# Patent

## Title
External contact plug connector

## Abstract

The present disclosure relates generally to connectors such as audio and data connectors and in particular to low profile audio connectors that can be used in place of standard audio and data connectors currently used. The plug connector has a reduced plug length and thickness, an intuitive insertion orientation and a smooth, consistent feel when inserted and extracted from its corresponding receptacle connector. The plug connector may be characterized by a flat tip portion at its distal end, a base portion near its proximal end, a shell coupled at the base portion and a plurality of external contacts.

## Background
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims the benefit of U.S. Prov. Pat. App. No. 61/357,023, filed Jun. 21, 2010, and titled “EXTERNAL CONTACT AUDIO CONNECTOR,” which is incorporated herein by reference for all purposes.


FIELD OF INVENTION
The present invention relates generally to connectors such as audio connectors and data connectors and in particular to low profile audio connectors and data connectors that can be used in place of standard audio connectors currently used.
BACKGROUND OF THE INVENTION
The present invention relates generally to input/output electrical connectors such as audio connectors and data connectors.
Standard audio connectors or plugs are available in three sizes according to the outside diameter of the plug: a 6.35 mm (1⁄4′′) plug, a 3.5 mm (1⁄8′′) miniature plug and a 2.5 mm ( 3/32′′) subminiature plug. The plugs include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions between the tip and sleeve resulting in the connectors often being referred to as tip, ring and sleeve (TRS) connectors.
FIGS. 1A and 1B illustrate examples of audio plugs 10 and 20 having three and four conductive portions, respectfully. As shown in FIG. 1A, plug 10 includes a conductive tip 12, a conductive sleeve 16 and a conductive ring 14 electrically isolated from the tip 12 and the sleeve 16 by insulating rings 17 and 18. The three conductive portions 12, 14, 16 are for left and right audio channels and a ground connection. Plug 20, shown in FIG. 1B, includes four conductive portions: a conductive tip 22, a conductive sleeve 26 and two conductive rings 24, 25 and is thus sometimes referred to as a tip, ring, ring, sleeve (TRRS) connector. The four conductive portions are electrically isolated by insulating rings 27, 28 and 29 and are typically used for left and right audio, microphone and ground signals. As evident from FIGS. 1A and 1B, each of audio plugs 10 and 20 are orientation agnostic. That is, the conductive portions completely encircle the connector forming 360 degree contacts such that there is no distinct top, bottom or side to the plug portion of the connectors.
When plugs 10 and 20 are 3.5 mm miniature connectors, the outer diameter of conductive sleeve 16, 26 and conductive rings 14, 24, 25 is 3.5 mm and the insertion length of the connector is 14 mm. For 2.5 mm subminiature connectors, the outer diameter of the conductive sleeve is 2.5 mm and the insertion length of the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MPEG-1 or MPEG-2 Audio Layer III (MP3) players and smart phones as well as other electronic devices. Electronic devices such as MP3 players and smart phones are continuously being designed to be thinner and smaller and/or to include video displays with screens that are pushed out as close to the outer edge of the devices as possible. The diameter and length of current 3.5 mm and even 2.5 mm audio connectors are limiting factors in making such devices smaller and thinner and in allowing the displays to be larger for a given form factor.
Many standard data connectors are also only available in sizes that are limiting factors in making portable electronic devices smaller. Additionally, and in contrast to the TRS connectors discussed above, many standard data connectors require that they be mated with a corresponding connector in a single, specific orientation. Such connectors can be referred to as polarized connectors. As an example of a polarized connector, FIGS. 2A and 2B depict a micro-Universal Serial Bus (micro-USB) connector 30, the smallest of the currently available Universal Serial Bus (USB) connectors. Connector 30 includes a body 32 and a metallic shell 34 that extends from body 32 and can be inserted into a corresponding receptacle connector. As shown in FIGS. 2A, 2B, shell 34 has angled corners 35 formed at one of its bottom plates. Similarly, the receptacle connector (not shown) with which connector 30 mates has an insertion opening with matching angled features that prevents shell 34 from being inserted into the receptacle connector the wrong way. That is, it can only be inserted one way—in an orientation where the angled portions of shell 34 align with the matching angled portions in the receptacle connector. It is sometimes difficult for the user to determine when a polarized connector, such as connector 30 is oriented in the correct insertion position.
Connector 30 also includes an interior cavity 38 within shell 34 along with contacts 36 formed within the cavity. Cavity 38 is prone to collecting and trapping debris within the cavity which may sometimes interfere with the signal connections to contacts 36. Also, and in addition to the orientation issue, even when connector 30 is properly aligned, the insertion and extraction of the connector is not precise, and may have an inconsistent feel. Further, even when the connector is fully inserted, it may have an undesirable degree of wobble that may result in either a faulty connection or breakage.
Many other commonly used data connectors, including standard USB connectors, mini USB connectors, FireWire connectors, as well as many of the proprietary connectors used with common portable media electronics, suffer from some or all of these deficiencies or from similar deficiencies.
BRIEF SUMMARY OF THE INVENTION
Various embodiments of the invention pertain to plug connectors and receptacle connectors that improve upon some or all of the above described deficiencies. Other embodiments of the invention pertain to methods of manufacturing such plug and/or receptacle connectors as well as electronic devices that include such connectors. Embodiments of the invention are not limited to any particular type of connector and may be used for numerous applications. Some embodiments, however, are particularly well suited for use as audio connectors and some embodiments are particularly well suited for data connectors.
In view of the shortcomings in currently available audio and data connectors as described above, some embodiments of the present invention relate to improved audio and/or data plug connectors that have a reduced plug length and thickness, an intuitive insertion orientation and a smooth, consistent feel when inserted and extracted from its corresponding receptacle connector. Additionally, some embodiments of plug connectors according to the present invention have external contacts instead of internal contacts and do not include a cavity that is prone to collecting and trapping debris. The contacts can be symmetrically spaced on one or both of the first and second major opposing sides. The plug connector can have a 180 degree symmetrical shape so that it can be inserted and operatively coupled to a corresponding receptacle connector in either of two insertion orientations. In some embodiments, the connector tab includes at least one retention feature, e.g., notches, adapted to engage with a retention feature, e.g., protrusions, on a corresponding receptacle connector. In some further embodiments the plug connector includes one or more ground contacts formed on the side surfaces or the retention features of the plug connector.
In one embodiment, a plug connector according to the present invention includes a metal plate and a dielectric spacer. The metal plate has a substantially flat tip portion at its distal end with first and second opposing major sides and a central opening formed through the metal plate. The dielectric spacer has a substantially flat tip portion formed within the opening in the metal plate and a base portion that is thicker than the tip portion formed at a proximal end of the metal plate. The spacer further includes a first and second opposing outer surfaces that extend from the tip portion to the base portion and a plurality of slots formed at each of the first and second outer surfaces. A plurality of external contacts positioned within the plurality of slots in the dielectric spacer.
A plug connector according to another embodiment of the invention comprises a dielectric core and a plurality of external contacts. The dielectric core has first and second opposing major surfaces and a plurality of grooves formed within each of the first and second major surfaces where the grooves are symmetrically formed on left and right halves of the dielectric core. The plurality of contacts includes a set of contacts positioned within the plurality of grooves in the dielectric core. The plug connector has a substantially flat tab portion at its distal end on which at least a portion of the plurality of external contacts are carried.
A plug connector according to yet another embodiment of the invention comprises a plug body having a substantially flat tab portion and first and second opposing major surfaces and a plurality of contacts positioned on the first and second opposing surfaces in a 180 degree symmetric relationship so the plug connector can be inserted into a corresponding receptacle connector in either of two positions. In some embodiments, the plug body comprises a ceramic core and includes a plurality of grooves formed on the first and second opposing surfaces in corresponding to the plurality of contacts. In other embodiments, the plug body comprises a metal core and a recessed area formed the first and second opposing surfaces, and the plurality of external contacts are formed on a flex circuit that is adhered to the metal core in the recessed area.
To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention.



BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show perspective views of previously known TRS audio plug connectors;
FIG. 2A shows a perspective view of a previously known micro-USB plug connector while FIG. 2B shows a front plan view of the micro-USB connector shown in FIG. 2A;
FIG. 3 is a simplified perspective view of an plug connector according to one embodiment of the present invention;
FIG. 4A is a simplified exploded perspective view of the connector 40 shown in FIG. 3;
FIG. 4B is a simplified cross-sectional view of connector 40 shown in FIG. 3 taken across lines A-A′ shown in FIG. 3;
FIG. 5A is a simplified exploded perspective view of a plug connector 60 according to another embodiment of the present invention;
FIG. 5B is a simplified cross-sectional view of plug connector 60 shown in FIG. 5A taken along the same A-A′ lines as the cross-section in FIG. 4B;
FIG. 6A is a simplified exploded perspective view of a plug connector 80 according to another embodiment of the present invention;
FIG. 6B is a simplified cross-sectional view of plug connector 80 shown in FIG. 6A taken along the same A-A′ lines as the cross-section in FIG. 4B;
FIG. 7A is a simplified exploded perspective view of a plug connector 100 according to another embodiment of the present invention;
FIG. 7B is a simplified cross-sectional view of plug connector 100 shown in FIG. 7A taken along the same A-A′ lines as the cross-section in FIG. 4B;
FIG. 8A is a simplified exploded perspective views of a plug connector 120 according to another embodiment of the present invention; and
FIG. 8B is a simplified cross-sectional view of plug connector 120 shown in FIG. 8A taken along the same A-A′ lines as the cross-section in FIG. 4B.



DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention are suitable for a multiplicity of electronic devices, including any device that receives or transmits audio, video or data signals among others. In some instances, embodiments of the invention are particularly well suited for portable electronic media devices because of their potentially small form factor. As used herein, an electronic media device includes any device with at least one electronic component that may be used to present human-perceivable media. Such devices may include, for example, portable music players (e.g., MP3 devices and Apple's iPod devices), portable video players (e.g., portable digital video disc (DVD) players), cellular telephones (e.g., smart telephones such as Apple's iPhone devices), video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, personal digital assistants (PDAs), desktop computers, as well as tablet (e.g., Apple's iPad devices), laptop or other mobile computers. Some of these devices may be configured to provide audio, video or other data or sensory output.
In order to better appreciate and understand the present invention, reference is first made to FIG. 3 which is a simplified perspective view of a first embodiment of an audio or data plug connector 40 according to the present invention. As shown in FIG. 3, connector 40 includes a substantially flat tab 41 that extends from a shell 50. Tab 41 includes a front major surface 43a upon which two contacts 44a and 44b are positioned and a back major surface 43b upon which two contacts 44c and 44d are located (43b, 44c, and 44d are not visible in FIG. 3). Two substantially thinner sides 43c and 43d (shown in FIG. 4B) extend between the front and back major surfaces.
In one particular embodiment, connector 40 is an audio plug connector and contact 44a is a left audio contact, contact 44b is a microphone contact, contact 44c (not visible in FIG. 3) is a right audio contact, and contact 44d (not visible in FIG. 3) is a second microphone contact. The contacts can be made from a copper, nickel, brass, a metal alloy or any other appropriate conductive material. Spacing is consistent between each pair of contacts 44a, 44b and 44c, 44d providing 180 degree symmetry so that plug connector 40 can be inserted into a corresponding receptacle connector in either of two orientations. For example, when connector 40 is mated with a corresponding receptacle jack, each of contacts 44a-44d is in electrical contact with a corresponding contact in the receptacle jack. Additionally, the two audio contacts 44a and 44c are located on opposite sides of the connector in a cater cornered arrangement (see FIG. 4B). Thus, microphone contact 44d is located directly opposite audio contact 44a and microphone contact 44b is located directly opposite audio contact 44c. In this manner, an audio contact is always on the right side of the connector and a microphone contact is always on the left side of the connector (as oriented from the connecter base to its distal end). A sensing circuit in the receptacle jack or the electronic device in which the receptacle jack is housed can detect the direction that the contacts 44a-44d are set and switch internal connections to the contacts in the connector jack as appropriate. For example, a software switch can be used to switch the receptacle jack's contacts for left and right audio depending on the insertion orientation while a hardware switch can be used to switch the connector jacks microphone and ground contacts to match the contacts of connector 40. In other embodiments, both switches can be implemented in software or both switches can be implemented in hardware. In another example, the orientation of the connector can instead be detected by circuitry associated with the corresponding receptacle connector based on signals received over the contacts. As one example, upon inserting a connector within a receptacle connector of a host device, the host device may send an Acknowledgment signal to the serial control chip over the contact in the receptacle connector designated for the specific contact and waits for a Response signal. If a Response signal is received, the contacts are aligned properly and audio and other signals can be transferred between the connectors. If no response is received, the host device flips the signals to correspond to the second possible orientation (i.e., flips the signals 180 degrees) and repeats the Acknowledgement/Response signal routine. In another embodiment, a physical orientation key (e.g., a unique notch or other physical features) formed on the plug connector, can be detected by an orientation contact or other appropriate mechanism in the receptacle connector to determine the orientation of the plug, and a hardware or software switch can set the receptacle connector contacts as appropriate for left and right audio or other data contacts to correspond to the plug connector contacts.
Two retention features, shown as V-shaped notches 45a and 45b in FIG. 3, are formed on opposing sides of tab 41 near its distal end. When tab 41 is inserted into a receptacle connector, notches 45a and 45b operatively engage with a retention mechanism, such as a cantilevered spring or detent, within the receptacle connector. In other embodiments, other retention mechanisms can be used such as mechanical or magnetic latches or orthogonal insertion mechanisms. Although retention features 45a and 45b shown in FIG. 3 are V-shaped notches, they may also be round notches (e.g., c-shaped or semi-circular notches), pockets, indentations, or similar recessed regions formed on each of the side surfaces 43c, 43d (43d is not visible in FIG. 3) that can operatively engage with a retention feature or mechanism in a corresponding receptacle connector. Connector 40 also includes a chamfered edge 43e surrounding tab 41 and extending from the front and back major surfaces 43a, 43b and thinner side surfaces 43c, 43d (not visible in FIG. 3) of the tab to base portion 42 (shown in FIG. 4A) of the connector that can be inserted within shell 50 (shown in FIG. 4A). Chamfered edge 43e stiffens and reinforces the connector near its base thus increasing its strength in a side-load condition.
As shown in FIG. 3, contacts 44a-44d are external contacts and connector 40 does not include an exposed cavity in which particles and debris may collect. To improve robustness and reliability, connector 40 is fully sealed and includes no moving parts. Furthermore, connector 40 has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, tab 41 of connector 40 has a width, X (shown in FIG. 4B), of 2 mm; a thickness, Y (shown in FIG. 4B), of 1 mm; and an insertion depth, Z, of 4 mm. In another embodiment, tab 41 of connector 40 has a width, X, of 4.1 mm; a thickness, Y, of 1.5 mm; and an insertion depth, Z, of 5.75 mm.
In other embodiments, connector 40 may include more than four contacts (with corresponding slots) total or more than four contacts (with corresponding slots) on each of surfaces 43a and 43b, e.g., 6, 8, 10, or more contacts and there may also be ground contacts at the distal tip of connector 40 or on side surfaces 43c and 43d. Where connector 40 is a data plug connector, many different types of digital signals can be carried by four or more contacts including data signals such as, USB signals (including USB 1.0, 2.0 and/or 3.0), FireWire (also referred to as Institute of Electrical and Electronics Engineers 1394 (IEEE 1394)) signals, Serial Advanced Technology Attachment (SATA) signals and/or any other type of data signal. Other digital signals that may be carried by the contacts of connector 40 include signals for digital video such as Digital Visual Interface (DVI) signals, High-Definition Multimedia Interface (HDMI) signals and Display Port signals, as well as other digital signals that perform functions that enable the detection and identification of devices, electronic media devices or accessories to connector 40.
FIG. 4A is a simplified exploded perspective view of connector 40 that better depicts how the various components of the connector are fabricated and joined together according to one particular embodiment of the invention. Connector 40 is formed around a metal plate 46 that can be stamped from high strength steel or formed in any other appropriate way. An insulation spacer 48 is molded around the metal plate 46 so that the combination of metal plate 46 and insulation spacer 48 define the basic shape of tab 41, base portion 42 and the chamfered edge 43e that extends between tab 41 and base portion 42. Two slots 47a, 47b are formed in an upper surface of insulation spacer 48 and two slots 47c, 47d (not visible in FIG. 4A) are formed in a lower surface of the spacer.
Contacts 44a-44d can be stamped from sheet metal formed in a sintering process from a metal powder or made according to other known techniques and inserted their respective slots, 47a-47d. Signal wires (not shown) are soldered to each of the contacts in an area within base 42 of the connector and a ground wire is soldered to metal plate 46 to provide a ground contact for connector 40. The wires extend through the connector to cord 52 that is coupled at its other end to an electronic device, such as a stereo headset. An acrylonitrile butadiene styrene (ABS) or similar shell 50 is positioned over and then fastened to base 42 of the connector to complete its formation.
Reference is now made to FIGS. 5A and 5B in which FIG. 5A is a simplified exploded perspective view of a plug connector 60 according to another embodiment of the present invention and FIG. 5B is a simplified cross-sectional view of plug connector 60 shown in FIG. 5A taken along the same cross-section of the connector in FIG. 4B. Connector 60 includes four signal contacts 64a-64d farmed around a dielectric core 66 and a ground contact 64e that runs through the center of the connector. In one embodiment, contact 64a is a left audio contact, contact 64b is a microphone contact, contact 64c is a right audio contact and contact 64d is a second microphone contact. As shown in FIG. 5B, the contacts are arranged on a substantially flat tab portion of connector 60 to have a 180 degree symmetrical design similar to that of connector 40. A sensing circuit in the receptacle jack or the electronic device in which the receptacle jack is housed can detect the direction that contacts 64a-64d are set and switch internal connections to the contacts in the connector jack as appropriate.
Dielectric core 66 can be molded from a thermoplastic polymer or similar material around ground contact 64e. Slots 67a-67d (67c and 67c are not visible in FIG. 5A) are formed in core 66 for contacts 64a-64d which can be wire formed or stamped from sheet metal and bent. Slots 67a-67d include ribs 68a, 68b that align with grooves 69a, 69b formed in the corresponding contacts. Grooves 69a, 69b provide shear strength in bending for the contacts. Connector 60 is designed so that contacts 64a-64d provide much of the strength of the plug. Similar to connector 40, connector 60 also has a chamfered edge between its tab and base portions that may reinforce the connector near its base thus increasing its strength in a side-load condition. Additionally, retention features, shown as small V-shaped notches 71 in FIG. 5A, is formed in each of contacts 64a-64d that aligns with retention features, shown as V-shaped notches 65a, 65b in FIG. 5A, formed in dielectric core 66. In some embodiments, the shape of the retention features of connector 60 may be varied as discussed with reference to the retention features of connector 40. Once the contacts are adhered within their respective slots, core 66 can be slid within and bonded to an ABS or similar shell 70.
As with connector 40, contacts 64a-64d are external contacts and connector 60 does not include an exposed cavity in which particles and debris may collect. To improve robustness and reliability, connector 60 is also fully sealed and includes no moving parts. Furthermore, connector 60 has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, the insertion portion of connector 60 has a width, X, of 2 mm; a thickness, Y, of 1 mm; and an insertion depth, Z (as measured in FIG. 3), of 4 mm. In another embodiment, the insertion portion of connector 60 has a width, X, of 4.1 mm; a thickness, Y, of 1.5 mm; and an insertion depth, Z (as measured in FIG. 3), of 5.75 mm.
In some embodiments, as with connector 40, connector 60 may include more than four contacts (with corresponding slots) total or more than four contacts (with corresponding slots) on each of major surfaces 63a and 63b (shown if FIG. 5B), e.g., 6, 8, 10, or more contacts and there may also be ground contacts formed on side surfaces 63c and 63d. Where connector 60 is a data plug connector, many different types of digital signals can be carried by four or more contacts including data signals such as, USB signals (including USB 1.0, 2.0 and/or 3.0), FireWire (also referred to as IEEE 1394) signals, SATA signals and/or any other type of data signal. Other digital signals that may be carried by the contacts of connector 40 include signals for digital video such as DVI signals, HDMI signals and Display Port signals, as well as other digital signals that perform functions that enable the detection and identification of devices, electronic media devices or accessories to connector 40.
A connector 80 according to another embodiment of the present invention is shown in FIGS. 6A and 6B in which FIG. 6A is a simplified exploded perspective view of the plug connector 80 and FIG. 6B is a simplified cross-sectional view of connector 80 taken along the same cross-section of the connector as in FIGS. 4B and 5B. Connector 80 includes a substantially flat tab 81 that extends from a shell 90. Tab 81 includes a front major surface 83a upon which two contacts 84a and 84b are positioned and a back major surface 83b upon which two contacts 84c and 84d are located. Additionally, a fifth contact 84e extends through the center of connector 80 and is located at distal end 89 of the connector.
In one particular embodiment, contact 84a is a left audio contact, contact 84b is a microphone contact, contact 84c is a right audio contact, contact 84d is a second microphone contact, contact 84e is a ground contact and the contacts are positioned on connector 80 so that it has a 180 degree symmetrical design similar to that of connectors 40 and 60 so that plug connector 80 can be inserted into a corresponding receptacle connector in either of two orientations. The contacts can be made from a copper, nickel, brass, a metal alloy or any other appropriate conductive material. A sensing circuit in the receptacle jack or the electronic device in which the receptacle jack is housed can detect the direction that the contacts 84a-84d are set and switch internal connections to the contacts in the connector jack as appropriate.
Two retention features, shown as V-shaped notches 85a and 85b in FIG. 6A, are formed on opposing sides of tab 81 near distal end 89. When tab 81 is inserted into a receptacle connector, notches 85a and 85b operatively engage with a retention mechanism, such as a cantilevered spring or detent, within the receptacle connector. In other embodiments, other retention mechanisms can be used such as mechanical or magnetic latches or orthogonal insertion mechanisms. Connector 80 also includes a chamfered edge 83e surrounding tab 81 and extending from the upper and lower major surfaces 83a, 83b and the thinner side surfaces 83c, 83d of the tab to a base portion of the connector. Chamfered edge 83e stiffens and reinforces the connector near its base thus increasing its strength in a side-load condition.
As with connectors 40 and 60, the contacts 84a-84d of connector 80 are external contacts so the connector does not include an exposed cavity in which particles and debris may collect. Furthermore, connector 80 has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, tab 81 of connector 80 has a width, X, of 2 mm; a thickness, Y, of 1 mm; and an insertion depth, Z (as measured in FIG. 3), of 4 mm. In another embodiment, tab 81 of connector 80 has a width, X, of 4.1 mm; a thickness, Y, of 1.5 mm; and an insertion depth, Z (as measured in FIG. 3), of 5.75 mm.
As shown FIG. 6A connector 80 is formed around a ceramic core 86 that generally defines the shape of tab 81 and base portion 82 as well as the chamfered edge 83e that extends between tab 81 and the base portion. Two slots 87a, 87b are formed in an upper surface of ceramic core 86; two slots 87c, 87d (not visible in FIG. 6A) are formed in a lower surface of the core; and a hole 88 traverses through the core's center.
Ceramic core 86 can be formed by a ceramic injection molding (CIM) process or by a dry pressing, machining or other suitable processes. Ground contact 84e can be made from a metal wire or cut from sheet metal and inserted through hole 88 so that the end of the ground contact is flush with the outer edge of ceramic core 86 at distal end 89 of the connector. Contacts 84a-84d can be made from sheet metal and inserted into respective ones of slots 87a-87d, and in another embodiment the contacts can be formed in a sintering process from a metal powder.
In some embodiments, contacts 84a-84d can be used to carry any appropriate data signal (e.g., the data signals mentioned with reference to connector 40) as well as audio signals, video signals and the like. In some embodiments, there may be more than four contacts on connector 80 with corresponding slots, e.g., 6, 8, 10, or more contacts, and there may also be ground contacts in the retention features or otherwise formed on sides 83c and 83d, as discussed with reference to previous embodiments.
Another embodiment of the present invention is shown in FIGS. 7A and 7B where FIG. 7A is a simplified exploded perspective view of a plug connector 100 and FIG. 7B is a simplified cross-sectional view of connector 100 taken along the same cross-section of the connector as in FIGS. 4B, 5B and 6B. Connector 100 has six contacts 104a-104f attached to a ceramic core 106 that defines a substantially flat connector tab 101 and a base portion 102. In one embodiment, contacts 104a-104f, represent a left audio contact (104a), a ground contact (104b), a microphone contact (104c), a right audio contact (104d), a second ground contact (104e) and a second microphone contact (1040. Similar to connectors 40, 60 and 80, connector 100 has 180 degree symmetry (as shown in FIG. 7B) so that it can be inserted in a jack connector in either of two orientations. A sensing circuit in the receptacle jack or the electronic device in which the receptacle jack is housed can detect the direction that the contacts 104a-104d are set and switch internal connections to the contacts in the connector jack as appropriate. Additionally, notches 105a, 105b provide a retention feature similar to notches 45a, 45b. Similar to connector 40, 60 and 80, connector 100 also has a chamfered edge between tab 101 and base portion 102 that may reinforce the connector near its base thus increasing its strength in a side-load condition.
Ceramic core 106 can be formed from a ceramic injection molding process among other techniques and in one particular embodiment is formed in a double shot process in which core 106 is formed in a first injection molding step that forms six slots in which contacts 104a-104f are subsequently formed with a metal injection molding process. In another embodiment contacts 104a-104f are formed using powdered metallurgy (PM) techniques. After the contacts are formed on core 106, it is bonded within an ABS or similar shell 110 at a base portion 102 of the core.
As with connectors 40, 60 and 80, the contacts 104a-104d of connector 100 are external contacts so the connector does not include an exposed cavity in which particles and debris may collect. Furthermore, connector 100 has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, tab 101 of connector 100 has a width, X, of 2 mm; a thickness, Y, of 1 mm; and an insertion depth, Z (as measured in FIG. 3), of 4 mm. In another embodiment, tab 101 of connector 100 has a width, X, of 4.1 mm; a thickness, Y, of 1.5 mm; and an insertion depth, Z (as measured in FIG. 3), of 5.75 mm.
In some embodiments, contacts 104a-104f can be used to carry any appropriate data signal (e.g., the data signals mentioned with reference to connector 40) as well as audio signals, video signals and the like. In some embodiments, there may be more than six or less than six contacts on connector 100 with corresponding slots, e.g., 4, 8, 10, or more contacts, and there may also be ground contacts in the retention features or otherwise formed on sides 103c and 103d, as discussed with reference to previous embodiments.
FIG. 8A is a simplified exploded perspective views of a plug connector 120 according to yet another embodiment of the present invention and FIG. 8B is a simplified cross-sectional view of plug connector 120 shown in FIG. 8A taken along the same A-A′ lines as the cross-section in FIG. 4B. Connector 120 includes a conductive core 126 that can be formed from a metal injection molding (MIM) process or another appropriate technique. Core 126 includes a connector tab portion 121 and a base portion 122 and acts as a carrier base for contacts 124a-124d. 
Connector tab 121 includes upper and lower major sides 123a and 123b as well as substantially thinner sides 123c and 123d that extend between the upper and lower major sides. A chamfered edge 123e connects tab portion 121 to base portion 122 that stiffens and reinforces the connector near its base thus increasing its strength in a side-load condition.
Retention features, shown as notches 125a, 125b in FIG. 8A, can be formed on side surfaces 123c, 123d near a distal end of the connector and operatively engage with a retention mechanism within corresponding connector jack. Although retention features 125a, 125b in FIG. 8A are shown as notches, they may also be v-shaped notches, pockets, indentations, or similar recessed regions that can operatively engage with a retention feature or mechanism in a corresponding receptacle connector. On its outer surface, conductive core 126 further includes a recessed region 127 that images extends along the first major surface 123a at base portion 122 of core 126 down the center of the core along chamfered edge 123e and tab 121 and wraps around the tip 129 and, on surface 123b mirrors its shape on surface 123a. A flex circuit 128 can be slipped over the end of the connector and adhered into recessed region 127. Flex circuit may include, for example, thick copper traces that act as contacts 124a-124d coated with nickel and palladium formed on a thin polymide or PEEK (polyether ether ketone) layer. In another embodiment, the recessed region 127 does not extend around tip 129 of connector 120 and instead comprises two separate recessed regions on each of the major surfaces. In this embodiment, flex circuit 128 can be made from two separate pieces each of which is directly adhered to one of the upper and lower major sides 123a, 123b within its respective recessed region. Similar to connectors 40, 60, 80 and 100, connector 120 has 180 degree symmetry so that it can be inserted in a jack connector in either of two orientations. A sensing circuit in the receptacle jack or the electronic device in which the receptacle jack is housed can detect the direction that the contacts 124a-124d are set and switch internal connections to the contacts in the connector jack as appropriate. Signal wires (not shown) are soldered to each of the contacts in an area within base 122 of the connector and a ground wire is soldered to conductive core 126 to provide a ground contact for connector 120. The wires extend through the connector to cord 132 that is coupled at its other end to an electronic device, such as a stereo headset. An ABS or similar shell 130 is positioned over and then fastened to base 130 of the connector to complete its formation.
As with connectors 40, 60, 80 and 100, the contacts 124a-124d of flex circuit 128 of connector 120 are external contacts so the connector does not include an exposed cavity in which particles and debris may collect. Furthermore, connector 120 has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, tab 121 of connector 120 has a width, X, of 2 mm; a thickness, Y, of 1 mm; and an insertion depth, Z (as measured in FIG. 3), of 4 mm. In another embodiment, tab 121 of connector 120 has a width, X, of 4.1 mm; a thickness, Y, of 1.5 mm; and an insertion depth, Z (as measured in FIG. 3), of 5.75 mm.
In some embodiments, contacts 124a-124d can be used to carry any appropriate data signal (e.g., the data signals mentioned with reference to connector 40) as well as audio signals, video signals and the like. In some embodiments, there may be more than 4 contacts on connector 100 with corresponding slots, e.g., 6, 8, 10, or more contacts, and there may also be ground contacts in the retention features or otherwise formed on sides 123c and 123d, as discussed with reference to previous embodiments.
When inserted into a matching connector jack, connectors according to some embodiments of the present invention are designed to break when side-loaded at a certain tension. It is preferable that the plug connector breaks as opposed to the connector jack because if the jack breaks, the electronic device in which it is housed may no longer be usable.
As will be understood by those skilled in the art, the present invention may be embodied in other specific foams without departing from the essential characteristics thereof. For example, while embodiments of the invention were discussed above with respect to audio plugs having four to six contacts, the invention is not limited to any particular number of contacts. Some embodiments of the invention may have as few as two contacts while other embodiments can have thirty or even more contacts. In many of these embodiments, the contacts can be arranged to have 180 degree symmetry so that the connector can be inserted into a receptacle connector in either of two different orientations.
Additionally, while the invention was described with respect to an audio connector in some cases, it is not limited to any particular type of signal and can be used to carry video and/or other signals instead of audio-related signals or in addition to audio-related signals. Also, in some embodiments, connectors according to the present invention can carry both analog and digital signals. As an example, connectors according to the present invention can be modified to include one or more fiber optic cables that extend through the connector and can be operatively coupled to receive or transmit optical signals between a mating connector jack. Fiber optic cables allow for high data rate transmissions and can be used for USB 4.0 compatibility (e.g. 10 gigabytes/second data transfer). Connectors according to the present invention may include power, audio and data connections and can be used to charge a device while simultaneously providing data and audio functions. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.

## Claims

1. A plug connector comprising:
a metal plate having a substantially flat tip portion at its distal end with first and second opposing major sides and a central opening formed through the metal plate;
a dielectric spacer having a substantially flat tip portion formed within the opening in the metal plate and a base portion that is thicker than the tip portion formed at a proximal end of the metal plate, wherein the dielectric spacer has first and second opposing outer surfaces that extend from the tip portion to the base portion and a plurality of slots formed at each of the first and second outer surfaces; and
a plurality of contacts positioned within the plurality of slots in the dielectric spacer.

2. The plug connector set forth in claim 1 wherein the plug connector is shaped to have 180 degree symmetry so that the plug connector can be inserted and operatively coupled to a corresponding receptacle connector in either of two orientations.

3. The plug connector set forth in claim 1 wherein the first and second outer surfaces of the dielectric spacer are substantially flush with the first and second major sides of the metal plate.

4. The plug connector of claim 1 further comprising a shell coupled to the base portion of the dielectric spacer.

5. The plug connector of claim 4 further comprising a plurality of wires corresponding to the plurality of contacts, wherein each of the wires is connected to its respective contact at a connection point on a proximate end of the base portion of the dielectric spacer.

6. The plug connector of claim 1 wherein the plurality of contacts are stamped from sheet metal and inserted within the plurality of slots.

7. The plug connector of claim 2 wherein the plurality of slots and the plurality of contacts are symmetrically spaced so that the plug connector has 180 degree symmetry and can be inserted and operatively coupled to a corresponding receptacle connector in either of two positions.

8. The plug connector of claim 1 wherein the plurality of slots comprise four slots formed at each of the first and second outer surfaces and the plurality of contacts comprise four contacts positioned within the four slots formed at each of the first and second outer surfaces.

9. The plug connector of claim 1 wherein the plurality of slots are formed to extend from the tip portion of the dielectric spacer to the base portion of the dielectric spacer.

10. The plug connector of claim 1 wherein the dielectric spacer is molded around the metal plate.

11. The plug connector of claim 1 further comprising:
the metal plate further comprising third and fourth opposing sides, each extending between the first and second major opposing sides of the metal plate, wherein the third and fourth opposing sides are significantly narrower than the first and second sides; and
the dielectric spacer further comprising third and fourth opposing outer surfaces, each extending between the first and second opposing outer surfaces of the dialectic spacer, wherein the third and fourth opposing outer surfaces are significantly narrower than the first and second opposing outer surfaces.

12. The plug connector of claim 11 wherein the metal plate further comprises retention features formed near its distal end on each of the third and fourth surfaces that are adapted to engage with a retention mechanism in a corresponding receptacle jack.

13. The plug connector of claim 12 wherein the retention features are V-shaped notches formed in the metal plate.

14. The plug connector of claim 4 wherein the dielectric spacer has a chamfered portion at its base so that the plug connector increases in diameter to match an outer profile of the shell.

15. The plug connector of claim 1 wherein connector comprises left and right audio contacts arranged cater cornered on opposing sides of the connector and the connector has 180 degree symmetry so that it can be inserted into a corresponding connector jack in either of two positions.

16. The plug connector of claim 15 wherein the metal plate acts as a ground contact.

17. The plug connector of claim 11 wherein the metal plate comprises ground contacts formed on the third and fourth opposing sides.

18. A plug connector comprising:
a dielectric core having first and second opposing major surfaces and a plurality of grooves formed within each of the first and second major surfaces, the grooves symmetrically formed on left and right halves of the dielectric core; and
a plurality of contacts positioned within the plurality of grooves in the dielectric core;
wherein the plug connector has a substantially flat tip portion at its distal end on which at least a portion of the plurality of contacts are carried;
wherein the plug connector has 180 degree symmetry so that it can be inserted into a corresponding connector jack in either of two positions.

19. The plug connector of claim 18 wherein the plurality of contacts comprise left and right audio contacts arranged cater cornered on opposing sides of the connector.

20. The plug connector of claim 18 wherein the dielectric core comprises a ceramic material.

21. The plug connector of claim 20 wherein the dielectric core further comprises a slot formed between the first and second major surfaces, the slot centrally located in the dielectric core such that it divides the core into left and right halves that mirror each other, and wherein the plug connector further comprises a centrally located ground contact positioned within the slot.

22. The plug connector of claim 21 wherein the ground contact is flush with the dielectric core at its distal end and at the first and second opposing major sides of flat tip portion of the dielectric core.

23. The plug connector of claim 19 further comprising a base portion formed at a proximal end of the dielectric core and a shell coupled to the base portion wherein the dielectric spacer has a chamfered portion between the substantially flat tip portion and its base so that the plug connector increases in diameter to match an outer profile of the shell.

24. The plug connector of claim 19 wherein the dielectric core further comprises a centrally located hole that extends from a distal end of the tip portion through the length of the dielectric core, and wherein the plug connector further comprises a ground contact positioned within the hole.

25. The plug connector of claim 24 wherein the dielectric core comprises a ceramic material.

26. A plug connector comprising:
a conductive core having a substantially flat tip portion and first and second opposing major surfaces;
wherein a recessed area is formed on the first and second opposing major surfaces, and
a plurality of contacts positioned on the first and second opposing surfaces in a 180 degree symmetric relationship so the plug connector can be inserted into a corresponding receptacle connector in either of two positions;
wherein the plurality of contacts are formed on a flex circuit that is adhered to the conductive core in the recessed area.

27. The plug connector of claim 26 wherein the recessed area comprises two separate recessed regions on each of the major surfaces.

28. The plug connector of claim 26 wherein the flex circuit comprises thick copper traces coated with nickel and palladium formed on a thin polymide layer that act as the plurality of contacts.

29. The plug connector of claim 26 further comprising a base portion formed at a proximal end of the conductive core and a shell coupled to the base portion of the conductive core.