Abstract:
A new method for making and manufacturing the User-Friendly USB Male connectors which is faster, lower cost, more energy efficient, waterproof and reliable, with no expensive tooling and molding required, having better quality and being easily adaptable for automated assembly.

Description:
CROSS-REFERENCES 
       [0001]    This application incorporates by reference the U.S. Pat. No. 7,717,717 in its entirety. Joseph Lai is the sole inventor of the U.S. Pat. No. 7,717,717 and the invention is disclosed in this application. 
       FIELD OF THE INVENTION 
       [0002]    This present invention is specifically to provide an optimized solution for making the new User-Friendly USB Male connector which is reversible and can fit and work in the female USB Male connectors in either orientation. 
       BACKGROUND OF THE INVENTION 
       [0003]    Conventional, non User-Friendly USB Male connectors have been in the market for over 16 years (since 1996.) The old-fashioned methods of making the conventional, non User-Friendly USB Male connectors have become obsolete now. Using old fashioned methods to make the User-Friendly USB Male connectors are too slow and expensive, very difficult to control the quality, and not operator/automation friendly. 
         [0004]    Conventional non User-Friendly USB Male connectors are very complicated to make. It uses a precision injection-molded holder to hold the precision stamped metal pins. Conventional methods of making old-fashioned USB Male connectors require many steps of pre-assembly of the components because of its complexity. The final assembly put everything together by shoving the pre-assembled holder with metal pins into the metal housing. 
         [0005]    On the other hand, the new User-Friendly USB is much simpler to make, Precision stamped pins are replaced by a thin, flat, rigid printed circuit board (PCB). There is no need for a precision injection-molded holder or the pre-assembly of the metal pins. The PCB is simply held afloat in the middle of the metal housing by a pair of spacers, one on the top and the other under the PCB. Therefore, the old prior art method of making conventional non User-Friendly USB Male connectors should not apply to the new User-Friendly USB Male connectors. 
         [0006]    As far as quality control is concerned, the new User-Friendly USB Male connectors require tighter, more rigid strength to hold the PCB without slack compares to regular male USB connector. It would be extremely difficult to achieve this method of manufacture with conventional methods. 
       SUMMARY OF THE INVENTION 
       [0007]    This present invention specifically addresses the issues of the drawbacks and difficulties of conventional methods to explain a new method of making the User-Friendly USB Male connectors. Not only does the new method provide a fast, low-cost solution to the manufacturing problem, but it also maintains the highest quality for making the User-Friendly USB Male connectors. 
         [0008]    The present invention takes advantage of the metal housing of the User-Friendly USB as the “mold base” to hold the PCB by either injecting hot melt or cold cure epoxy or adhesive materials into the metal housing. Here are the steps: 
         [0009]    The PCB is pre pick-and-placed onto a Teflon or similar heat-resistant and non-stick holding fixture. Then, the metal housing is inserted into the same heat resistance holding fixture with the PCB already in the fixture. 
         [0010]    The spacers of the User-Friendly USB Male connector now can be placed by pouring either a liquid form of heat or non-heat curable epoxy, UV curable adhesive or heat-up solid melt-able thermal plastic resin. A cool down period cures the sealant to finish the assembly of the User-Friendly USB Male connector. 
         [0011]    There are many advantages of the new method, such as: 
         [0012]    1. No mold is required to make the spacer, which saves tremendous time and money 
         [0013]    2. No pre-process of putting the PCB together with the spacers
       a. No over-mold of the spacer onto the PCB   b. No assembly of attaching spacers onto the PCB       
 
         [0016]    3. PCB is less expensive to fabricate since we can use low temperature (Tg as glass transition temperature) PCB material 
         [0017]    4. There is no waste of space since the PCBs can be placed closely together on an array 
         [0018]    5. There is no slack for the spacer holding the PCB as the resin is tightly cured inside the metal housing 
         [0019]    6. There is no final assembly of shoving the pre-assembled piece into the metal housing 
         [0020]    7. The New User-Friendly USB Male connector is air-tight and water-proof, which the old style was not 
         [0021]    8. Assembly time is reduced from 32 seconds to 8 seconds when using hand assembly 
         [0022]    9. The metal housing will not be distorted or expanded because of brute force of shoving the pre-assembled piece 
         [0023]    10. Temperature stable, unlike pre-attached then shoving method, the PCB is now mold over by the melted spacers, so it is very stable in a much wider temperature range 
         [0024]    11. Transition from manual labor assembly to automation can be easily realized 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  shows prior art of conventional USB Male connector using conventional method 
           [0026]      FIG. 2  shows prior art of User-Friendly USB Male connector using conventional method 
           [0027]      FIG. 3  shows presented new method of making User-Friendly USB connectors with all required components or raw-materials 
           [0028]      FIG. 4  shows the fixture for new method of making User-Friendly USB connector 
           [0029]      FIG. 5  shows step  1  of new method of making User-Friendly USB Male connector 
           [0030]      FIG. 6  shows step  2  of new method of making User-Friendly USB Male connector 
           [0031]      FIG. 7  shows step  3  of new method of making User-Friendly USB Male connector 
       
    
    
     DETAILED DESCRIPTION 
       [0032]      FIG. 1  shows the prior art of conventional parts for making conventional USB male connector. This method of making conventional USB Male connector is complicated, cumbersome, time consuming and expensive. It requires precision stamping to fabricate the four contacting pins  101 . With the four contacting pins, a precision plastic molded contacting pin holder  102  has to be made to hold these previously mentioned contacting pins. Notice the excessive plastic  106  which is used in the bottom of the plastic pin holder, making the conventional USB Male connector not User-Friendly (can not go either way). Once the four contacting pins  101  are inserted into the groves  107  of the plastic pin holder as  103 , final assembly is required to push the pin holder with the four contacting pins into the metal housing  104  to finish assemble conventional USB male connector  105 . 
         [0033]      FIG. 2  also shows prior art of parts and making User-Friendly USB male connector using conventional method. Metal housing  104  of User-Friendly USB and regular USB is the same. Using conventional method to make User-Friendly USB Male connector could be a painful, poor quality, slow and expensive process. Printed circuit board, or PCB  201  is pre-fabricated by a PCB house. Imitating the old conventional method, the two holding spacers  202  somehow must be attached to the PCB  201  tightly, so the pre-assembly  203  is realized. 
         [0034]    There are many other ways that the spacers can be attached to the PCB  201 . Precision molded plastic parts can be made or simply cut from a sheet of plastic (with the right thickness) individually for the operators by hand to attach to the PCB, or there could be more advanced over-molding for directly injecting, silk-screening or stencil printing the thermal plastic resin as spacers onto the PCB  201 . 
         [0035]    There are many issues of using the PCB  201  as part of the User-Friendly USB Male connectors. PCB by its nature has been fabricated by laminating layers of Fire Retardant (FR4) or fiber glass materials with pre-impregnated layers of epoxy sheets. It is very difficult to maintain the overall PCB thickness. Typical tolerance of a PCB has ±10% tolerance which would make it extremely difficult to maintain the overall thickness with the spacers for the pre-assembled piece  203  when the old method of assembly was used. 
         [0036]    If the PCB is too thick, the pre-assembled piece  203  would be very difficult to insert into the metal housing. If insertion is done by brute force, the metal housing  104  will be distorted, deformed, expanded or destroyed. On the other hand if the over-all thickness of the pre-assembled piece  203  is too thin, the whole pre-assembled piece will be too loose to hold inside by the metal housing, has no strength to hold the PCB and PCB will simply fall off. The PCB  201  may tilt, not straight, un-even space, weak, deflect and when user inserting the User-Friendly USB into the female USB socket. Damage of both the User-Friendly male USB and the mating female USB connectors will happen. 
         [0037]    It is experimented that the tolerance would have to be less than ±0.002 inch by using this old method. Overall error accumulates as the spacers  202 , metal housing  104  and PCB  201  all have their ± tolerances in thickness. Temperature coefficient is another factor as all materials have their own expanding or shrinkage ranges. 
         [0038]    To maintain the overall thickness, the over-molding method seems to be the answer to solve the precision tolerance problem as mentioned, assuming metal housing is in tight tolerances, but has its own price to pay. To be able to do the over-molding, PCB material  201  has to withstand very high temperatures, wasting PCB space as the PCBs can not be densely populated. An extremely expensive plastic injection mold would be required. Time would be wasted for injecting the molten resin with dedicated operators or automated machines to feed the PCB inside the mold. 
         [0039]    After the pre-assembled piece  203  is completed, final assembly would also be required to shove it  203  inside the metal housing  104  so the User-Friendly USB male connector product  204  is ready. 
         [0040]    The new method disclosed is a much easier way of making the User-Friendly USB Male connector.  FIG. 3  shows all the un-assembled parts/pieces, the same PCB  201 , with the same metal housing  104  the conventional USB would use. New spacer materials  301 ,  302  are made of thermal melt-able plastic, such as ABS, acrylic, Hi-impact styrene, glass filled Nylon or many other materials. The spacers are suggested to be scored/v-cut or molded a grove  304  on a thermal plastic strip  303  so the handling is much easier for operators or an automated machine to pick and place handling. 
         [0041]      FIG. 4  shows the required fixture for the new method of making User-Friendly USB Male connectors. Viewing from the front of the fixture strip  402  and showing the teeth/stick-up holders  401  for holding the PCB  201 , metal housing  104  and a pair of spacers  301 ,  302 . 
         [0042]    The two fixture strips  402 ,  403  are made of heat-resistance, chemical-resistance, anti-scratch, non-stick material such as Polytetrafluoroethylene (PTFE) or also known as Teflon™ or similar materials. With the thin gap (0.025 inch) between the two Teflon strips, the PCB  201  now can fit inside the gap  404  and be held onto the fixture. 
         [0043]      FIG. 5  shows the first step of new method of assembling the User-Friendly USB Male connector. The PCB  201  is inserted vertically from top into the gap  404  of the Teflon™ holder. Teflon™ is not only heat resistance, chemical resistance and non-stick but also great for friction resistance too. Therefore this Teflon™-made fixture is built to last. 
         [0044]      FIG. 6  shows the second step of the new method of assembling the User-Friendly USB Male connector. The metal housing  104  is also inserted vertically into the Teflon™ teeth holder as we can see. 
         [0045]    After the metal housing  104  was completely inserted into the Teflon™ fixture, the tail section  603  of the PCB  201  is shown. 
         [0046]      FIG. 6  also shows two cavities have now been created after we have successfully insert the metal housing  104  into the fixture as we can see  601 ,  602 , viewing from the top of the fixture. 
         [0047]      FIG. 7  shows how we finish the assembly by filling up the cavities  601 , 602  with thermal melt-able plastic material  301 ,  302 . The thermal melt-able plastic material will melt when we apply heat to it. When the thermal melt-able plastic material melts, the gravitational force will help leveling the melted plastic material and fill-up inside of the cavities. After it cooling down, cured plastic material will become the spacers to hold the PCB securely, seamlessly and tightly inside the metal housing. Thus we have finished the assembly of the User-Friendly USB Male connectors. 
         [0048]    Other means of meting the thermal melt-ableplastic spacers are also possible, chemical solvent, ultrasonic, supersonic and magnetic radio frequency field of induction for heat. 
         [0049]    Other spacer materials are also being considered for making high-temp User-Friendly USB Male connectors. For RoHS (non-toxic, no lead) or regular lead-soldered Surface Mount Technology (SMT) reflow oven, glass-filled Nylon™, ceramic, cement or fiber glass (FR4) materials are considered. It is not suggested to heat up and melt these type of material as the required melting temperature is very high (over 500 degree F.), therefore, slightly thinner solid material can be easily pre-inserted into the metal housing cavities  601 , 602  first, followed by applying high-temp grade of epoxy or adhesive materials to cure to secure the PCB as spacers. No heat on the spacers is required in this situation. 
         [0050]    Of course, directly dropping, dispensing or injecting the liquid-form or pre-heated and melted plastic, adhesive, UV glue, epoxy, hot-melt glue as spacers also should be considered. It is more difficult and slow to fill the cavities with a liquid form of adhesives without leaking Another major problem is when these materials cure; a mold release agent might be required for the finished User-Friendly USB Male connectors to separate from the Teflon fixtures. 
         [0051]    These methods are good for both making User-Friendly 2.0 male USB and 3.0 male USB connectors. The User-Friendly 3.0 male USB is backward compatible to User-Friendly 2.0 USB with 5 additional contacting pins on the PCB. The spacer materials are also melted and cured to secure the PCB inside the metal housing to make the User-Friendly 3.0 male USB connectors.