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`PNY Technologies, Inc.
`
`
`EXHIBIT 1005
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`PNY Exhibit 1005
`Inter Partes Review of
`US Patent No. 7,518,879
`
`

`

`US007074052B1
`
`(12) United States Patent
`(10) Patent N0.:
`US 7,074,052 B1
`Ni et al.
`(45) Date of Patent:
`Jul. 11, 2006
`
`
`(54)
`
`(75)
`
`(73)
`
`USB DEVICE WITH CASE HAVING
`INTEGRATED PLUG SHELL
`
`Inventors: Jim Ni, San Jose, CA (US); Ren-Kang
`Chou, Fremont, CA (US)
`
`9/2003 Tirosh
`6,618,243 B1
`6,671,808 B1 * 12/2003 Abbott et al. .................. 726/4
`6,744,634 B1
`6/2004 Yen
`..................... 439/79
`6,854,984 B1 *
`2/2005 Lee et al.
`6,944,028 B1 *
`9/2005 Yu et al. ..................... 361/737
`2003/0100203 A1
`5/2003 Yen
`2005/0085129 A1 *
`4/2005 Chiou et al.
`
`................ 439/607
`
`Assignee: Super Talent Electronics, Inc., San
`Jose, CA (US)
`
`* cited by examiner
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`Primary Examinerilames R. Harvey
`(74) Attorney, Agent, or FirmiBever, Hoffman & Harms,
`LLP; Patrick T. Bever
`
`(21)
`
`Appl. No.: 11/128,054
`
`(22)
`
`Filed:
`
`May 11, 2005
`
`(51)
`
`(52)
`
`(58)
`
`(56)
`
`Int. Cl.
`
`(2006.01)
`H01R 12/00
`US. Cl.
`..................... 439/76.1; 439/951; 174/261;
`361/752; 29/830; 29/876
`Field of Classification Search .................. 439/59,
`439/61, 64, 76.1, 79, 660, 951; 174/255,
`174/261; 361/752; 29/830, 832, 842, 876
`See application file for complete search history.
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5,941,725 A *
`6,036,544 A *
`6,309,255 B1
`
`8/1999 Brennan et al.
`3/2000 Brunker et al.
`10/2001 Yu
`
`............ 439/357
`............. 439/607
`
`(57)
`
`ABSTRACT
`
`A Universal-Serial-Bus (USB) device includes a PCBA
`mounted inside a plastic housing, which in turn is inserted
`or otherwise secured inside an outer case. The case is made
`
`of metal or hard plastic, and includes a handle portion that
`is integrally connected to a plug shell. The plug shell extends
`over a plug portion of the PCBA, which is mounted on a
`corresponding substrate portion of the housing, forming a
`structural arrangement similar to a conventional male USB
`connector plug, but without having the plug shell soldered to
`the PCBA. The case is, for example, sheet metal that is
`folded into a frame-like box for receiving the housing. The
`handle portion engages a cover portion of the housing such
`that plastic panels are exposed through openings formed in
`the metal casing walls.
`
`16 Claims, 11 Drawing Sheets
`
`
`
` 16582T
`165$2[16582B
`
`PNY EXHIBIT 1005
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 1 0f 11
`
`US 7,074,052 B1
`
`
`
`FIG. 2
`
`1558/1658
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 2 0f 11
`
`US 7,074,052 B1
`
`151S1T
`
`15681T
`
`156828
`
`151828
`
`
`
`
`1593 156818
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 3 0f 11
`
`US 7,074,052 B1
`
`
`
`III/llVII/III
`
`
`
`
`§
`G
`11o 1—67
`
`
`
`
`§
`“4
`‘120
`
`_‘_
`
`
`
`
`16581
`
`100/
`
`
`258-2/16582
`
`250165;
`
`26
`
`FIG. 4(A)
`
`238-1
`
`25B—1/165S1
`
`100
`
`164
`
`8
`
` Vl/I/I/IW/l/I/f
`
`164
`
`5 WIIIIIIII_IIIII'III/III
`
`FIG. 5(A)
`
`120
`
`100A
`22
`28
`
`
`\\\\\\\\‘\\\\\\\\\\\\\\\\\\\\\\\\\\\\\\‘JA\\\\\\\\\\\\‘V
`
`
`III
`
`
`//////
`
`IIIIIIIIIIIIIIIIII I
`
`
`WWII
`
`
`'I'l
`VII—IIIVIIIIII‘IM—fiim es
`
`
`
`I
`I
`—
`/\\\\\\\\\\\\\\\\\\\\\\\\\\\\\‘
`
`125
`
`WWII/III;
`
`IIIIIIIIIIIIIIIIIIII
`
`
`
`FIG. 5(3)
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 4 0f 11
`
`US 7,074,052 B1
`
`
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 5 0f 11
`
`US 7,074,052 B1
`
`
`
`361T
`
`35381/
`
`36381
`
`
`35181/
`36181
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 6 0f 11
`
`US 7,074,052 B1
`
`
` 461T 463T
`
`460
`453T
`
`FIG. 11
`
`410/450
`
`414
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 7 0f 11
`
`US 7,074,052 B1
`
` 1
`
`1S1T
`
`FIG. 13(3)
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 8 0f 11
`
`US 7,074,052 B1
`
` 750/760
`
`FIG. 14
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 9 0f 11
`
`US 7,074,052 B1
`
`PRIOR ART
`
`PRIOR ART
`
`’---------
`
`FIG. 15(3)
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 10 0f 11
`
`US 7,074,052 B1
`
`22
`
`24
`
`“"""53”"
`
`10
`
`21
`
`’- 3'11".
`
`
`
`26
`
`24
`
`Fn<3.'16(1\)
`
`PRIOR ART
`
`22
`24
`‘0
`
`lingers;
`
`71.1525.- ‘5
`
`. .. m
`
`rm
`
`26
`
`24
`
`2a
`
`20
`
`PRIOR ART
`m FIG. 16(B)
`
`

`

`U.S. Patent
`
`Jul. 11,2006
`
`Sheet 11 0f 11
`
`US 7,074,052 B1
`
`PRIOR ART
`
`:DRIOR ART
`
`
`
`PRIOR ART
`
`FIG. 18(B)
`
`

`

`US 7,074,052 B1
`
`1
`USB DEVICE WITH CASE HAVING
`INTEGRATED PLUG SHELL
`
`FIELD OF THE INVENTION
`
`This invention relates to portable electronic devices, and
`more particularly to portable electronic devices that utilize
`the Universal-Serial-Bus (USB) specification.
`
`BACKGROUND OF THE INVENTION
`
`Rapid advances in technology in several areas have
`converged to enable small, portable memory cards with vast
`capacities. Flash memory technologies such as those using
`electrically-erasable programmable read-only memory (EE-
`PROM) have produced chips storing 128 M-Bytes or more.
`Small flash-memory cards have been designed that have a
`connector that can plug into a specialized reader, such as for
`compact-flash, secure-digital, memory stick, or other stan-
`dardized formats.
`
`More recently, flash memory cards are being sold that
`contain a USB connector. Such USB-flash memory cards do
`not require a specialized reader but can be plugged into a
`USB connector on a host system, such as a personal com-
`puter (PC). These USB-flash memory cards can be used in
`place of floppy disks. A USB-flash card can have a capacity
`of more than ten floppy disks in an area not much larger than
`a large postage stamp.
`FIG. 15(A) shows a prior-art flash-memory card with a
`conventional male USB connector. Flash memory chip 12
`may be a 128 Mega-byte non-volatile chip or may have
`some other capacity. Controller chip 14 contains a flash-
`memory controller that generates signals to access memory
`locations within flash memory chip 12. Controller chip 14
`also contains a USB interface controller that serially trans-
`fers data to and from flash memory chip 12 over a USB
`connection.
`
`Male USB connector 20 may be mounted on board 10,
`which is a small circuit board with chips 12, 14 mounted
`thereon. Multi-layer printed-circuit board (PCB) technology
`can be used for board 10. A plastic case (not shown) can
`surround board 10.
`Male USB connector 20 contains a small connector
`
`substrate 16, which is often white ceramic, black rigid
`plastic, or another sturdy substrate. Connector substrate 16
`has four or more metal contacts 18 formed thereon. Metal
`
`contacts 18 carry the USB signals generated or received by
`controller chip 14. USB signals include power, ground, and
`serial differential data D+, D—.
`Male USB connector 20 contains a metal case (plug shell)
`11 that wraps around connector substrate 16. The plug shell
`touches connector substrate 16 on three of the sides of
`
`connector substrate 16. The top side of connector substrate
`16, holding metal contacts 18, has a large gap to the top of
`the plug shell. On the top and bottom of this metal wrap are
`formed holes 15. USB connector 20 is a type-A USB
`connector.
`
`FIG. 15(B) shows a female USB socket connector 22.
`Female USB socket connector 22 can be an integral part of
`a PC or other host system, or can be connected by cable 21
`to such a host system. Another connector substrate 26
`contains four metal contacts 28 that make electrical contact
`with the four metal contacts 18 of the male USB connector
`
`20 of FIG. 15(A). Connector substrate 26 is wrapped by a
`metal case, but small gaps are between the metal case and
`connector substrate 26 on the lower three sides.
`
`2
`
`Locking is provided by metal springs 24 in the top and
`bottom of the metal plug shell. When male USB connector
`20 of FIG. 15(A) is flipped over and inserted into Female
`USB socket connector 22 of FIG. 15(B), metal springs 24
`lock into holes 15 of male USB connector 20.
`
`FIGS. 16(A) and 16(B) are cross-sections highlighting
`connections between male and female USB connectors.
`Female USB socket connector 22 is on the left while male
`
`10
`
`15
`
`USB connector 20 is being inserted from the right. Male
`USB connector 20 is flipped over relative to the view of FIG.
`15(A). Metal contacts 18 are formed on the lower surface of
`connector substrate 16 on male USB connector 20, while
`metal contacts 28 are formed on the upper surface of
`connector substrate 26 on female USB socket connector 22.
`Thus the metal contacts face one another to allow for
`electrical contact when male USB connector 20 is inserted
`into female USB socket connector 22 as shown in FIG.
`
`16(B).
`Metal springs 24 formed on the metal case surrounding
`connector substrate 26 on Female USB socket connector 22
`
`20
`
`fit into holes on the plug shell of male USB connector 20.
`This helps to lock the connectors together.
`A problem associated with the production of conventional
`male USB devices that utilize standard male USB plug
`connectors typically require lead-based soldering methods
`to attach the standard plug structure (e.g., substrate 16 and
`plug shell 11) to circuit board 10. Lead (Pb) is recognized as
`a hazardous material, and may at some point in time be
`banned from use. Lead-free soldering requires higher peak
`temperatures (about 240° C.) that can shrink or warp plastic
`substrates 16, thereby making such conventional USB plug
`connector structures unsuitable for lead-free fabrication pro-
`cesses.
`
`FIG. 17 shows a prior-art USB flash memory card using
`a low-profile USB connector that avoids the need for attach-
`ing a separate substrate and plug shell to a circuit board by
`integrating male USB connector 30 with board 32, and by
`omitting the plug shell entirely. Board 32 is a PCB that has
`flash memory chip 12 and controller chip 14 mounted
`thereon. Board 32 is extended to include male USB con-
`nector 30, which has metal contacts 38 formed on end 36 of
`board 32. The width and thickness of board 32 at end 36
`
`containing male USB connector 30 is designed to approxi-
`mately match that of connector substrate 16 of FIG. 15(A).
`Plastic case 34 can enclose board 32 but have an opening for
`metal contacts 38. Plastic case 34 can cover the bottom and
`
`sides of male USB connector 30 up to end 36 to emulate
`potions of the metal case of the male USB connector of FIG.
`15(A).
`FIGS. 18(A) and 18(B) show cross-sections of the prior-
`art lower-profile USB connector being inserted into a stan-
`dard Female USB connector. Board 32 that has male USB
`
`connector 30 formed on end 36 is flipped over from the view
`shown in FIG. 17, and end 36 is inserted into female USB
`socket connector 22 from the right side.
`Metal contacts 38 are located on the lower surface of male
`
`USB connector 30. Plastic case 34 has an opening on the
`lower surface of male USB connector 30 to expose the metal
`contacts so they can make electrical connection with metal
`contacts 28 on the upper surface of connector substrate 26 of
`Female USB socket connector 22 when inserted as shown in
`
`FIG. 18(B).
`Plastic case 34 helps to fill the gaps between board 32 and
`the top edge of the metal case of Female USB socket
`connector 22. However, no holes are provided in plastic case
`34, so metal springs 24 are pushed up slightly when male
`USB connector 30 is inserted into Female USB socket
`
`25
`
`30
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`

`

`US 7,074,052 B1
`
`3
`connector 22. Plastic case 34 is also formed along the thin
`edges of board 32 and helps to fill in the gaps between
`connector substrate 26 and the sides of the metal case of
`Female USB socket connector 22 that are above and below
`
`the plane of FIG. 18(B).
`While USB connector 30 can be less expensive and
`smaller than the standard USB connector and avoids the
`
`need for plug shell, it can have the undesirable characteristic
`of wobbling in the female USB connector socket, and
`exposes contacts 38 to damage.
`What is needed is a USB device having a male USB
`connector plug that avoids the need for soldering the plug
`shell to the circuit board. What is also needed is a method for
`
`manufacturing such USB devices.
`
`SUMMARY OF THE INVENTION
`
`The present invention is directed to a USB device in
`which the plug shell
`is integrally connected to a case
`structure that mounts over a printed circuit board assembly
`(PCBA), thereby avoiding the need for soldering the plug
`shell to the PCBA as in conventional manufacturing meth-
`ods, thus facilitating a lead-free structure.
`In accordance with an embodiment of the present inven-
`tion, the PCBA is mounted inside of a plastic housing, which
`in turn is mounted inside (coupled to) the case. The PCBA
`includes a printed circuit board (PCB) a PCB body (rear)
`section and a PCB plug (front) section, metal contacts
`disposed on the PCB plug section, and USB-compatible
`integrated circuits (ICs) mounted on the PCB body section.
`The plastic housing includes a cover portion mounted over
`the PCB body section, and a plug substrate portion integrally
`connected to and extending from the cover portion. The PCB
`plug section is fixedly attached to the plug substrate portion
`such that the plug substrate portion covers the lower surface
`of the PCB plug section, and the upper surface of the PCB
`plug section is exposed above the plug substrate portion. The
`case includes a handle portion fixedly secured around the
`cover portion of the plastic housing, and the plug shell,
`which is integrally connected to and extends from the handle
`portion such that a lower wall of the plug shell contacts a
`lower surface of the plug substrate portion, and an upper
`wall of the plug shell is positioned over and spaced from the
`upper surface of the PCB plug section by a predetermined
`gap distance that allows insertion of the USB device into a
`standard female connector socket. With this arrangement,
`the plug substrate portion and the plug shell facilitate
`reliable and secure connection of the USB device to a
`
`standard female USB connection socket without requiring
`lead-based soldering of either the substrate or the plug shell
`to the PCB, thus facilitating the production of lead-free USB
`devices.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`These and other features, aspects and advantages of the
`present invention will become better understood with regard
`to the following description, appended claims, and accom-
`panying drawings, where:
`FIG. 1 is an exploded perspective view showing an
`exemplary USB device according to an embodiment of the
`present invention;
`FIG. 2 is a perspective view showing the USB device of
`FIG. 1 in an assembled state;
`FIG. 3 is an exploded perspective view showing the
`housing and PCBA of the USB device of FIG. 1;
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`
`FIGS. 4(A) and 4(B) are cross-sectional side views show-
`ing a plug section of the USB device of FIG. 1 and a
`standard female USB connector socket;
`FIGS. 5(A) and 5(B) are cross-sectional side views show-
`ing a plug section of an alternative USB device according to
`another embodiment of the present invention;
`FIG. 6 is an exploded perspective view showing an
`exemplary USB device according to another embodiment of
`the present invention;
`FIG. 7 is a perspective view showing the USB device of
`FIG. 6 in an assembled state;
`FIG. 8 is an exploded perspective view showing an
`exemplary USB device according to another embodiment of
`the present invention;
`FIG. 9 is a perspective view showing the USB device of
`FIG. 8 in an assembled state;
`FIG. 10 is an exploded perspective view showing an
`exemplary USB device according to another embodiment of
`the present invention;
`FIG. 11 is a perspective view showing the USB device of
`FIG. 10 in an assembled state;
`FIG. 12 is an exploded perspective view showing a
`housing and a PCB of the USB device of FIG. 10;
`FIGS. 13(A) and 13(B) are an exploded top and bottom
`perspective views, respectively, showing a case and housing
`and a PCB of the USB device of FIG. 10;
`FIG. 14 is a perspective view showing a wireless com-
`munication-type USB device produced in accordance with
`another embodiment of the present invention;
`FIG. 15(A) shows a prior-art flash-memory card with a
`USB connector;
`FIG. 15(B) shows a female USB connector;
`FIGS. 16(A) and 16(B) are cross-sections highlighting
`connections between male and female USB connectors;
`FIG. 17 shows a prior-art USB flash memory card using
`a USB connector; and
`FIGS. 18(A) and 18(B) show cross-sections of the prior-
`art USB connector of FIG. 17 being inserted into a standard
`female USB connector socket.
`
`DETAILED DESCRIPTION OF THE DRAWINGS
`
`The present invention relates to an improvement in USB
`connectors. The following description is presented to enable
`one of ordinary skill in the art to make and use the invention
`as provided in the context of a particular application and its
`requirements. As used herein, directional
`terms such as
`“upper”, “upwards”, “lower”, “downward”, “front”, “rear”,
`are intended to provide relative positions for purposes of
`description, and are not intended to designate an absolute
`frame of reference. In addition, the phrase “integrally con-
`nected” is used herein to describe the connective relation-
`
`ship between two portions of a single molded or machined
`structure, and is distinguished from the terms “connected” or
`“coupled” (i.e., without the modifier “integrally”), which
`indicates two separate structures that are joined by way of,
`for example, adhesive, fastener, clip or movable joint. Vari-
`ous modifications to the preferred embodiment will be
`apparent to those with skill
`in the art, and the general
`principles defined herein may be applied to other embodi-
`ments. Therefore, the present invention is not intended to be
`limited to the particular embodiments shown and described,
`but is to be accorded the widest scope consistent with the
`principles and novel features herein disclosed.
`FIG. 1 is an exploded perspective view showing a Um-
`versal-Serial-Bus (USB) device 100 according to a first
`embodiment of the present
`invention, and FIG. 2 is a
`
`

`

`US 7,074,052 B1
`
`5
`perspective view showing USB device 100 in an assembled
`state. USB device 100 generally includes a printed circuit
`board assembly (PCBA) 110, a housing 150 that is fixedly
`mounted onto PCBA 110, and a case 160 that is mounted
`over housing 150.
`Referring to the upper portion of FIG. 1 and to FIG. 3,
`PCBA 110 includes a printed circuit board (PCB) 111
`including a relatively wide PCB body section 112 and a
`relatively narrow PCB plug section 114 that extends from a
`front end of PCB body section 112. PCB 111 is a substan-
`tially flat substrate, and has opposing sides that are referred
`to below as upper surface 116 and lower surface 118.
`Formed on upper surface 116 in plug section 114 are four
`metal contacts 120. Metal contacts 120 are shaped and
`arranged in a pattern established by the USB specification.
`At least one control integrated circuit (IC) 130 and zero or
`more auxiliary ICs 135 (e.g., a flash memory device or an RF
`communication circuit) are mounted on at least one of upper
`surface 116 and lower surface 118. ICs 130 and 135 are
`
`electrically connected to each other and to metal contacts
`120 by way of metal traces 131 and 136, respectively (a few
`traces are depicted in FIG. 1 in a simplified manner by
`dashed lines for illustrative purposes). PCB 111 is formed in
`accordance with known PCB manufacturing techniques
`such that metal contacts 120 and ICs 130 and 135 (as well
`as zero or more other circuit components, which are omitted
`for brevity) are electrically interconnected by a predefined
`network including conductive traces 131 and 136 and other
`conducting structures that are sandwiched between multiple
`layers of an insulating material (e.g., FR4) and adhesive.
`Referring to FIG. 1, housing 150 generally includes a
`cover portion 152 mounted over PCB body section 112 such
`that ICs 130 and 135 are enclosed therein, and a plug
`substrate portion 154 integrally connected to and extending
`from cover portion 152 under PCB plug section 114. Cover
`portion 152 is a box-like structure including parallel upper
`and lower cover walls 151T and 151B and a peripheral side
`wall, formed by parallel side walls 15181 and 15182 and a
`rear wall 155F, that extends between upper and lower cover
`walls 151T and 151B. Plug substrate portion 154 includes a
`lower substrate wall 155B, parallel substrate side walls
`15581 and 15582, and a front substrate wall 155F. PCB plug
`section 114 is coupled to plug substrate portion 154 in the
`manner described below such that plug substrate portion 154
`covers lower surface 118 of PCB plug section 114, and the
`upper surface 116 of PCB plug section 114, which includes
`metal contacts 120, is exposed. In particular, metal contacts
`120 face away from and are exposed above plug substrate
`portion 154.
`Case 160 includes a handle portion 162 and a plug shell
`164 that is integrally connected at one to handle portion 162,
`and has a free end extending from handle portion 162.
`Handle portion 162 is a frame-like or box-like structure
`formed by parallel upper and lower handle walls 161T and
`161B and parallel handle side walls 16181 and 16582 that
`define a rear opening 168F. Plug shell 164 includes parallel
`upper and lower shell walls 165T and 165B and parallel
`shell side walls 16581 and 16582 that define a front opening
`168F. Optional
`locking depressions 166T are formed in
`upper plug shell wall 165T and are positioned to engage with
`metal springs 24 protruding from bottom wall 22A of
`standard female U8B socket connector 22 (see, e.g., FIG.
`15(B). In the present embodiment, upper shell wall 161T and
`upper handle wall 161T are co-planar, as are lower shell wall
`161B and lower handle wall 161B, but a width distance
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`6
`separating shell side walls 16581 and 16582 is smaller than
`a width distance separating handle side walls 16181 and
`16112.
`
`In accordance with an aspect of the present invention, as
`depicted in FIG. 2, plug substrate portion 154 and plug shell
`164 collectively form a structure that is substantially iden-
`tical to the plug shell of conventional male U8B connectors
`without requiring soldering either structure to PCBA 110, as
`required in conventional male U8B connectors,
`thereby
`facilitating the production of lead-free USB devices. That is,
`the assembly formed by PCBA 110 and housing 150 is
`inserted into or wrapped inside case 160 such that handle
`portion 162 is secured over housing cover portion 152, and
`such that plug shell 164 is positioned over PCB plug section
`114 and plug substrate portion 154 in a manner similar to the
`arrangement associated with conventional male U8B con-
`nector plugs. In particular, plug shell 164 is mounted over
`PCB plug section 114 and plug substrate portion 154 such
`that lower shell wall 165B contacts a lower surface of plug
`substrate portion 154 (i.e., bottom wall 155B), and upper
`shell wall 165T is positioned over and spaced from the upper
`surface of PCB plug section 114 (i.e., metal contacts 120) by
`a predetermined gap distance G. As indicated in FIG. 4(A),
`the gap distance G generally corresponds to a height H1
`between metal contacts 28 and upper wall 23C of conven-
`tional standard female USB connector socket 22. Similarly,
`plug substrate portion 154 is formed such that the upper
`surface of PCB plug section 114 (i.e., metal contacts 120)
`are spaced a predetermined distance T from a lower surface
`of plug shell 164 (i.e., the lower surface of bottom wall
`165B), which distance T corresponds to a height H2 between
`metal contacts 28 and lower wall 23A of conventional
`
`standard female USB connector socket 22. Finally, shell side
`walls 16581 and 16582 ofplug shell 164 are spaced apart by
`a width W1 that generally corresponds to the width W2
`associated with side walls 23B-1 and 23B-2 of standard
`
`female USB connector socket 22. Accordingly, as indicated
`in FIG. 4(B), when inserted into standard female USB
`connector socket 22, PCB plug section 114, plug substrate
`portion 154, and plug shell 164 are securely received in
`standard female USB connector socket 22 such that metal
`
`contacts 120 are reliably contacted with metal contacts 28.
`In particular, PCB plug section 114, plug substrate portion
`154, and shell lower wall 165B of plug shell 164 are sized
`to be received in lower socket region 25A of female USB
`connector socket 22 with shell side walls 16581 and 16582
`
`respectively received in side socket regions 25B-1 and
`25B-2, and shell upper wall 165T received in upper socket
`region 25C. One benefit of integrally connecting plug shell
`164 to case handle portion 162 (i.e., instead of to PCB 111,
`as in conventional structures) is that PCBA 110 can be
`produced using solder-free manufacturing techniques. That
`is, instead of using lead-based solder to secure plug shell 164
`to PCB 111 or substrate 152, the present invention avoids the
`need for the use of hazardous lead solder by integrating plug
`shell 164 onto handle portion 162. In addition, ICs 130 and
`135 are provided as surface mount components that don’t
`contain lead in their pins/balls,
`thereby further enabling
`lead-free fabrication. Thus, because plug shell 164 is not
`directly or indirectly connected to PCBA 110, the present
`invention facilitates the production of PCBA 110 as a
`lead-free structure (i.e., produced without the use of lead-
`based solder).
`In accordance with a specific embodiment of the present
`embodiment, housing 150 is mounted over PCBA 110 using
`the convenient snap-coupled arrangement depicted in FIG.
`3. In particular, housing 150 generally includes a lower
`
`

`

`US 7,074,052 B1
`
`7
`housing portion 150B and an upper housing portion 150T
`that snap-couple to each other over PCBA 110. Optional 180
`and 185 are utilized to further secure lower housing portion
`150B to upper housing portion 150T.
`Lower housing portion 150B generally includes a lower
`cover portion 152B and a lower plug substrate portion 154B.
`Lower cover portion 152B includes a lower wall 151B and
`an inner peripheral wall formed by lower side walls 151$1B
`and 151$2B and lower rear wall 151RB extending upward
`from (perpendicular to) peripheral edges of lower wall
`151B. Lower plug substrate portion 154B extends from a
`front wall 151FB of lower cover portion 152B, which
`defines a gap as shown in FIG. 3 to facilitate mounting of
`PCBA 110. Lower plug substrate portion 154B includes
`several support ribs 158B that extend upward from a lower
`plug wall 155B and, when mounted below PCBA 110,
`contact and help support plug section 114 of PCB 111.
`Support ribs 158B are surrounded on three sides by lower
`plug side walls 155$1B and 155$2B and lower plug front
`wall 155FB.
`
`Upper housing portion 150T generally includes an upper
`cover portion 152T and an upper plug substrate portion
`154T. Upper cover portion 152T includes upper wall 151T
`and an outer peripheral wall formed by upper side walls
`151$1T and 151$2T and upper rear wall 151RT, which
`extend downward from (perpendicular to) peripheral edges
`of upper wall 151T. Upper plug substrate portion 154T
`extends from an upper front wall 151FT, and includes a
`peripheral shelf 158T that is formed on an inside surface of
`a peripheral wall formed by upper plug side walls 155$1T
`and 155$2T and upper plug front wall 155FT. Note that
`peripheral shelf 158T is exposed through an upper opening
`158TO.
`
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`between a lower PCBA surface (e.g., the surface of IC 135B
`facing downward from PCB 111) and lower cover wall
`151B, and between an upper PCBA surface (e.g., the surface
`of IC 135T facing upward from PCB 111) and upper cover
`wall 151T in order to substantially permanently secure the
`housing formed by lower housing portion 150B and upper
`housing portion 150T over PCBA 110. Although the snap-
`coupling arrangement described above may be sufficient to
`prevent separation of housing portions 150B and 150T under
`normal operating conditions, the two housing portions may
`be separated during assembly. To prevent such disassembly,
`adhesive layers 180 and 185 serve to secure housing por-
`tions 150B and 150T together by way of PCBA 110. As
`mentioned above, PCBA 110 is formed using conventional
`PCB assembly procedures, and as such ICs 135B and 135T
`are rigidly secured to PCB 111. When secured to lower
`housing portion 150B by way of adhesive layer 180 and
`upper housing portion 150T by way of adhesive layer 185,
`PCBA 110 helps resist separation of the housing portions in
`response to an applied shearing force by resisting relative
`movement of the housing portions. In accordance with an
`embodiment of the present invention, adhesive layers 180
`and 185 are pres sure or heat activated, and mounted onto the
`inner surfaces of housing portions 150B and 150T before the
`assembly process is performed. In this manner, the snap-
`coupling procedure may be completed and reversed,
`if
`necessary, before permanent connection of housing portions
`150B and 150T to PCBA 110 (e.g., in response to an applied
`pressure or heat). Alternatively, a standard adhesive may be
`used, but this may result in inadvertently gluing the housing
`portions together in a non-optimal position. In yet another
`embodiment, a liquid adhesive may be injected into the
`housing after the snap-coupling process to secure the PCBA
`to the cover plates.
`Referring to the upper portion of FIG. 3, PCBA 110 also
`includes an optional light-pipe (light-generating device) 137
`mounted onto upper surface 116 of PCB 111 adjacent to a
`back edge of PCB 111. Light-pipe 137 is controlled by a
`signal generated, for example by control IC 130 and trans-
`mitted over an associated conductive trace formed on PCB
`
`111 according to known techniques. To facilitate viewing of
`light-pipe 137, the rear walls (e.g., rear bottom wall 151RB)
`are provided with suitable access openings (e.g., opening
`157B) that, when PCBA 110 is properly mounted inside
`housing 150, is aligned with light-pipe 137 such that light-
`pipe 137 is visible. Note that case 160 includes rear opening
`168R that facilitates viewing the activated/non-activated
`state of light-pipe 137,
`thereby enabling a user to, for
`example, confirm that USB device 100 is operably inserted
`into a female USB connector socket.
`
`In accordance with another optional aspect of the present
`invention, USB device 100 may be provided with a through
`hole that passes through case 160 and housing 150 to
`facilitate,
`for example,
`the engagement of a key-chain
`structure. In particular, referring to FIG. 3, lower housing
`portion 150B includes a lower opening 159B and upper
`housing portion 150T includes an upper opening 159T that
`align to form a coincident opening 159 (FIG. 1) when the
`upper and lower housing portions are snap-coupled together
`as described above. Similarly, as shown in FIGS. 1 and 2,
`case 160 includes an associated opening 169 that coincides
`with opening 159 when housing 150 is,
`for example,
`inserted into case 160.
`
`FIGS. 5(A) and 5(B) are simplified front views showing
`the plug portion of a USB device 100A according to a
`variation of the embodiment described above. Structures of
`USB device 100A that are identical to those of USB device
`
`35
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`40
`
`45
`
`In accordance with an aspect of the present embodiment
`invention, lower housing portion 150B and upper housing
`portion 150T are fabricated such that the housing portions
`can be snap-coupled over PCBA 110 during the housing
`assembly process. In particular, the respective peripheral
`walls of housing portions 150B and 150T are constructed
`such that the inner peripheral wall of lower housing portion
`150B can be inserted inside the outer peripheral wall of
`upper housing portion 150T, whereby the outside surfaces of
`the inner peripheral wall abut the inside surfaces of the outer
`peripheral wall. In addition, either a slot or a tab are
`provided on the outside surface of the inner peripheral walls,
`and a corresponding tab or slot are provided on the inside
`surfaces of the outer peripheral walls, wherein each tab is
`snap-coupled into a corresponding slot when upper housing
`portion 150T is mounted onto the lower housing portion
`150B. In the present embodiment, the outside surfaces of 50
`selected lower walls (e.g., lower side wall 151$1B and lower
`plug front wall 151FB) includes a corresponding tab (e.g.,
`tabs 156SlB and 156FB), and the inside surfaces of the
`outer peripheral walls (e.g., upper side wall 151$1T and
`upper plug front wall 155FT) of upper housing portion 150T
`defines a corresponding slot (e.g. 156SlT and 156FT) such
`that each tab is snap-coupled into a corresponding slot when
`upper housing portion 150T is mounted onto lower housing
`portion 150B. Note that the number of slots/tabs provided on
`each peripheral wall may be substantially arbitrarily
`selected, as well as the peripheral wall (inner or outer) on
`which the tabs/slots are provided. Note also that the various
`slots may either pass entirely through the corresponding
`wall, or as depicted by the dashed lines in the figures, be
`covered by an outer layer of the corresponding wall.
`According to another aspect of the present
`invention,
`adhesive layers 180 and 185 are resp