Abstract:
Low cost ground connections for standard connectors and connectors having reduced pin counts. One example may provide a connector system including a connector insert having a plurality of contacts along a top or bottom, or both top and bottom, of a connector insert, where first contacts in the plurality of contacts may be used to convey power, ground, or data and where second contacts in the plurality of contacts are used for ground. The second contacts may be arranged to have contacting portions that are positioned in the insert at different heights relative to the top or bottom of the connector insert and at different depths relative to a front opening of the connector insert.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application No. 62/003,004, filed on May 26, 2014, which is incorporated by reference. 
    
    
     BACKGROUND 
     The amount of data transferred between electronic devices has grown tremendously the last several years. Large amounts of audio, streaming video, text, and other types of information content are now regularly transferred among desktop and portable computers, media devices, handheld media devices, displays, storage devices, and other types of electronic devices. 
     Data may be conveyed over cables that may include wire conductors, fiber optic cables, or some combination of these or other conductors. Cable assemblies may include a connector insert at each end of a cable, though other cable assemblies may be connected or tethered to an electronic device in a dedicated manner. The connector inserts may be inserted into receptacles in the communicating electronic devices. 
     These connector inserts may include contacts or pins that form signal paths with contacts or pins in the corresponding connector receptacles. These signal paths may radiate signal noise to nearby signal paths and electrical circuits. These signal paths may also receive signal noise from nearby signal paths and electrical circuits. Accordingly, it may be desirable to shield these signal paths such that they do not radiate or receive this signal noise. 
     Also, while these connectors may be fully compliant with one or more various signaling interfaces, other connectors may be only partially compliant with these signaling interfaces. For example, in a connector intended to be used for charging, one or more signal pins may not be needed and may be omitted. However, some signal paths may remain. Further, it may be desirable to shield the power pins on such a connector. 
     Moreover, various connectors may sell in the millions of units. With these volumes, even a minor cost reduction can lower expenses significantly. 
     Thus, what is needed are connector inserts that may provide shielding in a low-cost manner in standard connectors and connectors having reduced pin counts. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide shielding in a low-cost manner in standard connectors and connectors having reduced pin counts. An illustrative embodiment of the present invention may provide a connector system including a connector insert having a plurality of contacts along a top or bottom, or both top and bottom, of a connector insert, where first contacts in the plurality of contacts may be used to convey power, ground, or data and where second contacts in the plurality of contacts may be used to convey ground. The second contacts may be arranged to have contacting portions that are positioned in the insert at different heights relative to the top or bottom of the connector insert and at different depths relative to a front opening of the connector insert, as compared to contacting portions of the first contacts. 
     In various embodiments of the present invention, the first contacts may convey signals and power compliant with one or more interface standards. In other embodiments of the present invention, the first contacts and the second contacts together may convey signals and power compliant with one or more interface standards. In other embodiments of the present invention, the connector insert may be intended for use in a charger or other application where one or more signal or other contacts of an interface standard may not be needed. In these embodiments, the signal or other contacts that are not needed may be replaced by ground contacts. These ground contacts may provide shielding, current returns, and other functions. These ground contacts may replace other grounding structures that would otherwise be employed, thereby simplifying the connector insert, saving space, and reducing costs. 
     In various embodiments of the present invention, the first and second contacts may be formed as a unit. That is, the first and second contacts may be formed or manufactured at the same time as part of the same stamping, molding, or printing operation. This may eliminate the need to form or manufacture a separate grounding structure, again, simplifying the connector insert and reducing costs. 
     Another illustrative embodiment of the present invention may provide a connector system including a connector receptacle having a tongue. The tongue may include a number of signal contacts for connecting signals, power, ground, or other data or supply voltages. The signal contacts may be on a bottom side of the tongue, a top side of the tongue, or both. The tongue may further include a ground contact behind the signal contacts such that the signal contacts are located between the ground contact and a front opening of the connector receptacle. The ground contact may be on a bottom side of the tongue, a top side of the tongue, or both. The ground contact may be elevated on a top side above the tongue and on a bottom side below the tongue. This embodiment may include a connector insert to mate with this connector receptacle. The connector insert may have a front opening having a major axis. For reference purposes, a centerline may be located in the center of the front opening along the major axis. The connector insert may have first contacts to form electrical connections with the signal contacts on the tongue of the connector receptacle. The connector insert may have second contacts to form electrical connections with the raised ground contacts behind the signal contacts in the connector receptacle. The first and second contacts may be located along a bottom of a front opening of the connector insert, along a top of the front opening of the connector insert, or both. 
     In this and other embodiments of the present invention, the first contacts may have first contacting portions to contact the signal contacts on the connector receptacle tongue, while the second contacts may have second contacting portions to contact the ground contacts on the connector receptacle tongue. The first contacting portions may be closer to the centerline of the front opening of the connector insert as compared to the second contacting portions. The first contacting portions may be located at a greater depth or distance from the front opening as compared to the second contacting portions. 
     In another illustrative embodiment of the present invention, the first and second contacts of the connector insert may be formed together as a unit. The unit may be attached to a first molded portion. First contacts along a top of the connector insert, when present, may have a downward sloping portion from the first molded portion to a contacting portion. First contacts along a bottom of the connector insert, when present, may have an upward sloping portion from the first molded portion to a contacting portion. Second contacts along a top of the connector insert, when present, may have an upward first sloping portion from the first molded portion to a shield contacting portion and a downward second sloping portion from the shield contacting portion to a contacting portion. Second contacts along a bottom of the connector insert, when present, may have a downward first sloping portion from the first molded portion to a shield contacting portion and an upward second sloping portion from the shield contacting portion to a contacting portion. 
     The shield contacting portions may form electrical connections with the shield to provide additional ground paths for shielding and return currents. This may result in ground connections that provide shielding for signals and power supplies in the connector system. Specifically, a shield of a connector insert may connect to a shield of a connector receptacle. The shield of the connector receptacle may connect to a ground contact on a tongue of the connector receptacle. Second contacts in the connector insert may connect to the ground contact on the tongue of the connector receptacle. The second contacts may connect back to the shield of the connector insert at the shield contacting portions. Additional ground paths may be provided by side ground contacts in the connector insert and on the tongue of the connector receptacle. 
     That is, the second contacts may provide a ground path from a shield of a connector insert to a ground contact in a connector receptacle. When second ground contacts are not used, a separate structure may be needed to the connect shield of the connector insert to the ground contact in a connector receptacle. This structure may be manufactured separately from the first contacts. It may also need to be added to the connector insert in a separate assembly step. It may also use additional space. These factors may increase space, complicate assembly, and increase costs of the connector insert. 
     Another illustrative embodiment of the present invention may provide a method of manufacturing a connector insert. A first plurality of first and second contacts for a top of the connector insert may be formed, for example by stamping. A second plurality of first and second contacts for a bottom of the connector insert may similarly be formed. A center ground piece may be formed. An injection molded portion may be formed around the center ground piece. The injection molded piece may have slots on a top to accept the first plurality of contacts and slots on a bottom to accept the second plurality of contacts. Additional molded pieces may be placed over the top and bottom of the injection molded piece to secure the first and second pluralities of contacts in place. A front molded portion having an opening may be placed around the contacts such that first contacts on a top and bottom of the insert are located in the opening and such that second contacts on a bottom of the insert are below the front molded portion and second contacts on a top of the insert are above the front molded portion. 
     In various embodiments of the present invention, contacts and other conductive portions of connector inserts and receptacles may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), or other nonconductive material or combination of materials. The printed circuit boards used may be formed of FR-4, BT or other material. Printed circuit boards may be replaced by other substrates, such as flexible circuit boards, in many embodiments of the present invention. 
     Embodiments of the present invention may provide interconnect structures that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector inserts and receptacles may provide pathways for signals that are compliant with one or more various standards such as Universal Serial Bus (USB), a High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), power, Ethernet, DisplayPort, Thunderbolt, Lightning and other types of standard and non-standard interfaces that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention may provide connector inserts that may be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector inserts and receptacles may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a connector insert according to an embodiment of the present invention; 
         FIG. 2  illustrates a connector receptacle that may mate with connector inserts according to embodiments of the present invention; 
         FIG. 3  illustrates a front view of a connector insert according to an embodiment of the present invention; 
         FIG. 4  illustrates a side view of a connector insert according to an embodiment of the present invention; 
         FIG. 5  illustrates a cutaway side view of a connector insert according to an embodiment of the present invention; 
         FIG. 6  illustrates a closer view of a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 7  illustrates a number of contacts that may be manufactured together according to an embodiment of the present invention; and 
         FIG. 8  illustrates a cutaway side view of a connector insert according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates a connector insert according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, a front insert portion may be at least partially surrounded by shield  110 . Shield  110  may surround first contacts  140  and second contacts  150 . First contacts  140  may be used to convey signals, power, ground, or other data or power supply or bias voltages. Second contacts  150  may be used to convey ground, signals, power, or other data or power supply or bias voltages. In a specific embodiment of the present invention, first pins  140  may be used to convey signals, power, and ground, while second contacts  150  may be ground contacts to provide ground shielding and return current paths. 
     Shield  110  may be mechanically supported by housing  170 . Housing  170  may provide a structure to be handled by a user while inserting this connector insert into a connector receptacle. Housing  170  may be formed of plastic or other nonconductive material and may include a front face  175 . Housing  170  may provide a covering for one or more circuits, light-emitting diodes, printed circuit boards, or other electronic circuits or components. Shield  110  may terminate in front portion  120 . Shield  110  may be metallic or formed of other conductive material. Front portion  120  may be plastic or other material. Front housing portion  130  may be included to support first contacts  140  and second contacts  150 . Front housing portion may be formed of plastic or other nonconductive material. 
     In various embodiments of the present invention, first contacts  140  may convey the signals, power, ground, or other data or power supply or bias voltages for one or more specific interfaces. In other embodiments of the present invention, a connector insert may only need to convey a reduced set of signals, power, ground, or other data or power supply or bias voltages. For example, where a connector insert may be used to connect an electronic device to a charger, one or more data or signal paths may be eliminated from first contacts  140 . In this case, a contact position, shown in this example as contact position  153 , may be used for second contacts  150 . Again, second contacts  150  may provide a ground connection for shielding or return current. The inclusion of second contacts  150  may allow the removal of one or more other ground structures that would otherwise be needed. This removal may save space in the connector insert, simplify its manufacturing, and reduce costs. This may be particularly true where second contacts  150  may be manufactured at the same time as first contacts  140 , as shown in examples below. In this example, a bottom row of first contacts  140  and second contacts  150  are shown, though in other embodiments of the present invention, an upper row of such contacts may also be included. 
     In this example, first contacts  140  and second contacts  150  may have contacting portions positioned at different depths relative to a front opening of a connector insert. The contacting portions of first contacts  140  and second contacts  150  may also be placed at different heights inside the connector insert. These contacts may be arranged in this way to properly engage contacts in a corresponding connector receptacle. An example of such a connector receptacle is shown in the following figure. 
       FIG. 2  illustrates a connector receptacle that may mate with connector inserts according to embodiments of the present invention. This connector receptacle may include shield  210  surrounding tongue  230 . Tongue  230  may support a number of contacts  240 . Ground contacts  250  may be located behind contacts  240  such that contacts  240  are between ground contacts  250  and a front opening of a connector receptacle. Ground contact  250  may lead to a front face  255  and an upper ground contact  260 . Upper ground contact  260  may be electrically connected to shield  210  through a laser welds at points  265 . 
     In this way, contacts  240  may be located near a front opening of a connector receptacle. Contacts  240  may be flush or substantially flush with a surface of tongue  230 . Ground contact  250  may be located behind contacts  240 . Ground contact  250  may also be positioned at a height above tongue  230  and contacts  240 . Contacts that are the same or similar to contacts  240  and ground contacts  250  may be included on underside of tongue  230 . 
     The connector insert of  FIG. 1  may mate with this connector receptacle. Specifically, tongue  230  of the connector receptacle may fit in an opening in the front portion housing  130  of the connector insert. First contacts  140  may form electrical connections with contacts  240  on tongue  230 . Similarly, second contacts  150  in the connector insert may form electrical connections at or near point  251  of ground contact  250  of the connector receptacle. 
     Again, ground contact  250  may be at a different height than contacts  240  in the connector receptacle. Accordingly, first contacts  140  and second contacts  150  the connector insert may have contacting portions at different heights. This is shown in the following figure. 
       FIG. 3  illustrates a front view of a connector insert according to an embodiment of the present invention. As before, housing  170  may have a front face  175  supporting a connector insert portion. The connector insert portion may have a front portion  120 . The portion  120  may form an opening exposing front housing portion  130 , which may support a number of first contacts  140  and second contacts  150 . 
     A front opening of a connector insert formed by front portion  120  may have a major axis, or longer portion, in a direction  302 , and a minor axis, or a shorter portion, in direction  304 . The front opening formed by front portion  120  may have a centerline  305  along the middle of the opening of along the major axis. First contacts  140  and second contacts  150  may be located along a top and bottom of the front opening formed by front portion  120 . 
     First contacts  140  and second contacts  150  may have contacting portions placed at different distances from center line  305 . That is, first contacts  140  and second contacts  150  may have contacting portions placed at different heights in the connector insert relative to a top or bottom of the opening formed by front portion  120 . In this example, contacting portions for contacts  140  may be at a shorter distance  310  from center line  305 , as compared to contacting portions for second contacts  150 , which may be at a distance  320  from center line  305 . 
     Again, first contacts  140  may be compliant with one or more signal standards. In other embodiments of the present invention, one or more contacts may not be needed, for example where the connector insert is connected to a charger. In this case, contact positions  153  may be vacated and used for second contacts  150 . Second contacts  150  may provide ground paths. These ground paths may not otherwise be available when contact positions  152  are used by first contacts  140  to meet compliance with one or more interface specifications. The ability to include the extra ground paths provided by second contacts  150  may eliminate the need for one or more other ground structures. This may again reduce space, simplify manufacturing, and reduce costs. 
     Specifically, ground contacts  150  may provide a ground path from shield  110  of the connector insert to ground contact  250  in a connector receptacle. When second ground contacts  150  are not used, a separate structure may be needed to connect shield  110  of the connector insert to ground contact  250  in a connector receptacle. This structure may be manufactured separately from first contacts  140 . It may also need to be added to the connector insert in a separate assembly step. It may also use additional space. These factors may increase space, complicate assembly, and increase costs of the connector insert. 
       FIG. 4  illustrates a side view of a connector insert according to an embodiment of the present invention. Again, housing  170  may support a front inserting portion surrounded by shield  110 . Shield  110  may be attached to front portion  120 . Cable  420  may house a number of conductors (not shown) that may enter housing  170 . The conductors may connect to first contacts  140 , second contacts  150 , or circuits, boards, or other components in housing  170 . These circuits, boards, or other components in housing  170  may further connect to first contacts  140  and second contacts  150  in the connector insert. Strain relief  410  may provide protection for cable  420 . 
     Again, first contacts  140  and second contacts  150  in a connector insert according to an embodiment of the present invention may have contacting portions located at different heights. These contacting portions may also be placed at different depths relative to a front opening of the connector insert. To properly place these contacting portions, first contacts  140  and second contacts  150  may have different shapes. An example is shown in the following figure. 
       FIG. 5  illustrates a cutaway side view of a connector insert according to an embodiment of the present invention. The insertion portion may be surrounded by shield  110 , which may support a front portion  120 . Front portion  120  may form a front opening in the connector insert. This opening may have a center line at a level  305 . The connector insert may include a number of first contacts  140  and second contacts  150  along a top and bottom of the connector insert. First contacts  140  and second contacts  150  may be mechanically supported by first molding portion  500 . First contacts  140  may have contacting portions  142  to engage contacts  240  in a connector receptacle. Similarly, second contacts  150  may include contacting portions  152  to engage ground contacts  250  at points  251  in a connector receptacle, as shown in  FIG. 2 . 
     As before, contacting portions  142  of first contacts  140  may be at a height or distance  310  from centerline  305 . Contacting portions  152  of second contacts  150  may be at a height or distance  320  from centerline  305 . In this example, height or distance  310  may be less than height or distance  320 . Similarly, first contacting portions  142  of first contacts  140  may be at a depth or distance  550  from a front opening of the connector insert. Second contacting portions  152  of second contacts  150  may be at a depth or distance  540  from a front of a connector insert. In this example, depth or distance  540  may be less than depth or distance  550 . 
     With this configuration, first contacting portions  142  of first contacts  140  may engage contacts  240  in a connector receptacle, while second contacting portions  152  of second contacts  150  may engage ground contacts  250  at points  231 . More specifically, contacting portions  142  of first contacts  140  may be closer to centerline  305  to mate with contacts  240  on tongue  230  of the receptacle, while contacting portions  152  of second contacts  150  are further away from centerline  305  to mate with ground contact  250 , which resides at a height above tongue  230  in the connector receptacle of  FIG. 2 . Also, contacting portions  142  of first contacts  140  may be further from a front of the connector insert to mate with contacts  240  on tongue  230  of the receptacle, while contacting portions  152  of second contacts  150  are closer to the front of the connector insert to mate with ground contact  250 , which may reside behind contacts  240  on tongue  230  in the connector receptacle of  FIG. 2 . 
     To properly position the contacting portions, first contacts  140  and second contacts  150  may have different shapes. First contacts  140  and second contacts  150  may be mechanically supported by first molding portion  500 . First contacts  140  may have a generally downward sloping portion  530  from first molding portion  500  to contacting portion  142 . Second contacts  150  may include a generally upward sloping portion from first molding portion  500  to shield contacting portion  154 , and a generally downward sloping portion  520  from shield contacting portion  154  to contacting portion  152 . When contacting portion  152  connects to a ground contact, second contact  150  may electrically connect shield  110  of the connector insert to ground contact  250  in a connector receptacle. 
     The inclusion of second contacts  150  may provide additional ground contacts. These additional ground contacts may be placed at the locations of pins that are not needed. That is, these additional ground contacts may be placed at an unused contact locations in a reduced pin-count connector insert. 
     Once this connector insert is inserted into a connector receptacle, such as the connector receptacle in  FIG. 2 , side ground contacts  160  may form a ground connection with contacts on sides of tongue  210  and may hold the connector insert in place relative to a connector receptacle, such as the connector receptacle of  FIG. 2 . 
       FIG. 6  illustrates a closer cutaway view of a portion of a connector insert according to an embodiment of the present invention. Again, ground shield  110  may be located around first contacts  140  and second contacts  150 . Front portion  120  may define an opening at a front of the connector insert. First contacts  140  may include contacting portions  142 , while second contacts  150  may include contacting portions  152 . The connector insert may include side ground contacts  160 . First contacts  140  may be supported by front housing portion  130 . Specifically, first contacts  140  may be located inside an opening in front housing portion  130 . The opening in front housing portion  130  may accept a tongue, such as tongue  210  of the connector receptacle in  FIG. 2 . Second contacts  150  may be supported by outer sides of front housing portion  130 . Contacting portions  152  may be in front of front housing portion  130 . That is, contacting portions  152  may be located between a front  610  of front housing portion  130  and an opening defined by front portion  120 . 
       FIG. 7  illustrates a number of contacts that may be manufactured together according to an embodiment of the present invention. In this example, first contacts  140  and second contacts  150  may be formed or stamped as a unit from a single piece of sheet metal. First contacts  140  and second contacts  150  may instead be formed by 3-D printing, metal-injection molding, or other process. Carrier  710  may be used to keep first contacts  140  and second contacts  150  together during manufacturing of the contacts and assembly of a connector insert. At an appropriate time, carrier  710  may be detached from first contacts  140  and second contacts  150 , thereby electrically separating these contacts from each other. 
     Connector inserts may be manufactured in different ways according to various embodiments of the present invention. One example is shown in the following figure. 
       FIG. 8  illustrates a cutaway side view of a connector insert according to an embodiment of the present invention. Again, shield  110  may support front portion  120  that forms an opening and a front of the connector insert. Shield  110  may be placed around first contacts  140  and second contacts  150 . 
     During assembly, a sensor ground plane  810  may be provided. This sensor ground plane may isolate signals on contacts on the top and bottom of the connector insert from each other. A first molded portion  500  may be molded around central ground plane  810 . First molded portion  500  may include slots to accept first contacts  140  and second contacts  150 . These slots may be located on top and bottom of first molded portion  820 . After first contacts  140  and second contacts  150  are placed in the slots, top and bottom caps  830  may be used to secure first contacts  140  and second contacts  150  in place. Front molded portion  130  may then be placed over a portion of center ground plane  810  and used to support first contacts  140  and contacts  150 . Shield  110  and front portion  120  may then be added. 
     In various embodiments of the present invention, first and second contacts, shields, ground planes, and other conductive portions of connector inserts and receptacles may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), or other nonconductive material or combination of materials. The printed circuit boards used may be formed of FR-4, BT or other material. Printed circuit boards may be replaced by other substrates, such as flexible circuit boards, in many embodiments of the present invention. 
     Embodiments of the present invention may provide connector structures that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector inserts and receptacles may provide pathways for signals that are compliant with various standards such as Universal Serial Bus (USB), a High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), power, Ethernet, DisplayPort, Thunderbolt, Lightning and other types of standard and non-standard interfaces that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention may provide connector inserts that may be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector inserts and receptacles may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.