Abstract:
A thumb drive with a miniaturized memory storage assembly package that employs an extended chassis structure to support the miniaturized memory device within an ergonomically designed casing that is also simple to manufacture. The miniaturized memory storage assembly has a flexible latch projection extending from its side that mates with a complimentary latch aperture in the side of the connector housing. Downwardly projecting tongues in the top surface of the connector housing also prevent movement of the assembly within the housing. The elongated platform chassis extending rearwardly from the USB connector housing snaps in place in an ergonomically designed thumb drive case.

Description:
[0001]    The present invention claims priority to provisional application No. 61/397,173 filed on Jun. 7, 2010 which is incorporated in its entirety by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates generally to portable memory devices and, more specifically, to a USB thumb drive chassis adapted to support a System-in-Package (“SiP”), miniaturized flash drive configured to mate with an ergonomically-sized housing. The invention also discloses a method of manufacturing the same. 
         [0004]    2. Discussion of the Related Art 
         [0005]    Portable memory storage devices, such as memory devices with USB connectors, are increasingly utilized to portably transfer electronic data. One type of the portable memory storage devices are commonly referred to as thumb drives, which have ergonomically-sized housing that could be easily handled in a user&#39;s hand. 
         [0006]      FIG. 1A  is a perspective view of a conventional thumb drive, and  FIG. 1B  is another perspective view of the conventional thumb drive shown in  FIG. 1A . In  FIGS. 1A and 1B , a thumb drive  10  has a casing  12  formed of upper  13  lower  14  halves. At the forward end of the thumb drive  10 , a male USB connector  11  projects out from the casing  12 . As seen from  FIG. 1B  in which the upper  13  half of the casing  12  (shown in  FIG. 1A ) is lifted, a Printed Circuit Board Assembly (“PCBA”)  15  is shown as exposed and is supported within the casing  12 . The PCBA  15  stretches along most of the entire length of the casing  12 . The PCBA  15  supports memory and controller chips and provides the circuitry connecting these chips as well as other components or electronics necessary for a portable memory device. 
         [0007]    The male USB connector  11  at the forward end of the thumb drive  10  is electrically connected to the circuitry of the PCBA  15  by means of soldering and secured to the PCBA  15  by this soldering as well as other mechanical means known in the art. The male USB connector  11  is a male USB connector with electrical contacts built in a metallic casing with two apertures on an upper surface, dimensions of its electrical contacts, casing and apertures are governed by the USB standard. 
         [0008]    The resulting thumb drive  10  can be connected to a USB port in a laptop computer, PC, peripheral device, or any other USB-compatible machine or device. The thumb drive  10  is small enough to fit easily in a user&#39;s pocket and is useful for portable storage of data. The casing  12  of the thumb drive  10  is a convenient size for a human hand. It is not so large that it is bulky, and it is not so small that it is hard to handle and use. 
         [0009]    Recently, miniaturized memory assemblies have appeared which replace the conventional PCBAs. These new assemblies incorporate memory storage, controller, and other necessary circuitry in a very small package, sometimes referred to as “System-in-Package”, or “SiP”. A SiP device can be a complete functional unit by itself in one multi-chip package and include appropriate electrical connectors for connection. The size of these SiP devices could be customized but generally very small. For example, a SiP device could be no thicker than a penny and less than about an inch (2.5 cm) in length. SiP memory devices generally are not much larger than the conventional male USB connector necessary for connecting the device to the USB port of a laptop or similar machine. But, the small SiP memory devices can be awkward for a person to use and carry, because it is too small for easy handling by a human hand and it could be more easily lost than conventional thumb drives. It is not easy to incorporate these miniaturized SiP memory devices into a conventional thumb drive casing, because the conventional thumb drive casing cannot provide sufficient support to the SiP device to prevent it from pivoting at the mouth of the conventional plastic case, thereby breaking the case when the USB connector is inserted into a USB port. 
         [0010]    Therefore, what is needed is a structure that can support a miniaturized memory device, such as a SiP memory device, so that is easier for the user to handle and less likely to be lost when carried. Also needed is an ergonomic thumb drive that can provide support to a miniaturized memory device, so that the miniaturized memory device will not pivot within its casing during insertion into a USB port. Also needed is a thumb drive that is simple and inexpensive to manufacture. 
       SUMMARY OF THE INVENTION 
       [0011]    Accordingly, embodiments of the invention are directed to a chassis structure and a method of manufacturing the same that substantially obviate one or more of the problems due to limitations and disadvantages of the related art. 
         [0012]    An object of embodiments of the invention is to provide a chassis structure and a method of manufacturing the same that provide support for a very small memory package, such as a “System-in-Package” or “SiP” memory device. 
         [0013]    Another object of embodiments of the invention is to provide a thumb drive chassis structure and a method of manufacturing the same that hold a very small memory package, such as a “System-in-Package” or “SiP” memory device, and couple the memory package to a male USB connector for connection with a USB port in an ergonomic casing. 
         [0014]    Another object of embodiments of the invention is to provide a thumb drive chassis structure and a method of manufacturing the same that hold a very small memory package, such as a “System-in-Package” or “SiP” memory device, and prevent pivoting at the mouth of the case and breaking the case when the USB connector is inserted into a USB port, and yet is inexpensive to manufacture. 
         [0015]    Additional features and advantages of embodiments of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of embodiments of the invention. The objectives and other advantages of the embodiments of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings. 
         [0016]    To achieve these and other advantages and in accordance with the purpose of embodiments of the invention, as embodied and broadly described, a device includes a casing, a connector housing, the connector housing including an opening at a first end and a stop wall partially cover the opening, and a memory package, the memory package including electrical contacts and the memory package being within the connector housing and abutted the stop wall of the connector housing, wherein a portion of the connector housing is within the casing, the opening at the first end of the connector housing is outside the casing, and the electrical contacts and the front opening of the connector housing form a connector. 
         [0017]    In another aspect, a device includes a casing, a connector housing, the connector housing including an opening at a first end and a stop wall partially cover the opening, a memory package, the memory package including electrical contacts and the memory package being within the connector housing and abutted the stop wall of the connector housing, and a chassis, the chassis extending from a second end of the connector housing and along lengthwise of the casing, wherein a portion of the connector housing is within the casing, the opening at the first end of the connector housing is outside the casing, and the electrical contacts and the front opening of the connector housing form a connector. 
         [0018]    In yet another aspect, a memory package device includes a package housing, the package housing enclosing at least a memory chip and a memory controller chip and electrical contacts exposed at one end of the package housing, wherein the memory package includes a raised portion at a second end of the package housing. 
         [0019]    The present invention discloses a USB thumb drive with a miniaturized memory storage assembly, such as a SiP memory device, that employs an extended chassis structure to support the miniaturized memory device within an ergonomically designed casing. The present invention discloses a miniaturized memory device secured within a USB connector housing, and further discloses an elongated platform chassis extending rearwardly from the back end of the USB housing. The elongated platform chassis forms a support structure, so that the USB connector housing and chassis can be supported within a thumb drive casing that is long and thick enough to be ergonomically compatible with a human hand and with portability. The USB housing and chassis structure prevents the USB housing from pivoting within mouth of the ergonomic casing when a user inserts the USB connector into the USB port of a laptop computer or similar machine. 
         [0020]    The present invention also discloses a miniaturized memory storage assembly, such as a SiP memory device, that is simple to manufacture. The miniaturized memory storage assembly is inserted into a USB connector housing, preferably through a rear opening. The miniaturized memory storage assembly has a ramped, flexible latch projection extending from its side. The USB connector housing has a complimentary latch aperture in its side. The flexible, ramped latch projection is pushed inward when the miniaturized memory storage assembly is inserted into the USB connector housing. When the miniaturized memory storage assembly is fully inserted into the USB connector housing, the flexible latch snaps outward through the complimentary latch aperture and restricts movement of the assembly within the housing by preventing the assembly from being pulled back out as well as preventing upward movement of the assembly within the housing. A stop at the front of the USB connector housing prevents the miniaturized memory storage assembly from being pushed forward. The top surface of the USB connector housing also includes stamped apertures that form downwardly projecting tongues. These tongues push down against the top surface of the miniaturized memory storage assembly and further prevent movement of the assembly within the housing. The elongated platform chassis extending rearwardly from the USB connector housing snaps in place in an ergonomically designed thumb drive case. In one embodiment, the plastic case is formed of lower and upper halves. The elongated platform chassis snaps in place in the lower half of the case. Latches in the lower case snap into notches in the chassis. The upper half of the case is then fixed to the lower half by adhesive or friction welding. 
         [0021]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of embodiments of the invention as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0022]    The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of embodiments of the invention. 
           [0023]      FIG. 1A  is a perspective view of a conventional thumb drive. 
           [0024]      FIG. 1B  is another perspective view of the conventional thumb drive shown in  FIG. 1A . 
           [0025]      FIG. 2  is a perspective view of a thumb drive according to an embodiment of the present invention. 
           [0026]      FIG. 3  is a perspective, exploded view of the SiP memory device and the USB connector housing and platform chassis extension according to an embodiment of the present invention. 
           [0027]      FIG. 4  is a perspective view of the SiP memory device secured in the USB connector housing and the platform chassis extension shown in  FIG. 3 . 
           [0028]      FIG. 5  is a perspective, exploded view of the lower half of the casing supporting a SiP memory device mounted in a USB connector housing with the platform chassis extension, as well as the upper half of the casing according to an embodiment of the present invention. 
           [0029]      FIG. 6  is a perspective view of the complete USB thumb drive with both halves of the casing (shown in ghost) covering a portion of the USB connector housing and all of the platform chassis extension according to an embodiment of the present invention. 
           [0030]      FIG. 7  is a perspective, exploded view of a portion of the USB connector housing and the SiP memory device according to an embodiment of the present invention. 
           [0031]      FIG. 8A  is a perspective view of the SiP memory device secured within the forward portion of the USB connector housing according to an embodiment of the present invention. 
           [0032]      FIG. 8B  is a detailed view of a portion of the USB connector housing and SiP memory device shown in  FIG. 8A . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0033]    Reference will now be made in detail to the preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. 
         [0034]      FIG. 2  is a perspective view of a thumb drive according to an embodiment of the present invention. In  FIG. 2 , a thumb drive  20  includes a lower casing half  41  and an upper casing half  42  (shown in  FIG. 5 ). The lower and upper casing halves  41  and  42  when assembled together form a mouth  44  at one end. The lower casing half  41  supports a portion of a USB connector housing  22  at the mouth of the casing  44 , and supports a platform chassis extension  25  extending rearwardly from the USB connector housing  22 . 
         [0035]    The lower casing half  41  includes stop structures  43  at the rear portion of the lower casing half  41  to provide positive mechanical fixture to the platform chassis extension  25 . Notches  29  (shown in  FIG. 3 ) at the rear end  28  of the platform chassis extension  25  mate with the notches  29  in the lower casing half  41 . Strengthening ribs  26  in the platform chassis extension  25  provide additional mechanical strength to the chassis. 
         [0036]    The USB connector housing  22  holds a miniaturized memory storage assembly, such as the SiP memory device  30  shown. The USB connector housing  22  and SiP memory device  30  form a miniaturized memory storage assembly  23 , or SiP assembly, as it will be referred to hereafter. When the SiP memory device  30  is in the USB connector housing  22 , the front of the USB connector housing  22  forms the male USB connector  21  for mating with a female USB port (not shown) of a laptop or other machine device designed to receive a USB connector. 
         [0037]      FIG. 3  is a perspective, exploded view of the SiP memory device and the USB connector housing and platform chassis extension according to an embodiment of the present invention, and  FIG. 4  is a perspective view of the SiP memory device secured in the USB connector housing and the platform chassis extension shown in  FIG. 3 .  FIGS. 3 and 4  show the assembly of the USB connector housing  22  and the SiP memory device  30 . The male connector end of the USB connector housing  22  forms an opening, the dimensions of which are governed by the USB standard. The lower portion of the opening includes a stop wall  27 , which prevents the SiP memory device  30  from being pushed past the front opening. Alternatively, or in addition to the stop wall  27 , the SiP memory device  30  can include a raised portion  34  at the rear of the SiP memory device  30 , and the USB connector housing  22  can include a cut-out  35  to receive the raised rear portion  34 , thereby preventing the SiP memory device  30  from being pushed forward in the USB connector housing  22 . 
         [0038]    On the top surface  32  of the forward end of the SiP memory device  30  are four electrical conductors  31 , the dimensions of which are governed by the USB standard. Extending from each side of the SiP memory device  30  are flexible, ramped latch projections  33 . At a complimentary position on each side of the USB connector housing  22  are latch openings  24 . The latch openings  24  are adjacent the bottom of the sides of the USB connector housing  22 . As shown in  FIG. 3 , the SiP memory device  30  is inserted into the rear opening of the USB connector housing  22 . When the SiP memory device  30  is inserted, the flexible, ramped latch projections  33  are forced inward until they reach the latch openings  24  in the sides of the USB connector housing  22 , at which point the latch projections  33  snap out and latch the SiP memory device  30  in place. 
         [0039]    As shown in detail in  FIG. 8B , the rear and upper portions of the latch projections  33  are not ramped, but straight, and prevent the SiP memory device  30  from being pulled back out of the USB connector housing  22  or lifted up within the USB connector housing  22 . As described above, the stop wall  27  at the front of the male USB connector  21  opening, and/or the raised portion  34  of the SiP memory device  30  and the cut-out  35  in the USB connector housing  22 , prevent the SiP memory device  30  from being pushed out of the USB connector housing  22 . The combined USB connector housing  22  and SiP memory device  30  form the SiP assembly  23 . 
         [0040]      FIG. 4  shows the assembled SiP assembly  23  and platform chassis extension  25 .  FIG. 5  shows how the upper casing half  42  is placed onto the lower casing half  41 , SiP assembly  23 , and platform chassis extension  25 . The platform chassis extension  25  projects rearwardly from the SiP assembly  23 . The platform chassis extension  25  includes an inclined portion that directly extends from the USB connector housing  22  and a substantially planar portion that extends rearwardly along the lengthwise of the casing  40 . 
         [0041]    It will be appreciated that the elongated platform chassis extension, which is part of the metal USB connector housing structure  22 , provides substantial support to the SiP assembly  23  and will prevent it from pivoting in the mouth  44  of the casing  40  when the male USB connector  21  is inserted into a female USB port (not shown). Users do not always exercise care when inserting a USB thumb drive into a USB port, and the resulting action of pushing a male connector can exert significant force. Without the platform chassis extension  25  according to an embodiment of the present invention, it would be easy to pivot a miniaturized USB connector and memory storage device within the mouth of an elongated, ergonomic plastic casing. The completed thumb drive  20  of the present invention is shown in  FIG. 6 . The casing  40  is long and thick enough to be ergonomically compatible with a human hand and, at the same time, small enough to be compatible with portability. The male USB connector  21  projects from the mouth  44  of the thumb drive  20 . The male USB connector  21  can be protected with a cap (not shown), or the assembly of the present invention is readily compatible with retractable mechanisms, such as the one shown in U.S. Pat. No. 7,422,454 to Tang et al. 
         [0042]    Referring now to  FIGS. 7 and 8A , additional detail of the SiP assembly is shown.  FIG. 7  shows the SiP memory device  30  being inserted into the rear opening of the USB connector housing  22 . On the top surface of the USB connector housing  22  are a pair of apertures  36  located at about the mid-way point of the housing, behind the USB apertures  38 . The dimensions and positions of the USB apertures  38  are dictated by the USB standard. The apertures  36  may be formed by stamping. The USB connector housing  22  is formed of metal and the stamping of the apertures  36  can leave the rearmost portion of the aperture  36  intact, so that a downwardly projecting tongue  37  is created by the stamping process. When the SiP memory device  30  is inserted in the USB connector housing  22 , this tongue  37  can push down on the upper surface  32  of the SiP memory device  30 , thereby providing additional mechanical security between the USB connector housing  22  and the SiP memory device  30 . Further, the apertures  36  can correspond to projections formed on an internal surface of the casing  40 . These projections can latch into the aperture  36  to provide further engagement of the USB connector housing  22  with the casing  40 . 
         [0043]    The casing  40  and the USB connector housing  22  can be formed of different materials. Although a Standard A male USB connector is shown, it will be appreciated that another type of connector can be formed and employed. Further, although the platform chassis extension  25  is shown to extend substantially along the entire lengthwise of the casing  40 , it will be appreciated that the length of the platform chassis extension  25  can be more than half of the length of the casing  40 . The platform chassis extension  25  is to provide a rigid framework for the miniaturized memory storage assembly and the connector housing. 
         [0044]    The chassis structure according to an embodiment of the present invention provides extended rigid framework to a miniaturized memory storage assembly such as SiP memory assembly. The chassis structure also prevents pivoting of the connector at an opening of a casing. The chassis structure extends from a connector housing of the connector. Further, the chassis structure can extend more than half lengthwise of a casing. The chassis structure also can include strengthening ribs along the lengthwise of the casing. 
         [0045]    The thumb drive chassis structure according to an embodiment of the present invention supports a miniaturized memory storage package such as SiP memory package. The thumb drive chassis structure provides rigid framework in an ergonomically-sized casing despite the miniaturized size of the memory storage package. The thumb drive chassis can include a chassis structure within the casing with strengthening ribs along the lengthwise of the casing. The chassis structure can be integrally formed with a connector housing, which are partially exposed outside of the casing. 
         [0046]    It will be apparent to those skilled in the art that various modifications and variations can be made in the chassis structure of embodiments of the invention without departing from the spirit or scope of the invention. Thus, it is intended that embodiments of the invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.