Abstract:
In one version, a PC card has a printed circuit board assembly ( 11 ) that is interposed between card shields ( 5,6 ). This PC card is frameless. In another version, a PC card has: card shields ( 103,104 ); a printed circuit board assembly ( 110 ) interposed between the card shields; and two interposing side frames ( 105, 105′ ).

Description:
This application claims the benefit of Provisional Application Nos. 60/014946 and 60/015146, both filed on Apr. 5, 1996. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical connectors and more particularly to memory cards. 
     2. Brief Description of Prior Developments 
     The Personal Computer Manufacturer Card International Association (PCMCIA) has established standards for type I, type II and type III memory cards. 
     Various arrangements have been suggested for fixing the upper shield to the cover shield in type II PCMCIA cards, for example, by press-fit or by gluing. Particularly with the press-fit method, difficulties may result in forming thin walled cavities in die cast materials to co-operate with the press-fit members. Consequently, it may be difficult to maintain sufficient rigidity in the structure to withstand flexing, bending and tension forces which would be expected to be placed on it in the course of ordinary use. There is, therefore, a need for a PCMCIA type II memory card which avoids the above mentioned difficulties. 
     SUMMARY OF THE INVENTION 
     In the first two embodiments the use of a plastic frame used in the prior art has been eliminated. Common to both assemblies is the use of a shielded receptacle I/O typically of the type B, mentioned in the previous write-up. The frame-less structure was chosen as means to avoid an extra component in the card kit assembly. It will, however, be appreciated that implicit in this concept is the fact that nay axial or torsional forces applied to the card, needs to be withstood directly at the (rivet) connection between PCB and the two end connectors. 
     In another two embodiment the PCMCIA type II card with the use of side frames or side bars as integral part of the card assembly. Another feature of these embodiments is the “slide-in” of the pre-assembled unit of the PCB with two end receptacle connectors, into a previously formed metal casing (using side frames or bars as holding means) as final assembly step. In this disclosure, the words “side frame” or “side bars” will be inter-changeably used and the differences specified in use. It needs to be mentioned that when the memory card is subjected to mechanical forces (tension pull, twist and flex) in application, these forces need to be withstood without rupture or damage to the delicate (and expensive) electronic assembly. In a frame-less design, the critical force loading areas are the junction of connectors with the PCB, which is often an area of concern for some users. Such conditions may be avoided by use of side frames or side bars as part of the assembly. The concept of “slide-in” of a fully assembled PCB including the two end connectors, gives the user a possibility of properly inspecting and if necessary, repair the module before finalizing the card assembly. These embodiments are adapted to having the final assembly undertaken at the user&#39;s premises by virtue of the assembly and the fact that tooling is relatively simple, inexpensive and user-friendly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is further described with regard to the accompanying drawings in which: 
     FIG. 1 is a perspective view of a memory card representing preferred embodiment of the present invention; 
     FIG. 2 is an exploded view of the memory card shown in FIG. 1; 
     FIG. 2 a  is a detailed view of circle II in FIG. 2; 
     FIG. 2 b  is an exploded view of the I/O connector element of the memory card shown in FIG. 2; 
     FIG. 3 is an exploded view of another embodiment of the memory card of the present invention; 
     FIG. 3 a  is a detailed view of the area within circle III in FIG. 3; 
     FIG. 3 b  is an exploded view of the I/O connector shown in FIG. 3; 
     FIG. 4 is a perspective view of a memory card representing another preferred embodiment of the present invention; 
     FIG. 4 a  is a view of the I/O connector of the memory card shown in FIG. 4; 
     FIG. 5 is a exploded perspective view of a memory card representing another preferred embodiment of the present invention; 
     FIG. 6 is a perspective view from the I/O connector side of a memory card representing another preferred embodiment of the present invention; 
     FIG. 6 a  is a detailed view of the area within circle VI in FIG. 6; 
     FIG. 6 b  is a perspective view of the shield element of the memory card shown in FIG. 6; 
     FIGS. 7 a-   7   c  are cross sectional schematic illustrations showing the engagement of the frame and shields as is described in greater detail hereafter; 
     FIGS. 8 a-   8   c  are other schematic illustrations showing the engagement of the frame and the shield; 
     FIG. 9 is a exploded perspective view of another preferred embodiment of the memory card of the present invention; and 
     FIG. 10 is a detailed view of the latching mechanism used in the memory card shown in FIG.  9 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, there is shown a  68  position receptacle connector  1  at one end of the card, with another receptacle I/O connector  2  at the other end. The upper and lower shields  5  and  6  in assembled position touch each other along side edges  3  and  4 , on two sides of the case. External means (eg. glue, laser or ultrasonics welding) are utilized to finalize the mechanical connection between the two shields. At card side with connector  1 , the two corners have the PCMCIA standardized polarizing keys  7  and  8 ; the purpose being to ensure that the card can only be inserted direction in the (header) card slot of the electronic equipment it needs to connect with. By the same token, the I/O plug (not shown) with cable can only connect to the I/O receptacle  2  also in a specified direction due to upstanding polarizing/ guide keys  9 . 
     FIG. 2 illustrates the general outline of this concept. The two metal shields  5  and  6  are formed from one integral stamping operation, being connected by a metal front  10  with openings  11  to allow entry connecting pins. The  68  position and I/O connector receptacles  1  and  2  are located on a PCB  11  with outwardly projecting tabs  11 A/ 11 B/ 11 C and  11 D. These tabs act as connector support at two card ends, while preventing connector rocking during card twist and flex. Metal rivets  14  are the means for mechanical fixation between board and connectors. The vias  17  in PCB  11  through which the metal rivets  14  extend are part of a ground track. The  68  position receptacle has on its two ends ridges  12 . The polarizing keys  7  and  8  are separate plastic parts with grooves  13  to cooperate with ridges  12 . Once the PCB with connector receptacles  1  and  2  and the remaining electronic circuitry is complete, this assembly can be placed into the integral metal card shield stamping (which initially has its I/O ends opened, forming an acute angle with a tax facing metal front  10 ). Case closure is affected by applying pressure on the shield at the I/O end to allow side edges  3  and  4  to touch each other on both sides of the casing. External means such as glue on ultrasonic welding can be utilized to mechanically joined the upper and lower shields. As a final step, the polarizing keys  7  and  8  can be longitudinally slid into case openings  15  to have its grooves  13  push fit over pre-glued ridges  12  on the ends of the  68  position receptacle connector  1 . 
     The elements described in the first embodiment, with the exception that the upper and lower shields are not integrated in one stamping. Instead they are two separate shields. FIG. 3 shows the second embodiment. The remaining description of parts are similar except the  68  pos receptacle connector has a ridge  16  on top and bottom sides to allow the upper and lower shields to “snap” together in final assembly when they are vertically pressed over the PCB assembly. Similar to the first embodiment, the second embodiment employs glue or Laser/Ultrasonic welding is used to mechanically connect the two shields; the separate polarizing keys  7  and  8  fixation. 
     Referring to FIG. 4 an assembled Type II card representing another embodiment is shown with a  68  position receptacle connector  101  at one end of the card, with another receptacle I/O connector  102  at the other end. The upper and lower shields  103  and  104  are attached on the two casings sides to the frame or side bars  105  and  105 ′ by mechanical fixation, to be discussed later. The front end of the card ( 68  position receptacle  102 ) has the specified polarizing keys ( 106  and  107 ) to ensure that the card may be inserted only in one direction into the PCMCIA slot (not shown) of the equipment it needs to fit. In a similar fashion, the upstanding polarizing/guide key  108  on the I/O receptacle connector  102  ensures that the I/O plug connector with cable (not shown) fits the card only in one direction. 
     As shown in FIG. 5, the upper and lower metal shields  103  and  104  with rear edges  114  and front edges  117 , have on its sides several upstanding hold-down  109 . Two plastic side frames  105  and  105 ′ are located to be interposed between the two shields. These frames have appropriately located recesses (not visible) to cooperate with the hold-down&#39;s to permit fixation to form an integral outer casing  118  shown in FIG.  6 . This feature consists of side stubs perpendicular to shield surface with a rectangular opening; when the shield is pushed towards the frame, a plastic latch from the frame engage in the window in opposing stubs. A further embodiment of the casing rear edge  114  shown in FIG. 6 is that on the inside surface of the upper and lower shields (facing the PCB), are knurls  116  over case width as evident from cross-section detail of FIG.  7 . The PCB assembly can be prepared as a module shown in the middle right side of FIG. 5, with a separate blow-up in FIG.  8 . The I/O receptacle connector  102  with metal shields  113  has been described elsewhere. 
     The  68  position receptacle connector  101  has a raised ridge  112  over the top and bottom along a substantial length of the connector, to cooperate with the shield front edge  117  as additional “snap-on” connection in the final assembled condition. Further, receptacle connector  101  has protrusions  110  at its two ends, which fit the grooves  111  on the inner facing side of the frame as shown in the middle of FIG.  5 . The PCMCIA polarizing keys  106  and  107  are integrated with the frame outer side. The PCB assembly can be slide-in from the side of the rear edge  114  of the integrated outer casing  118  until the area of front edge  117  of the shields are spring-loaded pushed over the raised ridge  112  of the  68  position receptacle connector  101 , in a snap-fit connection. In this condition, the rear edge  114  with knurls  116  on the inside surface, extends slightly beyond the  110  receptacle connector  102  end face of the PCB assembly. As demonstrated in the right hand side of FIG. 7, this extension portion of rear edge  114  can be laid against an anvil  115 , a nd th is area can be easily curled over and press against the shield  113  of the I/O receptacle connector  102 . Since the connector shield  113  engages the card shields  103 , 104 , and the connector shield  113  engages a ground track on the PCB  11  through metal rivets  14 , card shields  103 ,  104  are electrically connected to the ground track on the PCB  11 , forming a ground loop. This process is easy to conduct at the user&#39;s premises, and results together not only with a “snap-on” of shield front edge  117  on raised ridge  112  of  68  position receptacle connector  101 , but also in an longitudinal locking of the PCB assembly within the integrated outer casing. This longitudinal locking with clamping of the shields to the assembly in the vertical direction, implies that the card assembly can withstand the vigor of twisting, flex and accidental cable pull from the plug  10 . It is to be noted in this design that the strength of the assembly is to a large extent defined by the hold-down strength of the connection between the plastic latch from frame cooperating with the window in the metal stub extending from shield, as evident from FIG.  8 . Increasing the number of hold-down location contributes further to the mechanical integrity of the case. However, an increase in the number of positions may weaken the overall mechanical strength of the plastic frame. Nevertheless, it is possible to use additional glue along the sides of the upper and lower shields to increase hold-down surface to frame, to assist in the fixation but this means an additional process step. But this means an additional process step. Further, plastic side frame material is “transparent” for EMI application environment. Hence, although this design is considered useful in a certain application environment, the need for another concept is desirable for more sophisticated users requiring enhanced robustness and EMI shield possibility. This design is shown in FIG.  9 . The major difference from the design in FIG. 6 is the use of metal die-cast side bars, and a more rugged hold-down  109  device as part of the upper and lower shields. These die-cast side bars are in essence similar to the plastic side frame in previous design, but the cavities to receive the hold-down&#39;s are different. FIG. 10 shows this Christmas tree, e.g. type, a vertical hold-down latch with lateral projections of increasingly shorter length toward the terminal end with opposing cavity in die-cast side bars. The metal die-cast side bars are, in addition act as an EMI shield along the side surface of the PCMCIA card. Conventionally, zinc alloy die-cast material is used in connector shielding applications. Other alternatives being aluminum or magnesium compounds. Zinc and aluminum alloys lack mechanical strength and the stress-bearing capability desirable of press-fit connections; aluminum has a somewhat lower EMI shielding capability. For this reason, the choice to use magnesium alloy for die-cast, is the preferred option. Magnesium alloy is light-weight, and die-casting of intricate shapes and thin walls, resembles plastic&#39;s use. Consequently this magnesium alloy is the preferred material for the side bars. 
     While the present invention has been described in connection with the preferred embodiments of the various figures, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.