Abstract:
A USB connector including a metal shield for holding at least a portion of a printed circuit board having a plurality of connector contacts on a top side of the at least a portion of the printed circuit board, the metal shield including prongs which are attachable to the printed circuit board. A top support is separate from the printed circuit board and is provided within the metal shield above the at least a portion of the printed circuit board, the top support supporting the top side of the printed circuit board.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 12/273,514, entitled, “USB CONNECTOR AND METHOD OF MANUFACTURE,” filed on Nov. 18, 2008, and which is incorporated herein by reference in its entirety, 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a USB connector and more specifically to a USB connector which can accommodate a printed circuit board assembly (PCBA). 
     BACKGROUND OF THE INVENTION 
     USB connectors are utilized in a variety of environments for connecting devices to computer systems or other types of processing systems. A common USB connector utilizes a printed circuit board, with all core and discrete components soldered onto one or both sides.  FIG. 1  is a diagram of a conventional USB connector  10 . This type of connector, a standard USB connector  14  with a metal shield  12  is soldered onto the front of the same PCB board. The size of the metal shield is standard, where the opposite side of its 4-contact area  16  contain no components. U.S. Pat. No. 7,297,024, entitled “Universal-Serial-Bus (USB) Flash-Memory Device with Metal Wrap Formed Over Plastic Housing,” issued Nov. 20, 2007, describes an elongated USB casing device which is fully either plastic or metal wrapped with no sliding carrier or switching mechanism. The printed circuit board is encapsulated in resin and then placed on a molded plastic casing. 
     In another example, U.S. Pat. No. 7,094,074, entitled “Manufacturing Methods for Ultra-Slim USB Flash-Memory Card with Supporting Dividers or Underside Ribs,” issued Aug. 22, 2006, discloses an ultra slim device without a metal shield. All core and discrete components are soldered on a PC board and then enveloped in a plastic casing composed of top and bottom casing parts. This is not a standard USB connector and so it oftentimes has to be specifically adapted to the computer system. 
     Another manufactured device without a standard USB connector with a metal shield is disclosed with the core components in an unpackaged die form-factor with an intent to reduce the size. The PC board substrate is composed of such dies and discrete components soldered onto the PC board encapsulated in resin finishing. Then the device is covered by an external plastic casing. 
     The absence of a USB connector with metal shield causes high wear-out durability and quality issues. Also, if the device is too long, it will not be as rigid and sturdy. When the plastic is used for casing, and the device is inserted and extracted repeatedly by the user into the female USB port, there is increased wear. This results in loosened or weakened insertion when the thickness of the plastic of the device wears out. 
     In addition, with all of these prior art systems, there is a need for some kind of encapsulation process, such as resin encapsulation or the like, which is utilized to protect the part. This resin encapsulation costs money and requires longer manufacturing time and there are still reliability and quality issues. 
     Accordingly, what is needed is a system and method that overcomes the above-identified issues. The system should be cost-effective, easily adaptable, minimizing the length of the device, and utilized with USB-connector type systems. The present invention addresses such a need. 
     SUMMARY OF THE INVENTION 
     A special USB connector which can accommodate PCBA with discrete components soldered on the frontal portion of PCBA is disclosed. The components can be positioned inside the USB connector. A carrier is utilized for PCBA support within a special USB connector used for compact USB devices and sliding motion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a conventional USB connector. 
         FIG. 2  illustrates a first embodiment of the USB connector in accordance with the present invention. 
         FIG. 3  illustrates a carrier for containing the USB connector of  FIG. 2 . 
         FIG. 4  illustrates a second embodiment of a USB connector in accordance with the present invention. 
         FIG. 5A  illustrates a carrier for containing the USB connector of  FIG. 4 . 
         FIG. 5B  is a flow chart containing the assembly process of the USB connector of  FIG. 4 . 
         FIG. 6  illustrates a third embodiment of a USB connector in accordance with the present invention. 
         FIG. 7A  illustrates a carrier for the USB connector of  FIG. 6 . 
         FIG. 7B  is a flow chart containing the assembly process of the USB connector of  FIG. 6 . 
         FIG. 8A  is a top view of the printed circuit board with 4-contacts. 
         FIG. 8B  is a bottom view of the printed circuit board. 
         FIG. 9  is a view of the USB connector in combination with the printed circuit board. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention relates generally to a special USB connector and more specifically to a USB connector which can accommodate a printed circuit board assembly (PCBA). The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features described herein. 
     A USB connector in accordance with the present invention can house a printed circuit board assembly (PCBA) with four metal contacts on one side, and discrete components on the other side of the PCB. This PCBA extends all the way to the front of the connector, where its frontal edge rests on the connector&#39;s frontal support(s). 
       FIG. 2  illustrates a first embodiment of the USB connector  100  in accordance with the present invention. This embodiment of the USB connector  100  has two bends  105  made at the front panel  107  of the metal shield  104  to support the PCBA to be inserted. In  FIG. 2 , the connector  100  includes a top-rear support  102  which is inserted into the metal shield  104 . The metal shield  104  includes metal prongs  103  to be inserted into a printed circuit board (not shown). 
       FIG. 3  illustrates a carrier  120  for containing the USB connector of  FIG. 2 . Carrier  120  is utilized to insert the connector  100  into a computer or some other electronic device. Bottom-rear plastic PCBA support  122  is built as part of the front portion of the carrier  120 . It is deployed by being inserted into the rear of the special USB connector  100 , on the discrete components&#39; side (bottom side) of the PCBA. 
       FIG. 4  illustrates a second embodiment of a USB connector  200  in accordance with the present invention. In  FIG. 4 , the connector  200  is similar to connector  100  of  FIG. 2 , except there is a plastic rib  206  therein that is utilized with a top-rear support  204 . Both the plastic rib  206  and the top-rear support  204  are inserted into the metal shield  202 . The embodiment of the USB connector  200  has a plastic rib  206  attached to the metal shield  202  inside the frontal edge of the USB connector&#39;s metal shield  202  to augment the two bends  205  in front panel  207  for PCBA support.  FIG. 5A  illustrates a carrier  220  for containing the USB connector  200  of  FIG. 4 , and a bottom-rear support  222 . Carrier  220  is utilized to insert the connector  200  into a device. 
     Referring to  FIGS. 2 and 4 , the metal tabs  108 ,  208 , and the two metal prongs  103 ,  203  that attach to the perimeter of the PCB crimped at predetermined positions by a 90-degree angle, are then soldered on the PCB. 
     The process of assembly of the connectors  100  and  200  is described in conjunction with flow chart  5 B. First, a PCBA with all components is inserted into the rear of the USB connector with plastic internal part, via step  502 . Next, two metal prongs are fit on the perimeter of the PCBA and are soldered on for anchorage, via step  504 . Then, the PCBA with the USB connector is slipped into the plastic PCBA carrier and snapped in place, via step  506 . Then, the assembly is placed into an external casing and sonic welded, via step  508 . 
       FIG. 6  illustrates a third embodiment of a USB connector in accordance with the present invention. Referring to  FIG. 6 , a USB connector  300  is manufactured with a special plastic internal part  302  and an installation housing  304  that houses the PCBA with core components placed behind the USB connector  300 , and discrete components are soldered on the frontal portion of the PCBA which is inserted into the rear of the USB connector  300 .  FIG. 7A  illustrates a carrier  320  for the USB connector  300  of  FIG. 6 . 
     The assembly process is as follows, in accordance with a flow chart shown in  FIG. 7B . First, insert Special Plastic Internal part  302  to housing  304 , via step  602 . Next, insert PCBA with all components into rear of special USB connector, via step  604 . Then, two metal prongs are soldered on to the PCBA via step  606 . Then, a plastic support carrier is inserted into bottom rear of USB connector, via step  608 . The PCBA is snapped into position, via step  610 . Finally, the assembly is then placed into an external casing and then is sonic-welded to complete the assembly, via step  612 . 
     The operation of the connectors  100 ,  200  and  300  of  FIGS. 2 ,  4  and  6 , respectively when inserted in the carrier  120 ,  220  and  320  of  FIGS. 3 ,  5 A and  7 A respectively could be similar to, for example, that described in, “Retractable Memory Drive,” U.S. Pat. No. 7,422,454, which describes memory drives such as drives with USB connectors which are frequently utilized to portably transfer electronic data which is assigned to the assignee of the present application, and which is incorporated by reference in its entirety herein. 
     A retractable memory drive in accordance with the present invention comprises a top casing, a middle carrier, an electronic device such as a USB thumb drive, and a bottom casing. A positioning device on the middle carrier has a portion that protrudes outside the casing and operates like a button. The location of the positioning device where the button is located has two key attributes. First, there is a protrusion that acts as a lock with the casing. Second, the area below the button is not rigid and so it gives way when pressure is applied to the button. 
     The top and bottom casings provide a casing structure which includes two detents. One detent is for locking the device with the connector in the extended position, and one detent for locking the device with the connector in the “in” position. This allows for just one press of the extended portion of the positioning device to unlock it from its present position. When the device reaches its new position it will automatically lock. There are also guide rails that allow the middle carrier to remain in an appropriate position. 
       FIG. 8A  is a bottom view of the printed circuit board  400 . The front part  402  of the PCB  400  includes four metal contact pins on the top side. Front part  402  is inserted into the special USB connector (see  FIG. 9 ). 
       FIG. 8B  is a bottom view of the printed circuit board  400 . Discrete components are shown on the bottom side of the PCB on the front part  402 , under the four contact pins on the top side of the PCB  400 . 
       FIG. 9  is a view of the USB connector  500  in combination with the printed circuit board  400 . Referring to  FIG. 9 , the positions of a special plastic PCBA support  122 , which is the front part of carrier  120 , and plastic PCBA support  102  gives the PCBA support and protects the discrete components placed on the PCB (on the frontal part  402  of the PCB, under the 4 contact-pins). 
     ADVANTAGES 
     The special USB connector, along with sliding carrier mechanism for higher reliability and quality of device, allows for the following advantages. 
     1. The use of a specially designed USB connector with metal shield improves and enhances operation with regard to Electromagnetic Interference (EMI) and Electrostatic discharge (ESD) of the present invention. The metal shield enables the placement of discrete components under the USB connector&#39;s four contact pins in a protected way. Strong PCBA support is now achieved by the metallic frontal supports and plastic support blocks placed within the metal shield. 
     2. The use of a PCBA carrier will not only provide a sliding lock mechanism, but also provide for frontal PCBA support and protection for discrete components placed on the PC Board on the side of the PCBA under the USB connector&#39;s four contact pins. Such a feature simply strengthens the device&#39;s insertion area, and increases durability and quality of the device. 
     Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the spirit and scope of the present invention. Accordingly, although the present invention is disclosed in conjunction with a USB connector one of ordinary skill in the art readily recognizes that the present invention could be utilized with a variety of connectors and that use would be within the spirit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.