USB Receptacle Terminal Module Segmented Insulator Bridge Removal
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Solution Overview
Problem
The traditional two-stage insert-molding process for Type C USB receptacle connectors faces manufacturing difficulties in removing linking bridges between neighboring contacts due to the existing insulator structure, making it hard to finalize the terminal module and inspect the removal process.
Innovation Solution
A receptacle connector design featuring a terminal unit with a first and second insulator, a metallic shielding plate, and an insulative tongue piece, where the linking bridges are easily removable between the first front and rear insulators, allowing for complete removal and inspection before being filled with the tongue piece material, facilitating the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional insulator structure is used in the two-stage insert-molding process, then the contacts are protected and insulated, but the linking bridges between neighboring contacts cannot be easily removed or inspected
Solution Approach 1:
The insulator is divided into multiple segments: a first insulator portion, a second insulator portion, and a third insulator portion. The first and second insulator portions are spaced apart to create a removal space where linking bridges can be easily accessed and removed. This segmentation allows the insulator to provide protection while enabling easy access to linking bridges for removal and inspection.
Solution Approach 2:
The third insulator portion acts as an intermediary element that fills the space between the first and second insulator portions after linking bridge removal. This intermediary structure allows the mold cavity to be properly filled in the second stage while maintaining the insulating function and providing a pathway for linking bridge removal.
2Reliability
If the insulator completely surrounds the contacts, then insulation is maximized, but inspection of linking bridge removal becomes difficult
Solution Approach 1:
The insulator is segmented into first, second, and third portions with the first and second portions spaced apart. This creates an inspection space that allows visual or mechanical verification of linking bridge removal while the third portion maintains continuous insulation. The segmentation enables inspection access without compromising the overall insulating function.
Solution Approach 2:
The insulator structure creates a three-dimensional space between the first and second insulator portions, allowing inspection from multiple angles and dimensions. This spatial arrangement enables detection of linking bridge removal status without requiring complete disassembly or complex inspection tools.
3Stability of the object's composition
If linking bridges are not easily removable, then contact stability is maintained, but manufacturing efficiency decreases
Solution Approach 1:
The insulator is divided into spaced-apart portions that create accessible spaces around the linking bridges. This segmentation allows linking bridges to be easily removed using simple tools while the contacts remain stable and properly positioned during the process. The first and second insulator portions act as guides that maintain contact alignment.
Solution Approach 2:
The insulator structure is designed in advance with spaced portions to facilitate linking bridge removal. The geometry of the first, second, and third insulator portions is pre-configured to provide access pathways and removal spaces, enabling efficient linking bridge removal without requiring complex tools or procedures during manufacturing.
Data Source
AI summary
A receptacle connector for mating with the plug connector, includes a terminal unit, a metallic shield and a mating cavity surrounded by the metallic shield. The terminal unit includes a terminal module having a first insulator with a plurality of first contacts embedded therein via a first stage insert-molding process, a second insulator with a plurality of second contacts embedded therein via the similar first stage insert-molding process. The first insulator includes a first front insulator and a first rear insulator spaced from each other while linked together by the corresponding first contacts; the second insulator includes a second front insulator and a second rear insulator spaced from each other while linked together by the corresponding second contacts.