Abstract:
A cable connector and methods for the assembly thereof are disclosed. The cable connector eliminates potential for short events during plug insertion, provides good contact resistance, and can support high speed data transactions. The cable connector further includes a rotating lock design that provides a secure connection.

Description:
CROSS-REFERENCE TO A RELATED PATENT APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/207,055, filed Aug. 19, 2015, the disclosure of which is incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     This patent specification generally relates to electric cable connectors. 
     BACKGROUND 
     An electric cable may include one or more conductive lines or leads (e.g., wires) extending between a first connector assembly and a second connector assembly. Each connector assembly may be configured to electrically couple the conductive leads of the cable to a number of electrical contacts of the connector assembly. Conventional cable connectors have typically been made via standard inline audio jack. This type of connection has shortcomings such as, for example, as the plug is inserted into the jack, the front pin is the first pin that makes contact with the all the contacts, which can cause shorts. Special circuit protection may be needed to compensate for the short conditions. 
     SUMMARY 
     A cable connector and methods for the assembly thereof are disclosed. The cable connector eliminates potential for short events during plug insertion, provides good contact resistance, and can support high speed data transactions. The cable connector further includes a rotating lock design that provides a secure connection. 
     In one embodiment, a connector assembly is provided. The connector assembly can include a female sub-assembly having a circular cross-section and a male sub-assembly having a circular cross-section. The female sub-assembly can include a first core element having an opening for receiving a male sub-assembly, a first plurality of contacts disposed within the first core element, and a moveable locking member that at partially enshrouds the first core element and comprises a plurality of locking channels. The male sub-assembly can include a second core element having a interface portion constructed to be inserted into the opening, a second plurality of contacts disposed within the second core element, wherein the second plurality of contacts are coupled to the first plurality of contacts when the female sub-assembly and the male sub-assembly are connected together, and an overmold member that enshrouds a portion of the second core element, the overmold member comprising locking member protrusions that extend radially outward away from the second core element, wherein each locking member protrusion self-locks with a respective one of the locking channels when the moveable locking member is rotated from an unlocked position to a locked position. 
     In another embodiment, a female cable connector for use in being connected to a male cable connector is provided. The female cable connector can include a core element that includes a connector receiving region constructed to receive the male cable connector, a plurality of contact retaining regions positioned radially with respect to a center axis of the core element, and a plurality of contacts secured within respective ones of the contact retaining regions such that each contact includes an electrical coupling region that exists within the connector receiving region to make electrical contact with a contact contained in the male cable connector. The female cable connector includes a moveable locking member that at partially enshrouds the core element and comprises a plurality of locking channels to interlock with the male cable connector 
     In yet another embodiment, a male cable connector for use in being connected to a female cable connector is provided. The male cable connector includes a core member comprising an insertion member constructed to fit into a receiving member of the female cable connector, a plurality of contact retaining regions positioned radially with respect to a center axis of the core element and that extend from the insertion member to a distal end of the core member, a cylindrical member that surrounds a portion of the insertion member and the plurality of contact retaining regions, and a plurality of contacts contained in respective ones of the contact retaining regions. 
     A method for assembling a cable connector is also provided. The method can include inserting a male connector into a female connector, wherein the male connector comprises an insertion member and a cylindrical member having a plurality of channel guiding members, and wherein the female connector comprises a receiving member that receives the insertion member, a plurality of retention members coupled to the receiving member, and a movable sleeve including a plurality of interlocking channels, wherein when the insertion member is inserted into the receiving member, the plurality of channel guiding members are aligned with respective ones of the plurality of retention members. The method can include sliding the moveable member in a linear direction along a central axis towards the male connector, wherein each of the interlocking channels slide past one of the aligned pairs of the retention member and channel guiding member, and rotating the moveable member around the central axis such that the interlocking channels travel in a direction orthogonal to the linear direction along the aligned pairs of the retention member and channel guiding member. 
     A further understanding of the nature and advantages of the embodiments discussed herein may be realized by reference to the remaining portions of the specification and the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows illustrative cable connector in an uncoupled configuration, according to an embodiment; 
         FIGS. 2A-2U  show a series of assembly steps of various components in both female and male connectors according to various embodiments; 
         FIGS. 3A-3I  show several different views of female connector according to various embodiments; 
         FIGS. 4A-4H  show several different views of core member of the female member according to various embodiments; 
         FIG. 5  shows an illustrative perspective view of moveable member according to an embodiment; 
         FIGS. 6A-6C  show illustrative views of a contact according to various embodiments; 
         FIGS. 7A-7I  show several different views of a male connector according to various embodiments; 
         FIG. 8  shows an illustrative top view of the male connector with a second overmold according to an embodiment; 
         FIGS. 9A-9C  show several different views of the male core member according to various embodiments; 
         FIGS. 10A-10C  show illustrative views of a contact for use in male connector  150  according to various embodiments; and 
         FIG. 11  shows an illustrative process  1100  for assembling a cable connector, according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of the various embodiments of the present invention. Those of ordinary skill in the art will realize that these various embodiments of the present invention are illustrative only and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. 
     In addition, for clarity purposes, not all of the routine features of the embodiments described herein are shown or described. One of ordinary skill in the art would readily appreciate that in the development of any such actual embodiment, numerous embodiment-specific decisions may be required to achieve specific design objectives. These design objectives will vary from one embodiment to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming but would nevertheless be a routine engineering undertaking for those of ordinary skill in the art having the benefit of this disclosure. 
     The cable connector according to embodiments discussed herein are designed to occupy the smallest possible size, yet still retain desired electrical and physical characteristics. The cable connector is cylindrical in shape and is intended to have an only slightly larger diameter than the cable to which it is attached. The cable connector can be designed to carry power and ground, or power, ground, and data. For example, in some embodiments, the impedance of the data contacts can be designed to accommodate relatively high speed data transfer such as USB 2.0. 
     The cable connector includes a female connector and a male connector where the male connector can be inserted and removed from the female connector. The contacts in both connectors may be arranged radially with respect to a central axis of both male and female connectors such that inadvertent short circuits among contacts are eliminated when both connectors are coupled together. The radial arrangement of the contacts refers to the different planar placement of the contacts around each connector. This planar arrangement can exist in both male and female connectors. That is a first contact may exist on a first plane, a second contact may exist on a second plane that is perpendicular to the first plane, a third contact may exist on a third plane that is a parallel to the first plane, but offset with respect to the first plane, and a fourth contact may be parallel to and offset with respect to the second plane. When the male and female connectors are mated together, the contacts in the male connectors are substantially co-planar with the respective contacts in the female connectors, thereby ensuring that only respective contacts make contact with each other. 
     The cable connector can also include an interlocking mechanism that prevents the male and female connector from disengaging. The female connector may include a moveable member that engages and locks to retention members of the male connector. That is, when the male connector is inserted into the female member, the moveable member can move linearly along the central axis in the direction towards the male connector. When the moveable member cannot move linearly any further, it can be rotated radially around the center axis to a locked position. The moveable member can any include at least one region that interfaces with at least one reciprocal region of the male connector to lock in place. 
       FIG. 1  shows illustrative cable connector  100  in an uncoupled configuration, according to an embodiment. Cable connector  100  can include female connector  110  and male connector  150 . Female connector  110  shows core element  112 , overmold  117 , moveable member  130 , and cable  140 . Moveable member  130  can include interlocking channels  132  and interlocking friction members  133 . Male connector  150  shows core element  152 , overmold  157 , and cable  170 . Core element  152  can include insertion member  153  and cylindrical member  154 , which can include channel guide locking members  155 . Overmold  157  can include interlocking member  158 . When connectors  110  and  150  are coupled together, insertion member  153  is inserted into a receiving member (not shown) of female member  110 . Once inserted, moveable member  130  can slide axially along center axis  199  in the direction of male connector  150  such that an interlocking channel  132  slides around a respective one of the channel guide members  155 . Moveable member  130  may stop sliding towards male member  150  when it abuts overmold  157 , at which point it may be rotated around center axis  199  so that interlocking member  133  and  158  engage and lock moveable member  130  in place with respect to male member  150 . The outer dimension of female connector  110  and male connector  150  may each be about 5 mm or less. Despite the relatively small outer dimension of connectors  110  and  150 , cable connector  100  can carry up to 3 amps of current. 
       FIGS. 2A-2U  show a series of assembly steps of various components in both female and male connectors according to various embodiments. The components of  FIGS. 2A-2U  are discussed in a more general fashion to facilitate a quick understanding of the connectors, but a more detailed explanation the components can be found elsewhere in this specification. Starting with  FIG. 2A , core element  112  of female connector  110  is shown, and core element  152  of male connector  150  is shown. Core element  112  can include receiving member  113  that constructed to receive insertion member  153 . Core element  112  can include contact retaining regions  114  (four of which exist in the FIG.) that span the length of core element  112  from end  115  to end  116  and are designed to hold contacts (not shown) in place within receiving member  113 . Biasing members  118  may form part of receiving member  113  to prevent contacts (not shown) from extending out beyond a periphery of member  113 . Retaining members  119  may extend radially away from member  113  and can serve as stops that prevent movable member  130  (not shown) from sliding off core element  112 . 
     Core element  152  can include insertion member  153 , cylindrical member  154 , contact retaining regions  155  positioned radially with respect to a center axis of core element  152  and that extends from insertion member  153  to a distal end of core member  152 . Four contact retaining regions may exist, but only two are shown in the FIG. Cylindrical member  154  can include at least one channel guiding member  156  that extends outward away from an outer surface of the cylindrical member. At least one channel guiding member is designed to interface with movable member  130  of the female cable connector. 
       FIG. 2B  shows the addition of contacts  120  constructed to fit into and be retained by contact retaining regions  114 , and  FIG. 2C  shows contacts  120  secured within contact retaining regions  114 . Biasing members  118  prevent contacts  120  from protruding out of element  112  when insertion member  153  is inserted into element  112 . 
       FIG. 2D  shows addition of moveable member  130 , which includes interlocking channels  132 . In one embodiment interlocking channels may be “L” shaped. Moveable member  130  can be slid over core element  112 , as shown in  FIG. 2E . Retaining members  119  may prevent moveable member  130  from sliding off of core element  112 . 
       FIG. 2F  shows wires  141  within cable  140  being affixed to contacts  120  and  FIG. 2G  shows wires  141  soldered to contacts  120 . In some embodiments, wires  141  can be 18 gauge wire.  FIG. 2H  shows first overmold  122  that surrounds wires  141  and the portion of contacts  120  where wires  141  are soldered thereto. First overmold  122  may have a taper that changes in diameter as it progresses from cable  140  to core element  112 .  FIG. 2I  shows a second overmold  124  that surrounds first overmold  122  and a portion of core element  112 . First overmold  122  may be less elastic than second overmold  124 . Second overmold  124  may prevent moveable member  130  from sliding back down over core element  112  and cable  140 .  FIG. 2J  shows another view of female connector  110  showing the opening of receiving member  113 . As shown, receiving member  113  has a keying arrangement that ensures that insertion member  153  can be inserted in only one orientation. 
       FIG. 2K  shows addition of contacts  160  being inserted into contact retaining regions  155 . In particular,  FIG. 2K  shows contact  160 A and contact  160 B. Contact  160 A may have a longer length than contact  160 B. In this embodiment, since contact  160 A is longer than contact  160 B, it may be used as a ground pin to thereby establish a ground connection first before a power or data connection is established by contact  160 B.  FIG. 2L  shows contacts  160  fully inserted in and retained in place within retaining regions  155 . Note that the positioning of contacts  160  may differ depending on whether first mate, first break electrical connections are desired. 
       FIG. 2M  shows wires  171  of cable  170  being connected to contacts  160 , and  FIG. 2N  shows those wires being soldered onto contacts  160 . In some embodiments, wires  171  can be 18 gauge wire.  FIG. 2O  shows first overmold  162  that surrounds wires  171  and is positioned between cylindrical member  154  and cable  170 . First overmold  162  can have a taper, as shown.  FIG. 2P  shows second overmold  164  positioned over first movermold  162 , a portion of cylindrical member  154  and a portion of cable  170 . Second overmold  164  can include interlocking members  165  that are designed to interface with interlocking members  133 . Second overmold  164  can be constructed from a material that is more elastic than first overmold  162 . 
       FIG. 2Q  shows male connector  150  being inserted into female connector  110  where insertion member  153  will be inserted in receiving member  113 .  FIGS. 2R and 2S  show that when both connectors  110  and  150  are coupled together, respective retaining members  119  and channel guiding members  156  are aligned to provide guidance tracks for moveable member  130  to slide in a direction towards male member  150 .  FIG. 2T  shows moveable member  130  has finished sliding towards male connector  150  as its interlocking channels  132  prevent further travel in the linear direction. Note that at this point, interlocking members  133  and  165  are in an unlocked position. In  FIG. 2U , after moveable member  130  is rotated around a center axis, retaining members  119  and channel guiding members  156  further guide travel of moveable member  130 . Note that at this point, interlocking members  133  and  165  are in a locked position, resulting in secured lock up the connector assembly. The connector assembly can remain locked until a user counter rotates movable member  130  to unhinge interlocking members  133  and  165  to enable male connector  150  to be removed from female connector  110 . In one embodiment, channel guiding member  156  may be sized to be smaller than channel guiding member  119 . This way, channel guiding member  156  is engineered to fail before channel guiding member  119 . 
       FIGS. 3A-3I  show several different views of female connector  110  according to embodiments.  FIGS. 3A and 3B  show two different illustrative perspective views of female connector  110 .  FIG. 3C  shows an illustrative exploded view of female connector  110 , showing moveable member  130 , core member  112 , contacts  120 , and cable  140 .  FIG. 3D  shows an illustrative side view of female connector  110  without showing first or second overmolds  122  and  124 .  FIG. 3D  shows moveable member  130 , core member  112 , contacts  120 , cable  140 , and wires  141 . 
       FIG. 3E  shows an illustrative cross-sectional view taken along line A-A of  FIG. 3D .  FIG. 3E  shows with more particularity components contained within core element  112 . That is, contacts  120  are shown be contained within contact retaining regions  114 . Biasing members  118  show that contacts  120  are not permitted to deflect radially outward beyond biasing members  118 . Retaining member  119  is shown to prevent moveable member  130  from sliding off core member  112 . Wires  141  are shown coupled to contacts  120 . 
       FIG. 3F  shows an illustrative cross-sectional view taken along line B-B of  FIG. 3E .  FIG. 3F  shows with more particularity, additional details on contact retaining regions  114  and contacts  120  as they relate to core member  112 .  FIG. 3G  shows an illustrative cross-sectional view taken along line C-C of  FIG. 3F .  FIG. 3G  shows another view of contact  120  being secured by contact retaining region  114 , and in particular, shows retaining region  126  of contact  120  interfacing with retaining region  114 .  FIG. 3H  shows a blown up view of section H of  FIG. 3G  that that shows this interface in more detail. 
       FIG. 3I  shows an illustrative perspective view of female connector  110  that shows with emphasis wire connections to solder regions of contacts  120  and a distal end of core member  112 . Wires  141  are shown to be soldered to different contacts  120 , which are secured in place by retaining regions  114 . 
       FIGS. 4A-4H  show several different views of core member  112  of the female member according to embodiments.  FIGS. 4A and 4B  shows different illustrative perspective views of core member  112 .  FIG. 4A  shows receiving region  113  of core member  112 , along with biasing members  118 , retaining members  119 , and to a lesser extent, contact retaining regions  114 .  FIG. 4B  shows distal end of core member  112  with emphasis on contact retaining regions  113 . The distal end can represent where contacts (not shown) are inserted into retaining regions  114 . 
       FIG. 4C  shows an illustrative top view of core member  112  and  FIG. 4D  shows an illustrative side view of core member  112 . Both  FIGS. 4C and 4D  show contact retaining regions  114 , bias members  118 , and retaining members  119 .  FIGS. 4E and 4F  show illustrative cross-sectional views taken along lines A-A and B-B of  FIGS. 4C and 4D , respectively.  FIGS. 4E and 4F  show additional details of contact retaining regions  114 .  FIG. 4G  shows a back view of core member  112  and  FIG. 4H  shows a front view of core member  112 , along with views of retaining regions  114 , receiving member  113 , and retaining members  119 . 
       FIG. 5  shows an illustrative perspective view of moveable member  130  according to an embodiment Moveable member  130  can include interlocking channels  132  and interlocking members  133 . In some embodiments, moveable member  130  can include only one interlocking member  133 . Moveable member  130  may be constructed from a metal. 
       FIGS. 6A-6C  show illustrative views of a contact according to various embodiments.  FIG. 6A  shows an illustrative perspective view,  FIG. 6B  shows a side view, and  FIG. 6C  shows a top view of contact  120 . Contact  120  can include solder region  125 , retention region  126 , flex region  127 , and electrical coupling region  128 . Solder region  125  may be located where a wire is soldered to contact  120 . Solder region  125  may be offset with respect to retention region  126  by distance, d, as shown. Retention region may include barbs  129  that secure contact  120  within contact retaining region  114  (not shown). Flex region  127  may represent a region that provides downward flex bias for electrical coupling region  128 . This downward bias enables electrical coupling region  128  to extend into receiving member  113  (not shown) so that an electrical contact can be made with the male connector. 
       FIGS. 7A-7I  show several different views of male connector  150  according to embodiments.  FIGS. 7A and 7B  show two different illustrative perspective views of male connector  150 .  FIG. 7C  shows an illustrative exploded view of male connector  150 , showing core member  152 , contacts  160 , and cable  170 .  FIG. 7D  shows an illustrative side view of male connector  150  without showing first or second overmolds  162  and  164 .  FIG. 7D  does show core member  152 , insertion member  153 , cylindrical member  154 , channel guiding members  156 , contacts  160 , cable  170 , and wires  171 . 
       FIG. 7E  shows an illustrative cross-sectional view taken along line A-A of  FIG. 7D .  FIG. 7E  shows with more particularity components contained within core element  152 . That is, contacts  160  are shown to be contained within contact retaining regions  155 . Wires  171  are shown coupled to contacts  160 . 
       FIG. 7F  shows an illustrative cross-sectional view taken along line B-B of  FIG. 7E .  FIG. 7F  shows with more particularity, additional details on contact retaining regions  155 , contacts  160 , and wires  171  as they relate to core member  152 .  FIG. 7G  shows an illustrative cross-sectional view taken along line C-C of  FIG. 7F .  FIG. 7G  shows another view of contact  160  being secured by contact retaining region  155 , and in particular, shows retaining region  166  of contact  160  interfacing with retaining region  155 .  FIG. 7H  shows a blown up view of section H of  FIG. 7G  that that shows this interface in more detail. 
       FIG. 7I  shows an illustrative perspective view of male connector  150  that shows with emphasis wire connections to solder regions of contacts  160  and a distal end of core member  152 . Wires  171  are shown to be soldered to different contacts  160 , which are secured in place by retaining regions  155 . 
       FIG. 8  shows an illustrative top view of male connector  150  with second overmold  164  according to an embodiment. In particular,  FIG. 8  shows insertion member  153 , channel guiding members  156 , contacts  160 , second overmold  164 , interlocking member  165 , and cable  170 . 
       FIGS. 9A-9C  show several different views of core member  152  according to various embodiments.  FIG. 9A  shows an illustrative perspective view of core member  152 .  FIG. 9A  shows insertion member  153 , cylindrical member  154 , contact retaining region  155 , and channel guiding member  156 .  FIG. 9B  shows an illustrative side view of core member  152  showing insertion member  153 , cylindrical member  154 , contact retaining region  155 , and channel guiding member  156 .  FIG. 9C  shows an illustrative cross-sectional view taken along lines D-D of  FIG. 9B .  FIG. 9C  shows that core member  152 , contact retaining regions  155 , and cylindrical member  154 . Portions of retaining regions  155  located near insertion member  153  are tapered to thereby force contacts  160  (not shown) to nestle therein to promote male connector ingress into and egress from the female connector. 
       FIGS. 10A-10C  show illustrative views of a contact for use in male connector  150  according to various embodiments.  FIG. 10A  shows an illustrative perspective view.  FIG. 10B  shows a side view, and  FIG. 10C  shows a top view of contact  160 . Contact  160  can include solder region  167 , retention region  166 , and electrical coupling region  168 . Solder region  167  may be location where a wire is soldered to contact  160 . Retention region  166  may include barbs  169  that secure contact  160  within contact retaining region  155  (not shown). Retention region  166  may represent a baseline from which solder region  167  and electrical coupling region  168  are biased in a downward direction. 
       FIG. 11  shows an illustrative process  1100  for assembling a cable connector, according to an embodiment. Process  1100  can start at step  1110  by inserting a male connector into a female connector, wherein the male connector includes an insertion member and a cylindrical member having a plurality of channel guiding members, and wherein the female connector comprises a receiving member that receives the insertion member, a plurality of retention members coupled to the receiving member, and a movable sleeve including a plurality of interlocking channels, wherein when the insertion member is inserted into the receiving member, the plurality of channel guiding members are aligned with respective ones of the plurality of retention members. At step  1120 , the moveable member can be slid in a linear direction along a central axis towards the male connector, wherein each of the interlocking channels slide past one of the aligned pairs of the retention member and channel guiding member. At step  1130 , the moveable member can be rotated around the central axis such that the interlocking channels travel in a direction orthogonal to the linear direction along the aligned pairs of the retention member and channel guiding member. 
     Many alterations and modifications of the preferred embodiments will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description, it is to be understood that the particular embodiments shown and described by way of illustration are in no way intended to be considered limiting. Thus, references to the details of the described embodiments are not intended to limit their scope.