USB Type-C Connector with Integrated Contact Carriers
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Solution Overview
Problem
The manufacturing process of USB Type-C connectors is complex and costly due to their large number of terminals and intricate design, which complicates the production and increases costs.
Innovation Solution
A simplified electrical connector design featuring a first and second terminal assembly with conductive terminals connected by contact carriers, integrated with an insulative housing formed via injection molding, reducing the need for multiple discrete components and insert-molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional multi-step manufacturing processes are used for USB Type-C connectors, then manufacturing precision and reliability are improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. The insulative housing is molded with embedded contact carriers that hold conductive terminals, eliminating separate assembly steps for attaching terminals to the housing. This integration maintains manufacturing precision while reducing process complexity and production cost.
Solution Approach 2:
The insulative housing serves multiple functions simultaneously: it provides structural support, electrical insulation, and serves as a mounting platform for contact carriers. The contact carriers themselves function both as structural elements and as terminal holders, reducing the need for separate components and simplifying the overall manufacturing process.
2Reliability
If multiple discrete components and insert-molding processes are used, then bonding reliability is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent merges the housing and terminal assembly into a single integrated component. The insulative housing is molded with embedded contact carriers that are permanently integrated into the housing structure, eliminating the need for separate bonding processes and reducing manufacturing cost while maintaining reliability through integral construction.
3Ease of manufacture
If a simplified single-step manufacturing process is used, then production cost and complexity are reduced, but manufacturing precision and bonding reliability may deteriorate
Solution Approach 1:
The contact carriers are pre-positioned and embedded within the insulative housing during the molding process itself. This preliminary action ensures precise positioning and secure bonding before final assembly, maintaining manufacturing precision while enabling a simplified single-step production process that reduces cost.
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 approach simplifies the manufacturing process and reduces production costs by using a single metal sheet for both terminal assemblies and a single insert-molding process for the insulative housing, enhancing bonding reliability and wear resistance while maintaining the USB Type-C connector's functionality.
Implementation Method 1
an insulative housing being formed on the first terminal assembly and the second terminal assembly by the method of injection molding
Data Source
AI summary
An electrical connector comprising a first terminal assembly and a second terminal assembly which are formed on a same metal material. The first and the second terminal assemblies respectively comprise a plurality of first and second conductive terminals. The plurality of first and second conductive terminals respectively connect with each other by a first contact carrier and a second contact carrier which are connected by a third contact carrier formed on the metal material. Bending the third contact carrier at 180 degrees such that the first and the second terminal assemblies are arranged in parallel and up-and-down to each other. Providing an insulating material injecting molding on the first and the second terminal assemblies to form an insulating housing. Cutting and dislodging the first, the second and the third contact carriers to forming the electrical connector. The electrical connector is simple in manufacture and low in production cost.