Abstract: Methods are provided for manufacturing a shell assembly for an electrical connector. First and second shells of a shell assembly may be formed from metal sheets via a stamping process. The stamping process may produce a number of first shells attached to a section of metal sheet remaining after the stamping process—a guide rail—with the front end opening of the first shell being oriented at 90 degrees relative to the guide rail. A second shell may be formed and severed from a metal sheet as a result of the stamping process. One end of the first shells may be exposed after the stamping process such that the second shells may be assembled over the exposed end of the first shells to form a shell assembly. Additional operations can be performed on the shell assembly.

Abstract: Housings for electronic devices including adaptive plugs, and the use of adaptive plugs in methods of manufacturing housings. The housing may include an opening, and an adaptive plug releasably positioned within the opening. A method of forming a housing may include forming an opening within the housing, disposing a curable material within the opening of the housing, and curing the material to form an adaptive plug. The adaptive plug may be positioned within the opening of the housing. The method may also include performing at least one surface treatment on the housing. A method of protecting an edge of an opening in a housing may include providing the housing including the opening, forming an adaptive plug within the opening of the housing, and forming a barrier on the edge of the opening using the adaptive plug.

Abstract: Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks, and rounded and tapered openings. Methods for manufacturing the frame are also provided.

Abstract: Housings for electronic devices including adaptive plugs, and the use of adaptive plugs in methods of manufacturing housings. The housing may include an opening, and an adaptive plug releasably positioned within the opening. A method of forming a housing may include forming an opening within the housing, disposing a curable material within the opening of the housing, and curing the material to form an adaptive plug. The adaptive plug may be positioned within the opening of the housing. The method may also include performing at least one surface treatment on the housing. A method of protecting an edge of an opening in a housing may include providing the housing including the opening, forming an adaptive plug within the opening of the housing, and forming a barrier on the edge of the opening using the adaptive plug.

Abstract: Systems and methods are provided for manufacturing a shell assembly. First and second shells of a shell assembly may be formed from metal sheets via a stamping process. The stamping process may produce a number of first shells attached to a section of metal sheet remaining after the stamping process—a guide rail—with the front end opening of the first shell being oriented at 90 degrees relative to the guide rail. A second shell may be formed and severed from a metal sheet as a result of the stamping process. One end of the first shells may be exposed after the stamping process such that the second shells may be assembled over the exposed end of the first shells to form a shell assembly. Additional operations can be performed on the shell assembly.

Abstract: Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks and rounded and tapered openings. Methods for manufacturing the frame are also provided.

Abstract: A method of plating the connector frames includes, in part, placing the frames in a vibrating bowl to enable the bowl's vibrations load the frames in a predefined orientation onto the vibrating bowl's channel. The properly oriented frames are delivered from this channel to a track. Subsequently, a multitude of sub-racks securely engage and lift the frames from the track. The sub-racks are afterwards aggregated to form a larger rack which transports the frames to a plating tank in which the plating operation is performed. Optionally, the spacing between adjacent frames in the track is such that no contact between adjacent frames can occur. Each sub-rack has a multitude of hooks or springs adapted to engage the frames. The sub-racks may be aggregated in a horizontal direction or a vertical direction to form the larger rack.

Abstract: Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks and rounded and tapered openings. Methods for manufacturing the frame are also provided.

Abstract: Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks, and rounded and tapered openings. Methods for manufacturing the frame are also provided.