USB Type-C Connector Two-Stage Insert Molding

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Solution Overview

Problem

The manufacturing of USB Type C electrical connectors poses challenges due to their small size and complex design, requiring a new method that can ensure both superior electrical and mechanical connections while being easy to produce.

Innovation Solution

An electrical connector design featuring an insulative housing with upper and lower terminals and a metallic shielding plate, formed through a two-stage insert-molding process, where the terminals and shielding plate are integrally formed in the first stage, and the upper terminals are inserted into grooves with mold dies pressing to create specific holes for secure connections in the second stage, allowing for easy assembly and prevention of foreign particle invasion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional manufacturing method is used for USB Type C connectors, then the manufacturing process is simple, but the electrical and mechanical connection characteristics are insufficient

Engineering Contradiction:

Improveelectrical and mechanical connection characteristicsVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing process is divided into two distinct stages: first forming the lower terminals and shielding plate as a sub-assembly, then adding upper terminals and insulator to complete the contact module. This segmentation allows each stage to be optimized independently for both manufacturing ease and connection reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lower terminals and shielding plate are pre-formed into a sub-assembly with integrated grooves before the upper terminals are added. This preliminary action ensures proper positioning and alignment are built-in from the start, improving connection reliability while simplifying the final assembly process.

Inventive Principle:

Principle #10Preliminary action

2Volume of moving object

If the connector is made small in size, then it meets USB Type C specifications, but the manufacturing difficulty increases

Engineering Contradiction:

Improveconnector sizeVSAvoidmanufacturing difficulty

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

Multiple components (lower terminals, shielding plate, insulator, and upper terminals) are merged into a single integrated contact module through the two-stage insert-molding process. This combining approach maintains the small USB Type C form factor while simplifying manufacturing by creating one unified structure rather than assembling multiple separate parts.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If more than twenty contacts are included, then USB 2.0 and USB 3.1 signals are transmitted, but the manufacturing method becomes difficult

Engineering Contradiction:

Improvesignal transmission capabilityVSAvoidmanufacturing method complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The contact module is designed as a universal component that can transmit both USB 2.0 and USB 3.1 signals through its multiple contacts. The standardized insert-molding process makes this multi-functional connector manufacturable using conventional equipment, avoiding the need for specialized manufacturing methods despite the high contact count.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If mold dies press front end regions during second stage insert-molding, then connection reliability is improved, but the process complexity increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidmolding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mold dies automatically perform the pressing action on front end regions during the normal insert-molding process without requiring separate operations. This self-service approach integrates the connection-reinforcing action into the existing manufacturing flow, improving reliability while avoiding additional process complexity.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS9923286B2Electrical connector and method making the same

Publication Date: 2018.03.20 FOXCONN INTERCONNECT TECHNOLOGY LTD

AI summary

An electrical connector includes an insulative housing having a tongue portion with opposite upper and lower surfaces, a plurality of upper terminals and a plurality of lower terminals with contacting sections exposed upon the corresponding upper surface and lower surface, respectively. A metallic shielding plate located between upper terminals and the lower terminals. The tongue portion forms a first type hole in which the upper power terminal mechanically and electrically connects to the lower power terminal, and a second type hole in which either the upper grounding terminal mechanically and electrically connects to an upper face of the shielding plate or the lower grounding terminal mechanically and electrically connects to the lower face of the shielding plate.