USB flash device with rubber cover

1. A USB device comprising:

a printed circuit board assembly (PCBA) including a printed circuit board (PCB) having a handle portion and a plug portion, at least one integrated circuit mounted on the handle portion of the PCB, wherein the plug portion includes one or more metal contacts that are electrically connected to the integrated circuit;

a metal shell secured to the PCBA and including a plug shell connector disposed around the plug portion of the PCB such that the metal contacts are exposed through a front opening defined by the plug shell connector;

a plastic frame including a frame body having an enclosed first rear portion and defining a first central cavity and a first front end opening, wherein the PCBA is secured to the plastic frame such that the handle portion of the PCB is at least partially received inside the first central cavity adjacent to the closed second rear portion, and such that the plug shell connector is exposed outside of the first front end opening, the frame body including one or more locking protrusions disposed adjacent to the first rear end; and

a rubber case including a case body having a substantially closed second rear portion and defining a second central cavity and a second front end opening, wherein the plastic frame is received inside the second central cavity such that the entire handle portion of the PCB is covered by the case body, and such that the plug shell connector extends from the second front end opening, wherein the case body includes at least one engagement opening, and wherein the one or more locking protrusions are received inside said at least one engagement opening such that the case body is secured to the plastic frame.

2. The USB device of claim 1 , wherein said integrated circuit comprises a flash memory device.

3. The USB device of claim 1 ,

wherein said locking protrusions comprise at least one of a key hole protrusion and an ear tab extending from the frame body adjacent to the enclosed first rear portion, and

wherein said at least one engagement opening comprises at least one of a key hole defined through a wall of said case body with said key hole protrusion disposed therein, and an ear tab slot defined on an inside surface of said case body adjacent to said second rear portion with said ear tab disposed therein.

4. The USB device of claim 1 , wherein the rubber case further comprising a rubber cap having a closed third rear portion and defining a second central cavity and a third front end opening, wherein the plug shell connector of the metal shell is received inside the third central cavity such that the second front end opening abuts the third front end opening, whereby the entirety of said PCBA is enclosed within said rubber case.

5. The USB device of claim 4 ,

wherein the rubber cap includes a protrusion disposed adjacent to the third front end opening,

wherein the case body defines a recess disposed adjacent to the second front opening, and

wherein the protrusion extends into the recess.

6. The USB device of claim 5 , wherein the rubber cap comprises a soccer ball pattern disposed such that a portion of the soccer ball pattern forms said protrusion.

7. The USB device of claim 5 , wherein at least one of the rubber cap and the case body comprises slip-resistant texturing.

8. The USB device of claim 5 , wherein at least one of the rubber cap and the case body comprises a cosmetic feature including at least one of a ball, a sports team logo, and a company logo.

9. The USB device of claim 1 , wherein the plastic frame further comprises a collar disposed over the plug shell connector and attached to the frame body adjacent to the first front end opening.

10. The USB device of claim 9 , wherein the collar comprises a base defining a central opening through which said plug shell connector extends, the base also defining at least one slot disposed to receive a side edge of the PCB, and at least one locking finger engaged in a corresponding locking groove defined in said frame body.

11. The USB device of claim 1 ,

wherein the metal shell further comprises a handle shell portion integrally connected to the plug shell connector and disposed over the handle portion of said PCB, and

wherein the frame body is snap-coupled to a rear end of the handle shell portion.

12. The USB device of claim 11 , wherein the plastic frame further comprises a plastic tray disposed between a portion of the plug shell connector and the plug portion of the PCB.

13. A method for assembling a USB device comprising:

securing a metal shell onto a printed circuit board assembly (PCBA), the PCBA including a printed circuit board (PCB) having a handle portion and a plug portion, wherein the plug portion includes one or more metal contacts that are electrically connected to the integrated circuit, and wherein securing the metal shell includes disposing a plug shell connector around the plug portion of the PCB such that the metal contacts are exposed through a front opening defined by the plug shell connector;

securing a plastic frame onto the metal shell and the PCBA, the plastic frame including a frame body having an enclosed first rear portion and defining a first central cavity and a first front end opening, wherein securing the plastic frame includes disposing at least a portion of the handle portion of the PCB inside the first central cavity such that the plug shell connector is exposed outside of the first front end opening; and

mounting a rubber case onto the metal shell, PCBA and plastic frame, the rubber case including a case body having a substantially closed second rear portion and defining a second central cavity and a second front end opening, wherein mounting the rubber case includes inserting the frame body inside the second central cavity such that the entire handle portion of the PCB is covered by the case body, and such that the plug shell connector extends from the second front end opening.

14. The method of claim 13 , wherein mounting the rubber case comprises engaging one of a key hole protrusion and an ear tab extending from the frame body adjacent to the enclosed first rear portion into at least one of a key hole defined through a wall of said case body and an ear tab slot defined on an inside surface of said case body adjacent to said second rear portion.

15. The method of claim 13 ,

wherein securing the metal shell further comprises mounting a handle shell portion of said metal shell over the handle portion of said PCB, and

wherein securing the plastic frame comprises snap-coupling the frame body to a rear end of the handle shell portion.

16. The method of claim 13 , wherein securing the plastic frame further comprises pressing a plastic tray into the plug shell connector until tabs provided on the plastic tray are snapped into slots defined in the plug shell connector.

17. The method of claim 13 , further comprising mounting a rubber cap of said rubber case onto the plug shell connector of the metal shell such that the second front end opening of the case body abuts the a third front end opening of the rubber cap, whereby the entirety of said PCBA is enclosed within said rubber case.

18. The method of claim 17 ,

wherein the rubber cap includes a protrusion disposed adjacent to the third front end opening,

wherein the case body defines a recess disposed adjacent to the second front opening, and

wherein mounting the rubber cap further comprises causing the protrusion to extend into the recess.

19. The method of claim 13 , wherein securing the plastic frame comprises mounting a collar over the plug shell connector and attaching the collar over the first front end opening of the frame body.

20. The method of claim 19 , wherein mounting the collar comprises inserting said plug shell connector through a central opening defined by the collar, and sliding a side edge of the PCB into a slot disposed on an inside surface of the collar.