USB Connector Receptacle One-Piece Metal Shell Design
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Solution Overview
Problem
Conventional USB connector metal shells face durability and integrity issues due to the process requirements for soldering legs, and the two-part metallic body manufacturing method increases costs and complexity.
Innovation Solution
A one-piece metal shell design using an upper and lower metal shell connected via a deformable connection portion, allowing for assembly within a single mold and featuring multiple soldering legs for enhanced durability and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soldering legs are formed on the metal shell, then the metal shell can be combined with printed circuit board, but the integrity and durability of the metal shell deteriorate
Solution Approach 1:
The metal shell is divided into two separate halves (upper and lower), each with its own set of soldering legs. This segmentation allows each half to be formed independently with complete soldering legs, maintaining the integrity of each component while enabling assembly with the printed circuit board. The two halves are then joined together to form the complete metal shell enclosure.
2Reliability
If two-part metallic body is used to maintain integrity, then the durability is improved, but the manufacturing cost and process complexity increase
Solution Approach 1:
The metal shell is segmented into two halves that can be formed in separate molds, allowing each half to be optimized for its specific forming requirements. This segmentation enables parallel production of both halves, reducing overall manufacturing cycle time and complexity compared to forming a complete shell with integrated soldering legs in a single complex mold.
Solution Approach 2:
The two separately formed metal shell halves are joined together through a combination process to form the complete metal shell. This merging step consolidates the two components into a single functional unit that encloses the insulation body and terminals, while maintaining all necessary soldering legs for printed circuit board attachment.
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 maintains the integrity and durability of the metal shell while significantly reducing manufacturing costs by allowing assembly in a single mold and providing multiple soldering legs for secure engagement with printed circuit boards.
Implementation Method 1
the connection portion is deformable so as to combine the upper metal shell and the lower metal shell
Data Source
AI summary
A connector receptacle includes an insulation body defining a plurality of terminal slots formed thereon, multiple terminals securely received in the plurality of terminal slots of the insulation body and a metal shell which covers the insulation body and includes an upper metal shell and a lower metal shell wherein the lower metal shell is connected to the upper metal shell via a connection portion which is formed on corresponding sides of the upper metal shell and of the lower metal shell.