Abstract:
An interface module in a nonplanar form. The interface module includes an electronic device card, such as a SIM or memory card, in a cross-sectional shape that may be, for example, substantially a circle or ellipse, substantially rectangular meeting certain dimensional requirements, or a shape other than a rectangle having at least three sides. Selected embodiments of the card may be a shape other than one having parallel major surfaces. An interface module assembly includes a card and a card reader. Electrical contacts are provided on both the card and the card reader. The contacts on the card may extend around the card to improve opportunity for continuous contact.

Description:
FIELD OF THE INVENTION 
   This invention relates to the field of interface modules for electronic devices, and more particularly, to cards or the like that may include, but not be limited to, memory, memory and a processor combined, digital signal processors, and power sources, and associated card readers. 
   BACKGROUND 
   Many electronic devices include modules or plug-ins that perform a variety of functions. Such devices may be portable and may include, but are not limited to, cellular telephones, notebook computers, personal digital assistants (PDAs), calculators, and handheld games or controllers, or any device in which a removable memory, memory and processor combined, digital signal processor, or power source card is desired. There is an ongoing effort to reduce device size. As the size of electronic devices decreases, the reduction of the size of various components within each device becomes valuable and desirable in order to decrease the overall device size. 
   One example of the various mobile telecommunication devices in which such a card may be desired includes devices operating on the Groupe Special Mobile (also known as GSM or Global System for Mobile Communications) standard digital cellular phone service. Such devices commonly incorporate the use of a Subscriber Identity Module (SIM) card having standard SIM reader electrical contacts. A card reader typically receives a SIM card with contacts corresponding to the standard SIM card contacts. The SIM card reader may be integral to the mobile telecommunication device, and is often accessible beneath the battery. The SIM card may be installed or inserted into the SIM card reader of the mobile telecommunication device, linking that mobile telecommunication device to the subscriber-related information stored on the SIM card. The subscriber-related information facilitates a telephone call from any valid mobile communication device, because the subscriber-related information is used to complete the call rather than specific internal physical identifiers (such as an internal serial number) that may be associated with the mobile telecommunication device. 
   In general, the form factors of conventional SIMs are substantially planar, and in some cases SIMs may be about the size of a postage stamp. The size and shape of SIMs and other removable cards may limit desired reduction in size of the device in which the cards are disposed. Consequently, a need exists to reduce the size or change the shape of such cards to allow reduction in size or change of shape of the host device. 
   SUMMARY OF THE INVENTION 
   In accordance with an embodiment of the present invention, an interface module for an electronic device is provided, including a card with a body and at least one of memory, processor, power source, or other apparatus that includes desired functionality as known to one of ordinary skill in the art. The body has a longitudinal axis. The body has a cross-sectional shape other than one bounded by substantially parallel major surfaces. Examples of cross-sectional shapes of the body include substantially circular or substantially elliptical. Electrical contacts may be spaced along the longitudinal axis of the body and may extend substantially around the periphery of the body. 
   In accordance with another embodiment of the present invention, an interface module for an electronic device includes a card with a body and at least one component selected from the group including memory, a processor, and a power source. The body has a longitudinal axis and a cross-sectional shape other than substantially planar. A substantially planar shape is one having a height to width ratio of less than approximately 0.5. Examples of cross-sectional shapes of the body include substantially rectangular and shapes other than a rectangle having at least three substantially straight sides. 
   In accordance with another embodiment of the present invention, an interface module for an electronic device is provided including a card with a body and at least one component selected from the group including memory, a processor, and a power source. The body has a longitudinal axis, and the cross-sectional shape of the body is selected from the group including substantially circular, substantially elliptical, substantially rectangular and having a height to width ratio of at least 0.5, and a shape other than a rectangle having at least three substantially straight sides. 
   In accordance with another embodiment of the present invention, an interface module assembly for an electronic device is provided, including a card reader, a card, and electrical contacts. The card reader defines an opening and has a longitudinal axis. The card is reciprocally mounted to the card reader and is disposed in the opening. The card includes a body having a longitudinal axis and at least one component selected from the group including memory, a processor, and a power source. The electrical contacts are spaced along the longitudinal axis of the card body and of the card reader, and the electrical contacts on the card reader and the electrical contacts on the card body are in close and complementary registration. The cross-sectional shape of the body is selected from the group including substantially circular, substantially elliptical, substantially rectangular and having a height to width ratio of at least 0.5, and a shape other than a rectangle having at least three substantially straight sides. 
   In accordance with another embodiment of the present invention, a mobile terminal is provided including a housing and an interface module assembly. The interface module assembly is disposed in the housing and includes a card reader defining an opening and a card reciprocally mounted to the card reader, disposed in the opening. The card reader includes a body and at least one component selected from the group including memory, a processor, and a power source. The cross-sectional shape of the body is selected from the group including substantially circular, substantially elliptical, substantially rectangular and having a height to width ratio of at least 0.5, and a shape other than a rectangle having at least three substantially straight sides. 
   In accordance with another embodiment of the present invention, a method of making an interface module is provided. A cross-sectional shape of the interface module is selected. A frame is provided including material for structural support and material for active leads including bonding pads. A position for a die is selected within the limits of the prospective interface module. The die is placed in position and is supported by means for structural support. The bonding pads of the active leads are bonded to the die, with a length of each active lead left exposed outside of the limits of the prospective interface module. The die and active leads are encapsulated to form the body of the interface module. The frame material used for structural support and outside the limits of the interface module body is trimmed away. The exposed active leads are wrapped and secured around the interface module. 
   Features and advantages of the present invention will become more apparent in light of the following detailed description of some embodiments thereof, as illustrated in the accompanying figures. As will be realized, the invention is capable of modifications in various respects, all without departing from the invention. Accordingly, the drawings and the description are to be regarded as illustrative in nature, and not as restrictive. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIG. 1  is a perspective view including the front face of a prior art mobile terminal. 
       FIG. 2  is a perspective view of a SIM of the prior art as may be used in the prior art mobile terminal of  FIG. 1 . 
       FIG. 3  is a perspective view including the rear face of the prior art mobile terminal of  FIG. 1  with a portion of the back of the mobile terminal removed. 
       FIG. 4  is a top plan view of an embodiment of an interface module according to the present invention. 
       FIG. 5  is a top plan view of the interface module of  FIG. 4 , reversed in position. 
       FIGS. 6A ,  6 B, and  6 C are section views showing various shapes of interface module embodiments taken along line  6 - 6  of  FIG. 5 . 
       FIG. 7  is a top plan view of another embodiment of an interface module according to the present invention. 
       FIG. 8  is a section view taken along line  8 - 8  of  FIG. 7 . 
       FIG. 9  is a top plan view of another embodiment of an interface module reader according to the present invention. 
       FIG. 10  is a longitudinal section view taken along line  10 - 10  of  FIG. 9 . 
       FIG. 11  is a top plan view of an embodiment of an interface module assembly in accordance with the present invention. 
       FIG. 12  is another embodiment of an interface module reader in accordance with the present invention. 
       FIG. 13  is an embodiment of an electrical contact according to the present invention. 
       FIG. 14  is a configuration of an interface module embodiment and the electrical contact of  FIG. 13 . 
       FIGS. 15-17  are other configurations of embodiments of interface modules and electrical contacts. 
       FIG. 18  is a perspective view including the rear face of an embodiment of a mobile terminal in accordance with the present invention. 
       FIG. 19  is a side elevation view of another embodiment of a mobile terminal in accordance with the present invention. 
       FIG. 20  is apparatus for making an embodiment of an interface module according to the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  shows a typical mobile terminal  50 . As used herein, the term “mobile terminal” may include, among other things: a cellular radiotelephone with or without a multi-line display; a Personal Communications System (PCS) terminal that may combine a cellular radiotelephone with data processing, facsimile and data communications capabilities; a PDA that can include a radiotelephone, pager, Internet/intranet access, Web browser, organizer, calendar and/or a global positioning system (GPS) receiver; a conventional laptop and/or palmtop receiver or other appliance that includes a radiotelephone transceiver; a calculator; a handheld game or controller; and a personal music playback system such as for CDs, minidisks, MP-3 files, memory sticks, or the like. Conventional interface modules for such devices are, in general, substantially planar. The present invention may provide the ability to reduce the form factor and change the shape of associated modules. This may allow a module to conform to space requirements and may permit for reduction in size of the overall device. 
   The mobile terminal  50  may include, for instance, a housing  52 , an antenna  54 , a speaker  56 , a display  58 , a keypad  60 , a memory  62  located internal to the housing  52 , a microphone  64 , a battery  66 , a system connector  68  with one or more connection terminals  70 , and one or more additional connection terminals  72 .  FIG. 2  shows an interface module, in this case being a SIM card  80 . Many other types of interface modules exist, and it should be understood that a SIM card is but one type, to which the present invention is not limited. A SIM card  80  may have a body  82  and six SIM card electrical contacts  84   a - 84   f , although it will be recognized that any number of SIM card data contacts would fall within the scope of the invention. The SIM card  80  is substantially flat, or substantially planar, and has a first major surface  83  that is substantially parallel to a second major surface, opposite the second major surface and not visible in  FIG. 2 . A major surface is the surface on the part having the greatest area. As shown in  FIG. 3 , which shows the rear face of the mobile terminal with the battery  66  removed and battery contacts  85  and battery area  86 , a SIM card reader  87  may be integral to the mobile terminal, sometimes accessible beneath the battery  66 . 
   The SIM card reader  86  has contacts  88   a - 88   f  that correspond respectively to the SIM card contacts  84   a - 84   f . The SIM card reader  87  may be connected to SIM card reader circuitry (not shown). The SIM card  80  may be installed or inserted into the SIM card reader  87  of the mobile telecommunication device  50 . The card contacts  84   a - 84   f  are electrically connected to the reader contacts  88   a - 88   f , as the contacts  84   a - 84   f ,  88   a - 88   f  are in close and complementary registration, thereby linking that mobile terminal  50  to the subscriber-related information stored on the SIM card  80 . Although the card  80  used for discussion herein is a SIM card, it should be understood that the card could be any one of a variety of cards that include, for example, memory, a processor, or a power source, or other device providing functionality as desired. The invention is not limited by the type of card; rather, the use of SIMs, for the purpose of discussion, is merely one embodiment of the invention. The combination of a card, or interface module, and a card reader makes up an interface module assembly. 
     FIGS. 4 and 5  show an embodiment of a SIM card  90  according to the present invention. The SIM card  90  includes a body  92  and electrical contacts  94   a - 94   f , and has a longitudinal axis  96  along the body  92 . The electrical contacts  94   a - 94   f  on the card  90  are longitudinally spaced along the body  92 . The electrical contacts  98   a - 98   f  for a card reader (not shown) are schematically depicted, and match the spacing of the card contacts  94   a - 94   f . In each figure the card  90  abuts a physical stop  100 . The configuration of  FIG. 4 , however, does not allow the card contacts  94   a - 94   f  to be in registration with the card reader contacts  98   a - 98   f , because the card is disposed in a reverse position from the correct orientation, which is shown in  FIG. 5 . In  FIG. 5  the card contacts  94   a - 94   f  are in close and complementary registration with the card reader contacts  98   a - 98   f . Unequal spacing of the card contacts at the ends of the card provide for correct installation orientation. 
   The card  90  may be a variety of shapes as viewed on a plane perpendicular to the axis, which is the cross-section taken along line  6 - 6  of  FIG. 5 . Such shapes are shapes other than planar and include but are not limited to shapes that are substantially circles  102 , ellipses  104 , and rectangles  106 , as shown in  FIGS. 6A ,  6 B, and  6 C respectively. Other shapes that change the form factor of the card from that of a substantially planar card may also be selected by one of ordinary skill in the art, such as any shape that has at least three substantially straight sides. “Substantially rectangular” or other shapes may be considered to be nonplanar when the height to width ratio (H/W,  FIG. 6C ) is at least approximately 0.5. Height, or thickness, H, is the shortest overall dimension in cross-section, and width, W, is the longest overall dimension perpendicular to H. A shape may be considered to be planar when the height to width ratio is less than approximately 0.5. 
     FIG. 7  shows another embodiment of a SIM card  110 . The card  110  includes a body  112 , a head  114 , and six electrical contacts  116   a - 116   f . As shown in  FIG. 8 , the body  112  is circular in cross-section and the head  114  is rectangular. Again, the shapes may vary as selected for a particular application. 
     FIGS. 9 and 10  respectively show a top view and a side elevation view of an embodiment of a card reader  120  for the card  110  of  FIG. 7 . The card reader  120  may also be referred to as a socket. The card  110  may be inserted into the socket  120  downward  122  from the top ( FIG. 10 ). The card reader  120  includes an area  124  to receive the body  112  and an additionally recessed area  126  for the head  114 . Six electrical contacts  128   a - 128   f  are provided with the card reader  120 .  FIG. 11  shows a plan view of the card  110  inserted into the socket  120 . The head  114  ensures that the card is properly installed, since the head  114  will only fit into the corresponding recessed area  126 . A benefit of a head that is not round is that the card will not roll on a work surface during handling and installation. 
     FIG. 12  shows another embodiment of a socket  130  that may be used with the card  110  of  FIG. 7 . A card  110  (not shown) may be inserted  132  into the socket  130  from the open end  134 . Again the head  114  will prevent incorrect installation, as it must end up in the recessed area  135  at the end of the socket  130 . The card body  112  is received in an opening  136 , where the card contacts  116   a - 116   f  will register with the socket contacts  138   a - 138   f.    
     FIGS. 13 through 17  show several embodiments of electrical contacts for the socket. The contact  140  of  FIG. 13  and  FIG. 14  substantially encircles the card  102 , providing continuous contact and also restraint to hold the card  102  in place. The bottom portion  142  of the card may connect to a printed wiring board (PWB) or other conductor.  FIGS. 15 through 17  show various configurations using cantilever spring-type contacts.  FIG. 15  shows a single spring  144  and contact point  146 , while  FIG. 16  shows two springs  148 ,  150  and two points of contact  152 ,  154 .  FIG. 17  has three contact points  156 - 158 , one from one spring  160  and two from another spring  162 . Ends  164 - 168  of the springs may connect to printed wiring boards or other conductors. Multiple contacts provide redundancy, which may be particularly desirable for applications where the device may be jarred. Methods of removal of cards from sockets may also be provided. Examples of such methods include providing a ribbon underneath a top-loaded card such that pulling the ribbon discharges the card. A lever may also be used to pry the card upward out of the top-loading socket or outward from an end-loaded socket. A string with a loop could also extend from the card itself. 
     FIG. 18  shows an example of mobile terminal as a cellular telephone  170  that incorporates an embodiment of an interface module assembly  172  according to the present invention. The interface module assembly  172  includes a card  174  and card reader  176 . 
     FIG. 19  shows another example of a cellular telephone  180  that incorporates an interface module assembly  172  with a card  174  and card reader  176 . The cellular telephone  180  includes a housing  182 , a display  184 , function buttons  186 , a volume button  188 , an earpiece  190 , and a microphone  192 . The shape of the interface module assembly  172  may allow the housing  182  to be round and potentially approximately the size of a conventional fountain pen, for example, approximately 1 cm diameter by 14 cm long. Other cross sectional shapes are also possible. Access to user interface aspects of the phone  180 , display  184 , microphone  192 , earpiece  190 , as so forth could be external devices that connect to the phone  180  by wired or wireless methods such as Bluetooth or infrared. 
     FIG. 20  shows a configuration for making a card  200  according to the present invention. A metal frame is provided that includes portions for structural support  202  outside of the prospective card limits (shaded), portions for structural support  204  within the card limits, and portions that will serve as the active leads  206   a - 206   f . A die  208 , which is a piece of silicon on which an integrated circuit is fabricated prior to packaging, is placed in the center of the card, though the location may vary from that shown. Each of the active leads  206   a - 206   f  have a bond pad  210   a - 210   e  proximate to the die, and wire bonds are made from the die  208  to the bond pads  210   a - 210   f . The assembly of the die  208 , the leads  206   a - 206   f , bond pads  210   a - 210   f , and portion  204  of the frame within the card&#39;s limits is then encapsulated in an epoxy encapsulate, plastic, or the like. The body may instead be formed by preformed top and bottom elements that are affixed to each other, or by other means known to one of skill in the art. 
   Once encapsulated, the structural support portions  202  of the frame that are outside of the limits of the card  200  are trimmed to be separated from the card  200  and active lends  206   a - 206   f . The remaining active leads  206   a - 206   f  are wrapped around the card  200  to form a ring. The end of each active lead  206   a - 206   f  is then tack welded, soldered, adhesively bonded, or by other means connected to a point on the same band. 
   One of ordinary skill in the electrical device arts will quickly recognize that the invention has other applications in other environments. It will also be understood by someone of ordinary skill in the art that the functionality of the interface modules may vary widely. In fact, many embodiments and implementations are possible. For example, the cards may function as storage devices for identification information, security information, financial information, and programs, all without departing from the scope of the present invention. An interface module could be used as a memory device with a mobile terminal that could provide expanded memory for storage of phonebooks, pictures, ring-tones, feature content, and the like. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described. It should be understood by those skilled in the art that the foregoing modifications as well as various other changes, omissions and additions may be made without parting from the spirit and scope of the present invention.