Abstract: Plastic casings are simultaneously molded onto several PCBAs attached to a carrier in a closely-spaced arrangement. All edges of each PCBA have integral connecting segments that extend through grooves formed in the associated mold assembly, and are pinched when the molds assembly is closed to precisely and reliably position the PCBA inside of an associated cavity during the molding process. In one embodiment, the PCB substrate is positioned in a bent arrangement to accommodate the use of inexpensive memory devices. Write-protect switches are provided.

Abstract: A Universal-Serial-Bus (USB) device has a USB plug that is centered over a center-line of a circuit board. The circuit board with flash memory and a USB flash controller has metal pads that a USB connector is soldered to. The USB connector has a rear step that is about half the height of the USB connector plug. Contacts on the rear step are soldered to the metal pads on the circuit board so that the USB connector is centered around the edge of the circuit board. The overall height of the flash device can be reduced since the bulky USB connector is not attached off-center to the circuit board, but is attached at the half-height rear step. Both the USB connector and the circuit board share the same center line, allowing a printed-circuit board assembly (PCBA) to be symmetric around the center line.

Abstract: A flash-memory device has a printed-circuit board assembly (PCBA) with a PCB with a flash-memory chip and a controller chip. The controller chip includes an input/output interface circuit to an external computer over a Secure-Digital (SD) interface, and a processing unit to read blocks of data from the flash-memory chip. The PCBA is encased inside an upper case and a lower case, with SD contact pads on the PCB that fit through contact openings in the upper case. Supporting end ribs under each of the SD contact pads and middle ribs support the PCB at a slanted angle to the centerline of the device. The PCB slants upward at the far end to allow more thickness for the chips mounted to the bottom surface of the PCB, and slants downward at the insertion end to position the SD contact pads near the centerline.

Abstract: A memory module assembly includes two-plate heat sink attached to one or more of the integrated circuits (e.g., memory devices) of a memory module PCBA by adhesive. The adhesive is either heat-activated or heat-cured. The adhesive is applied to either the memory devices or the heat-sink plates, and then compressed between the heat-sink plates and memory module using a fixture. The fixture is then passed through an oven to activate/cure the adhesive.

Abstract: A Universal-Serial-Bus (USB) device includes a PCBA mounted inside a molded plastic housing structure such that metal contacts are exposed on a plug portion of the housing structure, and includes a plastic plug shell integrally molded to the housing structure such that an upper wall of the plug shell is spaced from the metal contacts by a predetermined gap distance. A USB controller IC is mounted onto a relatively narrow portion of the PCBA under the metal contacts to reduce overall length of the USB device. An optional locking collar strengthens a rear edge of the plastic plug shell and front handle wall of the housing structure. An optional rear cover is attached over a rear opening of the housing structure and secures a rear edge of the PCBA.

Abstract: A Universal-Serial-Bus (USB) device includes a PCBA mounted inside a molded plastic housing structure such that metal contacts are exposed on a plug portion of the housing structure, and includes a metal plug shell attached to the housing structure such that an upper wall of the metal plug shell is spaced from the metal contacts by a predetermined gap distance. A USB controller IC is mounted onto a relatively narrow portion of the PCBA under the metal contacts to reduce overall length of the USB device. The metal plug shell is molded or snap-coupled onto tabs formed on the plug portion of the housing structure. An optional locking collar secures a rear edge of the metal plug shell to the housing structure. An optional rear cover is attached over a rear opening of the housing structure and secures a rear edge of the PCBA.

Abstract: Secure-digital (SD) type memory cards are produced using one or more prefabricated cover portions and a molded casing portion. A sub-assembly is formed by mounting a printed circuit board assembly (PCBA) onto the cover portion such that the contact pads of the PCBA are exposed through associated windows defined in the cover. The sub-assembly is placed into a cavity formed in a mold assembly, and molten thermoplastic material is then injected into each cavity of the mold assembly under heat and pressure using known injection molding techniques, thereby forming a molded plastic casing portion that secures the PCBA to the cover and completes the memory card housing.

Abstract: A computer peripheral device including a USB plug connector in which a reinforced connecting ring is mounted over the front flange of a one-piece or two-part housing, and includes an opening through which the USB plug connector protrudes. The connecting ring includes a collar that is sized to mount over the front flange using an interference fit, or a snap-coupled arrangement is used. The connecting ring also includes a front plate that protects a front of the housing from damage during use. An optional rear connecting ring is used to further secure a key ring and/or light-pipe device onto the housing.

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.

Abstract: A Universal-Serial-Bus (USB) device includes a PCBA mounted inside a plastic housing molded from a hard plastic (e.g., PVC), and includes a handle portion mounted or molded over a body section of the PCBA, and a plug portion mounted or molded over a plug section of the PCBA. The plug portion of the housing is integrally connected to (i.e., molded at the same time as) the handle portion, and includes a plug substrate extending under the plug section of the PCBA and a plug shell that extends over the plug portion, forming a structural arrangement similar to a conventional male USB connector plug that allows access to metal contacts formed on the PCBA, but without having the plug shell soldered to the PCBA.

Abstract: A memory card including a PCB assembly that is consistent with existing 13-pad MMC mechanical form factors, and a housing that is consistent with the SD mechanical form factor, thereby providing a single PCBA and housing arrangement that can be used to produce both MMC and SD memory cards. The thirteen contact pads support all MMC and SD contact pad patterns, but are modified to facilitate a write protect switch. The housing includes an enlarged window (or windows) that exposes two or more contact pads in each of the multiple rows, thereby facilitating slidable insertion of the memory card into a socket of a host system. Alignment notches are formed in the side edges of the PCB, and/or alignment pins are utilized for properly aligning the PCBA within the housing.

Abstract: A computer peripheral device including a USB plug connector in which a reinforced connecting ring is mounted over the front flange of a two-part housing, and includes an opening through which the USB plug connector protrudes. The connecting ring includes a collar that is sized to mount over the front flange using an interference fit. The connecting ring also includes a front plate that protects a front of the housing from damage during use. An optional rear connecting ring is used to further secure the housing together.

Abstract: A memory module assembly includes two-plate heat sink attached to one or more of the integrated circuits (e.g., memory devices) of a memory module PCBA by adhesive. The adhesive is either heat-activated or heat-cured. The adhesive is applied to either the memory devices or the heat-sink plates, and then compressed between the heat-sink plates and memory module using a fixture. The fixture is then passed through an oven to activate/cure the adhesive.

Abstract: A socket having thirteen contact springs arranged in a manner that supports existing MMC and SD form factors, and also supports a combination SD/MMC flash memory card. The combination memory card includes a PCB assembly that is consistent with existing 13-pad MMC mechanical form factors, and a housing that is consistent with the SD mechanical form factor, thereby providing a single PCBA and housing arrangement that can be used to produce both MMC and SD memory cards. The thirteen contact pads support all MMC and SD contact pad patterns, but are modified to facilitate a write protect switch. The contacts springs of the socket are arranged to make contact with the modified pad pattern, but to also be backward compatible with existing SD and MMC form factors. A system including the socket and combination SD/MMC flash memory card is also disclosed.

Abstract: A low-profile Universal-Serial-Bus (USB) connector includes a substantially flat base structure that is received in the lower section of a conventional female USB connector, and includes metal contacts formed on an upper surface of the base structure. Wobble or vertical play is reduced by rails extending along side edges of the base structure that are partially inserted into gaps formed between the metal case and base structure of the female USB connector. Between metal contacts on the low-profile USB connector are raised ribs (dividers) that prevent undesirable damage or contamination to the metal contacts. The connector base structure of the low-profile USB connector can be separate or can be integrated with a circuit board that holds a flash memory chip and a USB controller chip.

Abstract: A removable Flash integrated memory module card has a plastic shell and an integral Flash memory module. On the backside of the card, there are exposed contact pads. When the card is inserted into a card-hosting device, the card can communicate with the device through the exposed pads. The manufacturing method includes manufacturing of the memory module and utilizing plastic molding techniques for making the card outer body. The method involves preparing the substrate, mounting the components, testing the module, preparing the molding device, and molding the card body.

Abstract: A memory card having thirteen contact pads arranged on a PCB in a manner that supports an integrated SD/MMC system. Eight contact pads form a front row, four contact pads form a second row behind the front row, and a thirteenth contact pad is located between the front and back rows adjacent to a chamfer formed on the PCB. An L-shaped gap region is provided between the first and second rows, and between the second row and side edge of the PCB. An optional alignment notch is defined along the side edge adjacent the second row. An optional alignment hole is defined between adjacent contact pads of the second row that receives an alignment pin passing between two covers of a two-part housing. The memory card electronics are compatible with either the MMC or SD protocols, and the housing is consistent with either the MMC or SD mechanical form factors.

Abstract: A memory card including a PCB assembly that is consistent with existing 13-pad MMC mechanical form factors, and a housing that is consistent with the SD mechanical form factor, thereby providing a single PCBA and housing arrangement that can be used to produce both MMC and SD memory cards. The thirteen contact pads support all MMC and SD contact pad patterns, but are modified to facilitate a write protect switch. The housing includes an enlarged window (or windows) that exposes two or more contact pads in each of the multiple rows, thereby facilitating slidable insertion of the memory card into a socket of a host system. Alignment notches are formed in the side edges of the PCB, and/or alignment pins are utilized for properly aligning the PCBA within the housing.

Abstract: A metal-tube flash-memory-drive device has an integrated slim Universal-Serial-Bus (USB) connector that fits into a standard USB socket. The slim USB connector has 4 metal contacts. The 4 metal contacts are on a circuit board that slides into a slot on a front holder to form the USB connector. Components are pre-mounted onto the circuit board. The circuit board is fitted into the slot in the front holder and then both are inserted into a front opening of a metal tube. A rear holder is inserted into a rear opening of the metal tube to seal the circuit board inside the metal tube. The 4 metal contacts may also be an integral part of a front holder-connector that fits over and edge of the circuit board. A metal or plastic shield may be added over the USB connector to cover the 4 metal contacts.

Abstract: A metal-wrapped flash-memory-drive device 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 circuit board that is encapsulated by a plastic case. Components are mounted onto the circuit board. A metal wrap conforms to the general shape of a plastic sub-assembly of the plastic case and a plastic cover that enclose the circuit board. The metal wrap can be bent around the plastic sub-assembly in a forming process, or can be pre-formed into a metal tube that the plastic sub-assembly is inserted into. Alignment holes in the metal wrap can fit over plastic stubs on the plastic sub-assembly, or friction can hold the metal wrap to the plastic sub-assembly. The plastic cover and case can be bonded together by molding, ultrasonically, with adhesive films, or using snaps to form the plastic sub-assembly.