating complex structures and welding issues, ensuring reliable operation and reduced production costs.
Implementation Method 1
the metal housing is pressure-welded on the conductive layer on the surface of the PCB
Data Source
AI summary
A universal serial bus (USB) connector and an electronic device including the USB connector are disclosed. The USB connector includes a USB head, a printed circuit board (PCB), and a shell element, where the USB head includes an insulation plastic core and a metal housing; a conductive layer is arranged on the surface of the PCB, the PCB is assembled inside the USB head and the PCB and the USB head are mutually positioned; and the USB head and the PCB are fastened at the shell element by using a fastening member, and the metal housing is pressure-welded on the conductive layer on the surface of the PCB. The USB connector has improved structural strength and enhanced grounding reliability, and can also achieve product miniaturization and cost reduction.