US Patent 7259967 USB device with plastic housing having integrated plastic plug shell

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.