Manufacturing methods for ultra-slim USB flash-memory card with supporting dividers or underside ribs

• US 7,094,074 B2
• Filed: 10/28/2004
• Issued: 08/22/2006
• Est. Priority Date: 09/11/2003
• Status: Expired due to Fees

• Current Assignee: Super Talent Electronics, Inc.
• Original Assignee: Super Talent Electronics, Inc.
• Inventors: Ni, Jim Chin-Nan, Chiou, Ren-Kang
• Primary Examiner(s): Nguyen, Truc T.
• Assistant Examiner(s): Leon, Edwin A.
• Application Number:
  US10/904,207
• Publication Number:
  US 20050059273A1
• Time in Patent Office: 663 Days
• Field of Search: 439607-610, 439/79, 439/379, 439/541.5, 439/660, 439/639, 439/291, 439/680, 439/518, 439/638, 439/292, 439/295, 439/677, 439/76.1, 439/377, 235/431, 235/451, 235/441, 361/785, 361/752, 361/791, 361/756, 361/803, 361/727, 361/746, 361/686, 361/802
• US Class Current: 439/79
• CPC Class Codes: G06K 19/07732 the record carrier having a housing or construction similar to well-known portable memory devices, such as SD cards, USB or memory sticks housings for electrical equipment in general, see H05K5/02
• CPC Class Codes: G06K 19/07733 the record carrier containing at least one further contact interface not conform ISO-7816
• CPC Class Codes: H01R 13/717 with built-in light source
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H01R 24/62 Sliding engagements with one side only, e.g. modular jack coupling devices

Abstract

A flash-memory-drive card has an integrated slim Universal-Serial-Bus (USB) connector that fits into a standard USB socket. The slim USB connector has 4 metal contacts on a board that is encapsulated by upper and lower plastic cases. Components are mounted onto the board on the side opposite the metal contacts. A thinner portion of the plastic case forms a light window that allows a light-emitting diode on the board to shine through the case. The plastic cases can be bonded together ultrasonically or with adhesive or using snaps and groves. Supporting underside ribs in the lower plastic case opposite the metal contacts allow most of the card to be thinner than the spacing in the standard USB socket. Dividers between the metal contacts are formed between openings in the upper case. The dividers help to fill gaps between the slim USB connector and the standard USB socket.

Claims

1. A portable, pluggable card with an integrated slim Universal-Serial-Bus (USB) connector comprising:

a connector substrate;

a plurality of metal contacts disposed on a first surface of the connector substrate, the metal contacts for carrying USB signals;

one or more integrated circuits mounted to a second surface of the connector substrate, the second surface being a side of the connector substrate that is opposite the first surface;

a lower case and an upper case for encapsulating the connector substrate when assembled;

a plurality of openings in the upper case that correspond in number and location to the plurality of metal contacts, the plurality of openings in the upper case allowing the plurality of metal contacts to make physical contact with metal pads on a female USB socket when inserted; and

a plurality of dividers formed between the plurality of openings in the upper case, each divider disposed between an adjacent pair of the metal contacts, the plurality of dividers rising above the first surface of the connector substrate when assembled;

wherein the plurality of dividers are for filling in a gap between the connector substrate and a female socket substrate when the integrated slim USB connector is inserted into the female USB socket.

2. The portable, pluggable card of claim 1 wherein the upper case and the lower case are plastic cases;

wherein the upper case is bonded to the lower case during assembly by ultra-sonic bonding, by inserting snap tabs into grooves, or by an adhesive.

3. The portable, pluggable card of claim 2 wherein the upper case contains ridges that first make contact with the lower case during assembly by ultra-sonic bonding, the ridges being absorbers of a ultra-sonic energy that are heated by the ultra-sonic energy, or

wherein the lower case contains ridges that first make contact with the upper case during assembly by ultra-sonic bonding, the ridges being absorbers of the ultra-sonic energy that are heated by the ultra-sonic energy.

4. The portable, pluggable card of claim 2 wherein the upper case contains

snap tabs that fit into groves in the lower case during assembly, or wherein the lower case contains snap tabs hat fit into groves in the upper case during assembly.

5. The portable, pluggable card of claim 4 further comprising:

end rails on the upper case, substantially parallel to the metal contacts when assembled, formed along side edges of the upper case;

wherein the end rails are for sliding in gaps between sides of the female connector substrate of the female USB socket and a metal case surrounding the female connector substrate when the integrated slim USB connector is inserted into the female USB socket.

6. The portable, pluggable card of claim 4 further comprising:

a light window formed by a thinning of plastic in the upper case or in the lower case, the light window allowing some light from a light-emitting diode to pass through the upper or lower case;

a light-emitting diode mounted to the connector substrate, for generating light for passing through the light window to indicate a status to a user.

7. The portable, pluggable card of claim 4 wherein the connector substrate is a printed-circuit board (PCB) containing wiring traces.

8. The portable, pluggable card of claim 4 further comprising:

supporting underside ribs formed on the lower case in an insertion end underneath the connector substrate, the insertion end for inserting into the female USB socket, the supporting underside ribs increasing a thickness of the insertion end of the portable, pluggable card.

9. The portable, pluggable card of claim 8 wherein a non-insertion end of the portable, pluggable card is thinner than the insertion end.

10. The portable, pluggable card of claim 8 wherein the supporting underside ribs slide over metal springs on the female USB socket.

11. The portable, pluggable card of claim 4 wherein the one or more integrated circuits mounted to the second surface of the connector substrate comprises:

a flash memory chip.

12. The portable, pluggable card of claim 11 wherein the one or more integrated circuits mounted to the second surface of the connector substrate further comprises:

a controller chip mounted on the connector substrate, for reading data from and for writing data to the flash memory chip and sending the data over the metal contacts as USB signals to the female USB socket.

13. A Universal-Serial-Bus (USB) card assembly comprising:

a circuit board having wiring traces, the circuit board having four metal contacts on an insertion end of a contact side of the circuit board, the four metal contacts for connecting to USB contacts in a USB socket when inserted;

an upper case for substantially covering the contact side of the circuit board when assembled;

a lower case for substantially covering a reverse side opposite the contact side of the circuit board when assembled;

four openings in an insertion end of the upper case, the four openings allowing the four metal contacts to contact the USB contacts through the upper case when inserted into the USB socket; and

three dividers in the upper case, each divider begin a portion of the upper case between two of the four openings, the dividers protruding upward from the contact side of the circuit board when assembled;

wherein the upper case is bonded to the lower case with the circuit board encased between the upper case and the lower case when assembled.

14. The USB card assembly of claim 13 further comprising:

ultrasonic protrusions on a first case that first initially contact a second case during assembly, the ultrasonic protrusions partially melting to bond the upper case to the lower case when ultrasonic energy is applied during assembly;

wherein the first case is the upper case and the second case is the lower case, or the first case is the lower case and the second case is the upper case.

15. The USB card assembly of claim 13 further comprising:

an adhesive applied to a first case before assembly to bond to a second case;

wherein the first case is the upper case and the second case is the lower case, or the first case is the lower case and the second case is the upper case.

16. The USB card assembly of claim 13 further comprising:

supporting underside ribs formed on an insertion end of the lower case, the supporting underside ribs situated in a direction parallel to the four metal contacts when assembled.

17. The USB card assembly of claim 16 further comprising:

wherein a height of the insertion end of the USB card assembly is less than a standard height of a standard USB male connector,

whereby the USB card assembly has a reduced height.

18. The USB card assembly of claim 17 further comprising:

wherein the supporting underside ribs are located to engage metal springs on the USB socket,

whereby the supporting underside ribs provide a secure fit into the USB socket when inserted.

19. The USB card assembly of claim 13 further comprising:

snap protrusions on a first case;

grooves on a second case;

the snap protrusions fitting into the grooves during assembly;

wherein the first case is the upper case and the second case is the lower case, or the first case is the lower case and the second case is the upper case.

20. The USB card assembly of claim 19 further comprising:

chips mounted to the reverse side of the circuit board,

wherein the chips include a flash-memory chip and a controller chip.

21. A reduced-height Universal-Serial-Bus (USB) plug card comprising:

circuit board means for supporting integrated circuits on a bottom side, having an insertion end for insertion into a USB socket;

metal contactor means, formed on the insertion end of a top side of the circuit board means, for making electrical contact with a USB socket when the insertion end is inserted into the USB socket;

top body means, formed from plastic, for partially encapsulating the top side of the circuit board means;

bottom body means, formed from plastic, for encapsulating the bottom side of the circuit board means;

divider means, formed between openings in the top body means, for dividing gaps between the insertion end of the USB plug card and the USB socket when inserted, the openings being over the metal contactor means when assembled;

bottom support means, formed on the insertion end of the bottom body means, for sliding along metal springs on the USB socket during insertion; and

end means, on the top body means, for extending side edges of the top body means to fill in gaps to sides of the USB socket produced by lack of a surrounding wrap surrounding the top body means;

whereby stability when inserted into the USB socket is increased by the divider means, the end means, and the bottom support means.

22. The reduced-height USB plug card of claim 21 wherein the top body means is bonded to the bottom body means to enclose the circuit board means, wherein a snap together bonding process bonds the top body means to the bottom body means.

23. The reduced-height USB plug card of claim 22 further comprising:

light window means, formed by a thinning of plastic in the top body means or in the bottom body means, for allowing some light from a light-emitting diode to pass through;

a light-emitting diode mounted to the circuit board means, for generating light for passing through the light window means to indicate a status to a user.