USB Plug Connector With Nested Metal Shell
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing USB plug connectors lack a robust and secure manufacturing method that ensures proper alignment and prevention of short circuits during engagement with receptacle connectors.
Innovation Solution
A USB plug connector design featuring an insulative housing with a tongue portion and a metal shell assembly, where the metal shell is stamped into a cross shape and assembled onto the insulative housing with recesses and interspaces to securely cover the connector, preventing short circuits by ensuring correct alignment and engagement with the receptacle connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional plug connector design is used without a metal shell, then the device complexity is reduced, but the reliability is worsened due to lack of short circuit prevention and proper alignment assurance
Solution Approach 1:
The metal shell is nested within the insulative housing, with the metal shell forming a cavity that receives and protects the contacts. The insulative housing is inserted into the metal shell, creating a nested structure where the metal shell provides external protection and alignment while the insulative housing provides internal contact retention and electrical insulation.
Solution Approach 2:
The connector is segmented into distinct functional components: the metal shell for structural support and short circuit prevention, the insulative housing for contact retention and electrical insulation, and the contacts for electrical connection. Each segment performs its specific function independently, improving overall reliability.
2Manufacturing precision
If a conventional manufacturing method without insert-molding is used, then the manufacturing precision is worsened, but the ease of manufacture is improved
Solution Approach 1:
The insert-molding process merges the manufacturing of the insulative housing and contacts into a single integrated step. The contacts are embedded within the insulative housing material during molding, ensuring precise alignment and eliminating separate assembly operations for attaching contacts to the housing.
3Reliability
If the metal shell is not assembled on the insulative housing, then the ease of manufacture is improved, but the reliability is worsened due to lack of proper alignment and short circuit prevention
Solution Approach 1:
The metal shell is pre-formed with a cavity and positioning features before assembly. The insulative housing is pre-assembled with contacts retained in precise positions through insert-molding. These preliminary preparations enable straightforward assembly where the insulative housing is simply inserted into the metal shell cavity, ensuring proper alignment without complex assembly operations.
Data Source
AI summary
A USB plug connector (100) includes an insulative housing (1) having a main portion (11) and a tongue portion (12), a number of contacts (2), and a metal shell (3). The tongue portion has an upper surface (16), a lower surface (17), a pair of lateral surfaces (18), and a frontal vertical surface (121). A pair of recesses (122) is defined on both sides of the upper surface and the lower surface. An interspace (181) is defined between each lateral surface of the tongue portion and the main portion. The metal shell includes a front wall (31), a pair of horizontal walls (32), and a pair of vertical walls (34). Each vertical wall includes a rigid beam (342) inserted in the interspace and a pair of wing portions (343) received in the recesses. A method for manufacturing the USB plug connector is also disclosed.