Backward compatible connector system

Various embodiments of connectors and connector assemblies provide modified structural features to meet evolving industrial design requirements while maintaining backward compatibility. In one embodiment, alignment posts on the two sides of a plug connector are substantially removed and the remaining connector shell reshaped so as to preserve alignment capability. Other pre-existing features such as alignment grooves and some or all springy raised tabs can be eliminated resulting in a more compact and monolithic structure for the connector without impacting functionality or backward compatibility. In another embodiment, a trim ring is molded to the base of the connector to form an integrated unit. The integrated unit results in a reduced size of the connector when it is incorporated into other devices such as a docking station. In yet another embodiment, a printed circuit board is integrated into the boot of a connector assembly to act as an intermediate connection mechanism between the cable wires and the connector pins. Other functionality such as identification circuitry or electrostatic discharge protection circuitry can be incorporated on to the integrated printed circuit board.

CROSS-REFERENCES TO RELATED APPLICATIONS

BACKGROUND OF THE INVENTION

The present invention relates in general to connectors for electronic systems. More particularly, the invention relates to various implementations of and methods of manufacture for connector systems that connect portable or handheld devices to other electronic devices.

The last half decade has witnessed a rapid proliferation of handheld consumer electronic devices such as mobile phones, digital media players, personal digital assistants and the like. The connector technology that enables electrical interconnection between these devices and other electronic systems such as host computers, accessories and power supplies, has evolved to meet the various requirements of these systems from electrical specifications and interface protocols to form factor. A good example of a highly versatile connector system can be found in the 30-pin connector platform various aspects of which are described in the above-referenced issued patent and pending patent applications. A vast array of electronic devices has been developed incorporating the 30-pin connector platform as the primary means for providing electrical interconnectivity. As the industry evolves, subsequent generations of devices for new and old applications rely on backward compatibility of the connector platform in order to interface and operate with existing devices. On the other hand, the ever present demand for reducing the size of electronic devices or otherwise modifying their structure for other industrial design considerations, particularly in the handheld consumer electronics market, often requires a redesign of many aspects of the device including the connectors. There is therefore a need for improved connector systems that meet the challenges presented by these competing demands.

BRIEF SUMMARY

Various embodiments of the present invention provide improved connector systems with more compact and monolithic design while maintaining backward compatibility. In one embodiment, alignment posts on the two sides of a plug connector are substantially removed and the remaining connector shell reshaped so as to preserve alignment capability. The reshaped connector includes, in one embodiment, a shell that is made of a single sheet of conductive material wrapped around the connector forming a single seam. Other pre-existing features such as alignment grooves and some or all springy raised tabs can be eliminated resulting in a more compact and monolithic structure for the connector without impacting functionality or backward compatibility. In another embodiment, a trim ring is molded to the base of the connector to form an integrated unit with the connector. The integrated unit can result in reduced size for the connector when it is incorporated into other devices such as a docking station. In yet another embodiment, a printed circuit board is integrated into the boot of a connector assembly to act as an intermediate connection mechanism between the cable wires and the connector pins. Other functionality such as identification circuitry or electrostatic discharge protection circuitry can be incorporated on to the integrated printed circuit board.

Accordingly, in one embodiment, the present invention provides a plug connector for use in a connector system having a receptacle connector, the receptacle connector having alignment projections projecting toward an interior of a box shaped housing of the receptacle connector, the plug connector including: a body having a bottom plate with a width W, a top plate with a width W′ that is smaller than W, a first side plate and a second side plate each having a step to accommodate the width differential between the top and bottom plates, wherein the first and second side plates are smaller relative to the top and bottom plates providing a substantially flat body; and an array of electrodes extending in the direction of the depth of the body and being positionally secured by insulating material to an interior surface of the bottom plate of the body leaving an insertion cavity in the interior of the body between the array of electrodes and the top plate, wherein the steps in the first and second side plates are aligned with the alignment projections of the receptacle connector to guide insertion of the plug connector into the receptacle connector housing. The plug connector further includes a shell that is made of a single sheet of conductive material wrapped around the body.

In another embodiment, the plug connector further includes an integrated trim ring molded to a base of the plug connector. In a specific embodiment the integrated trim ring is made of glass reinforced nylon. In a further embodiment, the number of barbs that hold in place an electrode inside the plug connector is reduced.

In yet another embodiment, the invention integrates a printed circuit board inside the boot of a cable connector assembly. In this embodiment, wires from the cable electrically couple to the connector electrodes via the printed circuit board. In a specific embodiment the printed circuit board further includes additional functionality such as an identification circuit or an electrostatic discharge protection circuit.

These and other features of the modified connector yield a more compact and monolithic connector assembly that remains compatible with previously existing mating connectors. The following detailed description and the accompanying drawings provide a better understanding of the nature and advantages of the connector system of the present invention.

DETAILED DESCRIPTION

Referring toFIG. 1, there is shown a connector system100that is currently in use by a vast array of electronic devices including handheld media players such as the iPod™ and a host of accessories developed for such handheld media players. Connector system100includes a plug connector101that is insertable into a receptacle connector102. The connectors are designed such that when in mating position, an array of pins110housed in plug connector101are in contact with a corresponding array of pins104housed in receptacle connector102. To properly align the two arrays of pins during the insertion process, receptacle connector102includes a pair of projections108A and108B that project from its outer shell inwardly. In one embodiment, projections108A and108B are formed by cutting the top plate of the connector shell in an angled C (or bracket) shape and bending the resulting tongue pieces toward the interior of the plug housing. Plug connector101in turn includes a corresponding pair of grooves or slits114A and114B that when brought into contact with receptacle connector102, engage projections108A and108B and help guide the insertion process.

In some embodiments, plug connector101includes a shell or chassis with a top plate and a bottom plate made of conductive material to reduce electromagnetic interference (EMI) when the connectors carry electrical signals. Plug connector101further includes raised springy tabs116A and116B that increase compressive action between the two mating connectors for more secure engagement and to further improve EMI containment. In other embodiments, plug connector101also includes a latching mechanism such as springy retention pins118on either side of the plug connector body. When inserted into receptacle connector102, retention pins118are first pushed in and then released once inside the body of the receptacle connector to latch the two connectors.

FIGS. 2A and 2Bprovide exemplary top and cross-sectional views, respectively, of plug connector101. In the embodiment depicted, plug connector101includes alignment posts122A and122B on sides of the connector housing. In this embodiment, top plate120as well as tabs116A and116B are made of conductive material such as metal while alignment posts122A and122B are made of non-conductive material such as plastic resin. The frontal cross-sectional view of plug connector101inFIG. 2Bshows array of pins110that are affixed to the inside wall of the lower plate of the connector housing in a bed of dielectric material, leaving a cavity124in the remaining portion of the connector interior. In one embodiment the bed of dielectric material can accommodate 30 pins. An exemplary pin designation for the 30 pins plus two chassis ground tabs or pins as used in the iPod™ media player is shown inFIG. 3. While the dielectric bed may accommodate 30 pins, the actual number of conductive pins included in the dielectric bed can vary depending on the application. Also, the number of chassis pins can be fewer or more than the two listed inFIG. 3. In one example, as many as six chassis pins provide the grounding for the connector shell as well as the mechanism to physically fasten the connector by soldering them to a board.FIG. 2Balso shows a pair of springy raised tabs116on each side of the connector housing. This particular connector101is about 21.30 mm wide when measured from the outer edges of alignment posts118and about 19.2 mm wide when excluding alignment posts122. Other structural and electrical details of illustrative embodiments for the connector system100are provided in the above-referenced U.S. Pat. Nos. 6,776,660 and 7,441,062, and pending patent application Ser. No. 10/423,490, all three of which are incorporated herein by reference.

As mentioned above, connector system100has provided an interconnection platform that has been widely employed by a vast array of electronic devices. Connector system100interconnects handheld media players with other electronic devices including host computers and accessory devices such as dock stations, many different types of cable connectors, battery chargers and power adapters, Hi-Fi sound systems and RF systems, and camera connectors, among many other types of devices. As the consumer electronics industry evolves, changing industrial design considerations and the demand for further miniaturization require modifications to the structure and design of the connectors. The challenge is therefore to meet the evolving industrial design requirements while maintaining compatibility with existing devices. In one embodiment, the present invention modifies the structural design of plug connector100to achieve a more compact and monolithic structure without impacting functionality or compatibility with exiting receptacle connectors.

Referring toFIG. 4, there is shown a connector400according to one embodiment of the present invention. Connector400is more compact compared to plug connector101yet it is functionally equivalent and structurally compatible with connector system100. A number of structural modifications have allowed connector400to be more compact yet backward compatible. Among these are the elimination of alignment posts118. This has resulted in two advantageous features. First, the total width W of the connector has been reduced from about 21.30 mm to about 19.2 mm. Second, the elimination of the alignment posts allows for the option of building the connector shell402from a single sheet that wraps around the entire connector housing. In one embodiment, the single sheet forming the connector shell is made of conductive material such as metal further improving the connector's EMI containment.

Second, instead of grooves or slits (114inFIGS. 1 and 2), a step404has been formed at each of the side plates of shell402as shown inFIG. 4. This results in an upper plate (as depicted inFIG. 4) having a width W′ of about 17.35 mm which is smaller than the width W of the lower plate which is about 19.2 mm. The dimensions of the plates and those of the resulting steps404A and404B are designed to frictionally fit engagement projections108of receptacle connector102when connector400is inserted into receptacle connector102. The angles and radius of curvature for steps404are designed to facilitate manufacturability of shell402as a single sheet of conductive material. In the example shown, each of the three edges resulting from the step on each side has a curved contour as opposed to sharp angles.

FIGS. 5A and 5Bshow isometric views of the front and back of connector400according to this embodiment of the invention. As shown inFIGS. 5A and 5B, shell402is made of a single sheet of material that wraps around the connector coming to a seam406. In this embodiment, connector400includes springy tabs408A and408B on one plate and not the other of shell402of the connector. It is to be understood that the provision of tabs408can vary from two or more on each side to none at all. The combination of these modifications yields a connector structure that is more compact and monolithic yet is still compatible with previously existing connector system100.

As explained above, the plug connector has numerous applications from cables to dock stations. According to another embodiment of the invention, further miniaturization of the connector assembly is achieved when connector400is part of a dock station.FIG. 6provides a perspective view of a subset of components of a docking system600. A connector such as plug connector101(FIG. 1) is mounted on a top surface of printed circuit board (PCB)602while a receptacle connector such as receptacle connector102(FIG. 1) is attached to the side of PCB602. Before fully assembling docking system600, a protective ring604that is typically made of plastic, is inserted around the base of connector101.FIG. 7Aillustrates an isometric view of the combined connector101and plastic trim ring604, whileFIG. 7Bprovides a side view of the same. As shown both inFIG. 6andFIG. 7B, the connector/ring assembly is typically tilted at an angle, in this example, of about 15 degrees from the vertical axis. This angle results in the device that is being docked in system600to be tilted to provide a better viewing angle to the user. Also noted inFIG. 7Bis the total thickness of the resulting base structure of the assembly which in this case is about 3.9 mm.FIG. 7Balso shows pin606that extends out from under the base and onto the PCB.

According to one embodiment of the invention, instead of using a separate plastic trim ring that is inserted around the base of the connector, a smaller trim ring is molded to the connector base to form an integrated unit.FIGS. 8A and 8Bshow isometric views of the back and front of a connector assembly800with an integrated trim ring802.FIG. 8Billustrates the opening in trim ring802through which pins804can be accessed. The soldering process that electrically connects pins804to conductive traces on the PCB exposes connector assembly800to high temperatures. Trim ring802is therefore preferably made of material that can withstand higher temperatures, such as glass reinforced nylon and the like.

Connector assembly800with integrated trim ring802has appreciably reduced thickness and can therefore sit lower in the dock base.FIG. 9Anotes the reduction in the base thickness for an illustrative embodiment wherein the thickness of the base is reduced to about 1.42 mm. WhileFIGS. 8A and 8Bshow the use of the more compact connector design (400inFIGS. 4 and 5) as part of connector assembly800, previously existing connectors can also benefit from the molded trim ring design. It should be noted that in some applications it may be desirable to have a gap between the bottom of the device being docked and the dock surface around the connector. For example, a handheld electronic device may have an integrated sound system, such as a microphone and speakers, with openings that are located at the base of the device in proximity to the connector that mates with the dock connector. The acoustic requirements of such a device may dictate that there be a gap between the bottom of the device and the dock surface when the device is docked. For such applications, the overall height of connector assembly800may be adjusted to create the desired gap to improve acoustic performance of the device.

In another embodiment, connector assembly800uses pins (804inFIG. 8B) that are smaller in size.FIG. 9Bshows the shape of an exemplary pin900. Pin900is both shorter in height and has fewer barbs, in this example one barb,902. The pins used in existing connectors such as plug connector101(FIG. 1) are typically designed with multiple barbs and are taller. The barbs are generally added to the pin structure to add to the retention force when they are housed inside the connector. The reduced size of the overall connector structure allows connector assembly800to employ pins900that are shorter and have fewer barbs. In one embodiment, connector assembly800is designed to sit on the PCB of the docking system at a reduced angle as compared to that shown inFIG. 7B. According to this embodiment, the angle of connector assembly is reduced to about 10 degrees from the vertical axis. The reduced angle reduces the likelihood of tipping when a media player device is inserted into the dock station and therefore allows for a smaller footprint for the docking station. Exemplary docking systems wherein connector assembly800and its various features can be employed are described in greater detail in commonly-assigned patent application Ser. No. 11/212,302, titled “Docking Station for Handheld Electronic Devices,” filed on Aug. 24, 2005, as well as patent application Ser. No. 10/423,490, titled “Media Player System,” filed Apr. 25, 2003, both of which are hereby incorporated by reference in their entirety.

In yet another embodiment, the invention provides an improved cable connector assembly that integrates a PCB inside the connector boot. Referring toFIG. 10A, there is shown one end of a cable1002connecting to a cable connector assembly1000. Cable connector assembly1000includes a connector1004that is attached to cable1002via a boot section1006. Boot1006is typically made of material such as plastic and is provided to protect the wiring that electrically interconnects connector1004to wires inside cable1002, and to provide a handle for the user. Instead of directly soldering the wires inside cable1002to the pins from connector1004, the invention according to this embodiment, uses a PCB as an intermediary connection mechanism between the cable and the connector. The PCB is housed inside boot1006of cable connector assembly1000. The connector1004as shown inFIG. 10Ais of the type shown inFIGS. 1 and 2(plug connector101). It is to be understood that this embodiment of the invention works equally as well with the modified connector such as those described in connection withFIGS. 4 and 5.

FIG. 10Billustrates the internal construction of cable connector assembly1000according to an illustrative embodiment of the present invention. Insulated wires1008extend outside cable1002near the point of contact between cable1002and connector1004. It is to be understood that while in this example only four wires1008are shown, the number of wires can vary depending on the application for the cable connector. For example, when the other end of the cable connects to a universal serial bus (USB) connector the cable would carry four wires. In the embodiment shown in addition to the four wires1008cable1002also includes a braid1010that is split extending out from the cable end. Braids1010are preferably in the form of mesh braid and provide shielding for ground and other conductive components of the connector. The assembly further includes a PCB1012that is attached to connector1004by, for example, solder mechanism. PCB1012includes solder pads1014where wires1008land and make electrical connection thereto. Conductive traces on PCB1012(not shown) connect pads1014to appropriate pins in connector1004via contacts1016. PCB1012as depicted in the example shown inFIG. 10Bhas the shape of an angled C (or a bracket), or if viewed along with cable1002, it is in the shape of the hat of the letter T. Other shapes for PCB1012are possible.

Directly connecting cable wires to connector pins requires a higher degree of precision when multiple cable wires are connected to multiple closely spaced connector pins. An advantage of integrating PCB1012in boot1006of cable connector assembly1000is the intermediate connection made via PCB1012relaxes those requirements. Another advantage of the cable connector assembly according to this embodiment of the invention is that the inclusion of PCB1012allows the manufacturer to incorporate other functionality such as electrostatic discharge (ESD) protection circuitry, cable identification circuitry or EMI containment provisions onto the PCB.

In one embodiment, PCB1012further includes a cable identification circuit that allows the device to which the cable is connected, to identify the type of cable. According to this embodiment, PCB1012includes a resistive element1018that is connected between two predetermined pins of connector1004. In one example, resistor1018is connected between pins10and15of connector1004, where pin10is an “Accessory Identify” input pin and pin15is a digital ground pin, according to the pin assignment table shown inFIG. 3. When cable connector assembly1000is inserted into an electronic device such as a portable media player or a mobile telephone, the device will be able to identify the type of cable by detecting the presence or absence of resistor1018. As mentioned above, other functionality can be incorporated on to the integrated PCB depending on the application requirements. For example, cable1002itself may be wrapped in Ferrite which increases EMI absorption and further improves the cable RF performance. This aspect of the connector cable assembly is described in greater detail in co-pending and commonly-assigned patent application Ser. No. 11/649,656, titled “Cable with Noise Suppression,” filed Jan. 3, 2007, now U.S. Pat. No. 7,342,172, which is incorporated herein by reference in its entirety.

Various embodiments for improved connectors and connector assemblies according to the present invention have been described. While these inventions have been described in the context of the above specific embodiments, many modifications and variations are possible. The above description is therefore for illustrative purposes and is not intended to be limiting. For example, references to various types of materials such as metal or glass reinforced nylon and the like are for illustrative purpose and other similar alternatives fall within the scope of the present invention. Also, references to top or bottom, or front and back of the various structures described above are relative and are used interchangeably depending on the point of reference. Similarly, dimensions and sizes provided throughout the above description are for illustrative purposes only and the inventive concepts described herein can be applied to structures with different dimensions. Accordingly, the scope and breadth of the present invention should not be limited by the specific embodiments described above and should instead be determined by the following claims and their full extend of equivalents.