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

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.

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.