Patent Publication Number: US-6217350-B1

Title: Media jack adaptor and system

Description:
BACKGROUND OF THE INVENTION 
     1. The Field of the Invention 
     The present invention relates to the field of computers. More particularly, the present invention relates to an interface between a connector and a communications card in a computer system, and specifically to an adaptor and housing for a physical/electrical media connector interface for use in a PCMCIA-architecture communications card. 
     2. The Prior State of the Art 
     As is well known, telecommunications-type devices—such as modems, network interface cards and the like—require some means for physically and electrically interconnecting with a corresponding communications medium. For instance, a modem will typically interface with the telephone subscriber line with a standard RJ-11 media jack and modular plug type of arrangement. Similarly, a network interface card may be connected to a communications network via a RJ-45 jack and plug. 
     Where such telecommunications devices are of a larger size, such as an external, desktop size modem for instance, the incorporation of such a media jack connector within the device itself is relatively straight forward. However, the incorporation of this type of connector is more difficult in miniature, or smaller sized communications devices, such as those that conform with the PCMCIA-specified architectures, or similar devices that are incorporated within handheld or notebook sized computer devices. 
     In these types of devices, the ability to provide a suitable connector arrangement is often limited by the spatial limitations of the device itself. Thus, there have been a variety of attempts to provide a suitable interface with standard modular connection schemes—such as the RJ-type arrangement—that can be implemented within a very limited physical space. Often, such approaches provide a media interface, or media jack, that can be retracted and stored within the physical confines of the device housing when not in use. When needed, the media jack can be extended out from the housing and provide a suitable interface for connecting to a corresponding modular plug. While these types of approaches are very satisfactory in terms of providing a media connection that can be implemented and used within smaller-sized environments, they do present a variety of additional problems. For instance, such connection devices often have a number of parts that can be difficult to assemble, manufacture and service. Moreover, the assemblies may be more prone to failure with prolonged use. 
     FIG. 1 illustrates one example of a communications card  10  of the prior art. Communications card  10  is of the sort that conforms with the size limitations specified by the PCMCIA architecture standard. It includes a printed circuit board  12 , which contains corresponding circuitry for implementing a particular communications function, such as a modem. Also included is a suitable media jack  14  designed for receiving a corresponding modular plug, such as a standard RJ-type jack and plug arrangement. 
     The jack is electrically interconnected with the corresponding circuitry on the printed circuit board by way of a suitable internal connector, such as a flexible ribbon cable  16 . In the example shown, the retractability of media jack  14  is provided, in part, by way of a media jack adaptor assembly  18 , which essentially is comprised of a plastic U-shaped frame  20 . Frame  20  includes a track  21 , along which the media jack  14  can be extended and retracted. Moreover, frame  20  may include a spring post  22 . Corresponding spring  19  biases media jack  14  toward the extended position, and can be compressed when media jack  14  is in a retracted position. A suitable arrangement is also provided to retain the jack within the retracted position, and that allows a user to selectively extend the jack when needed. For instance, a cam follower  23  can be positioned between media jack  14  and a cam track  24  configured within frame  20 . Cam follower  23  follows the path of cam track  24  as media jack  14  is extended and retracted. 
     FIG. 1 a  shows a cutaway view of a front comer portion of assembled card  10  in which spring  19  is mounted on spring post  22  and plates  25 ,  26  are mounted on frame  20 . As shown in FIGS. 1 and 1 a , as a hub  27  of media jack  14  slides along track  21  of frame  20 , tabs  28 ,  29  on hub  27  slide within respective opposing slots  30 ,  31  of track  21  while opposing tabs  32 ,  33  slide along an outside surface of track  21 . Stops  34 ,  35  in respective slots  30 ,  31  of track  21  limit the extension of media jack  14  out of track  21 . 
     Also as shown, frame  20  is mounted between upper and lower thin metallic shells  25 ,  26 . Shells  25 ,  26  are configured with surfaces that correspond in size and shape with the edges of frame  20 . Lips  36 ,  37  on the sides of respective shells  25 ,  26  extend into respective grooves  38 ,  39  in upper and lower portions of frame  20 . A thermally activated adhesive material  41  placed on shells  25 ,  26  joins shells  25 ,  26  permanently to opposing sides of frame  20 . 
     Despite the many advantages of adaptor assembly  18 , the sandwiching of frame  20  between shells  25 ,  26  is a cumbersome process. For instance, frame  20  is a flimsy molded component and is cumbersome to handle and mate with shells  25 ,  26 . Furthermore, the bond accomplished through the use of adhesive material  41  between frame  20  and shells  25 ,  26  is subject to failure over time. 
     FIGS. 2 and 2 a  illustrate yet another example of a communications card  40  assembled in accordance with the teachings of the prior art. Card  40  is shown in a partially assembled, exploded view. Communications card  40  features upper and lower shells  42 ,  44 , which substantially surround printed circuit board  45 . A media jack  46  is also shown along with an adapter  48  for slidably receiving jack  46 . A cam follower  50  and leaf spring  52  for biasing cam follower  50  into cam track  53  as jack  46  moves along adaptor  48  are also shown. Spring  54  is provided and mounted on spring post  55  for biasing against jack  46 . 
     Media jack  46 , circuit board  45 , springs  52  and  54 , cam follower  50  and adaptor  48  are mounted between shells  42 ,  44 . Shells  42 ,  44  include respective outer plastic rails  56 ,  57  mounted on metallic plates  58 ,  59  respectively. Plastic rails  56  of shell  42  have a groove  60  therein for receiving a ridge  61  on rails  57  of shell  44 , such that rails  56 ,  57  can be coupled in a mating relationship. Rails  56 ,  57  are typically permanently joined through ultrasonic bonding. 
     Tabs  62 ,  64  extend from a rail  56  of shell  42 . A phantom view of adaptor  48  is shown adjacent the tabs  62 ,  64  in FIG.  2 . Grooves  66 ,  68  of adaptor  48  are secured to the tabs  62 ,  64 . Tabs  62 ,  64  extend from the rail  56  over the metallic plate  58 . 
     Since cam track  53  is configured within jack  46 , transversely oriented leaf spring  52  is required for biasing cam follower  50  into track  53 . Leaf spring  52  can become bent, causing it to press at the wrong angle against cam follower  50 . Also, leaf spring  52  adds additional complexity to the assembly and the manufacture thereof. 
     The assembly can present additional problems as well. For instance, cam follower  50  can be difficult to properly mount within adaptor  48 , and can become disconnected during assembly. In addition, the dovetail coupling of adaptor  48  to tabs  62 ,  64  results in the adaptor  48  being coupled only to a single shell  42 . Furthermore, a stop  70  is required to be placed on jack  46  to prevent media jack  46  from exiting the assembled communications card housing. In addition, cam track  53  is exposed outside of the assembled card when media jack  46  exits the housing, and can thus be subject to damage. 
     There is therefore a need in the art for an improved media jack adaptor assembly and associated adapter housing. More specifically, there is a need in the art for a media jack adaptor which can be more conveniently and efficiently mounted within the housing of a communications card. 
     SUMMARY AND OBJECTS OF THE INVENTION 
     It is therefore an object of the invention to provide an improved media jack adaptor for movably receiving a media jack. 
     It is another object of the invention to provide an improved housing for mounting a media jack adaptor thereon. 
     It is another object of the invention to provide an improved system and method for housing a media jack and for movably adapting the media jack to the housing. 
     It is another object of the invention to provide a system having a pair of shells and a media jack adaptor mounted therebetween for movably receiving a media jack. 
     It is another object of the invention to develop a system and method which enables improved automated assembly of a communications card. 
     One presently preferred embodiment of the present invention comprises an adaptor and a housing that are particularly useful in connection with a PCMCIA-architecture communications card. In general, the adaptor is configured so as to be implemented within the housing defined by the communications card. Moreover, the adapter permits a media jack, such as a standard RJ-type modular connector, to be selectively and slidably received within the communications card housing. 
     An example of an adaptor constructed in accordance with the teachings of the present invention features an adaptor body having (i) a track for movably receiving the media jack; and (ii) a cam track or other means for arresting the movement of the media jack along the track. In addition, in a preferred embodiment the adaptor includes a wing portion that is adapted and configured to couple the adaptor to the desired object, such as the housing of the communications card. For instance, the wing preferably has a plurality of apertures and posts that are arranged and oriented so as to provide suitable means for aligning and coupling the adapter to the interior of the card housing, which is formed with corresponding and complimentary shaped structures. 
     In one embodiment, apertures are formed within the wing portion of the adapter and are positioned and configured so as to receive correspondingly sized and shaped posts that extend from a first shell portion of the housing. Also, a second shell portion of the housing has receiving sockets that are also positioned and configured so as to receive the same posts. In an assembled state, the wing of the media jack adaptor is mounted onto the posts of the first shell. The second shell is then mounted onto the posts, which extend through the apertures formed within the wing portion. The media jack adaptor is thus conveniently sandwiched and aligned between the upper and lower shells, and is secured by way of the wing apertures, and the corresponding shell posts and sockets. 
     In a further preferred embodiment, the shells that form the communications card housing include bonding sites formed around the edges thereof, where rails are mounted on the plates of the shells. Mating bonding sites are formed in opposing rails. The mating bonding sites are formed through the use of mating posts and sockets in opposing rails. Mating rails on one side of the shells each have a platform configured to receive the wing of the adaptor therein. Posts extend from the platform of one rail for mating within the apertures of the wing. 
     The adaptor and housing system have a variety of advantages. The adaptor may receive a variety of different cam followers and a variety of different media jacks thereon. The adaptor may be mounted on to a variety of different objects, including the housing shells and other equipment or devices. The wing of the adaptor has substantially the same length as the body of the media jack, and thereby conserves space. The configuration also conserves materials and provides for convenient and efficient mounting of the adaptor between the shells. The posts and sockets ensure that the housing assembly and the adapter are attached in an aligned relationship, and thereafter maintain the adaptor in a fixed, tight relationship. 
     The adaptor may be held mechanically between the shells or may be mounted therebetween through ultrasonic bonding. The posts which couple the shells to each other are parallel to the posts which couple to the adaptor. Thus, it is possible during the compression and ultrasonic bonding of the shells to simultaneously compress and ultrasonically bond the wing to the posts configured to extend through the wing. 
     In addition to ultrasonic bonding, the adaptor of the present invention may be coupled together to the housing shells through variety of different means, including mechanical means such as screws and the like, adhesives and various chemical bonding techniques, heat bonding, compression fit, or a variety of other means known in the art. Similarly, the shells may be coupled through a variety of different means. 
     These and other objects, features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded view of a communications card of the prior art. 
     FIG. 1 a  is a cross sectional, cut away view of a front corner of the assembled communications card of FIG.  1 . 
     FIG. 2 is a partially assembled, exploded view of another communications card of the prior art. 
     FIG. 2 a  is a partially assembled cut-away view of the communications card of FIG.  2 . 
     FIG. 3 is an exploded view of a communications card of the present invention having a media jack adaptor of the present invention shown separate from a media jack. 
     FIG. 4 features the communications card of FIG. 3 with the media jack of FIG. 3 slidably mounted onto the media jack adaptor of FIG.  3 . 
     FIG. 5 is a view of the communications card of FIG. 4 with the combined media jack adaptor and media jack shown as being mounted onto the lower shell of the communications card. 
     FIG. 6 a  is a perspective view of the inner surface of the media jack adaptor of FIG. 3, featuring the spring post and the cam track on opposing ends of the media jack adaptor. 
     FIG. 6 b  is a perspective view of the outer surface of the media jack adaptor of FIG.  3 . 
     FIG. 6 c  is a bottom view of the media jack adaptor of FIG. 6 a  and  6   b.    
     FIG. 7 is a perspective view of the assembled communications card of FIG. 3, having the media jack thereof shown in an extended position. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to FIG. 3, an exploded view of a communications card  80  of the present invention is shown. Communications card  80  features an adaptor  82  and housing shells  84 ,  86  of the present invention. Communications card  80  also includes a printed circuit board  88 , a biasing spring  90  and a media jack  92 . 
     Circuit board  88  contains circuitry for implementing a particular communications function, such as a modem. Media jack  92  is preferably designed for receiving a corresponding modular plug, such as a standard RJ-type jack and plug arrangement, thereby electrically coupling the plug to circuit board  88 . 
     Adaptor  82  is configured for movably receiving media jack  92  and is configured to be coupled to a desired object, e.g., shell  84  or shell  86  and preferably both shells  84 ,  86 . Adaptor  82  comprises an elongate body  94  having (i) a track  96  for movably receiving media jack  92 ; and (ii) means for arresting the movement of media jack  92  along track  96 , such as cam track  98  which receives a cam follower coupled to jack  92 . In addition, adaptor  82  further comprises a spring post  100  coupled to adaptor body  94  for mounting spring  90  thereon. Spring post  100  and spring  90  mounted thereon serve collectively as an example of means for biasing media jack  92  in a desired direction. 
     Adaptor  82  further comprises (i) a wing  102  extending from one side of adaptor body  94 ; and (ii) means for coupling wing  102  to an object, e.g., shells  84 ,  86 . Wing  102  (also shown in FIGS. 6 a - 6   c ) defines a plane, and the means for coupling wing  102  to shells  84 ,  86  extends transversely to the plane of wing  102 . 
     Examples of the transversely extending coupling means include (i) apertures  104 ,  105  (apertures  105  shown in FIGS. 6 b - 6   c ) which extend through the plane of wing  102 , (ii) posts  106  on wing  102  which mate within a portion of shell  84 , (iii) posts  108 ,  110  of shell  86  which extend into apertures of wing  102 , and a variety of other transversely extending members or devices. Posts  106  of wing  102  have apertures  104  extending therethrough, but other posts may extend from wing  102  for mating with shell  84  which do not feature apertures therethrough. 
     By extending transversely to the plane of wing  102 , apertures  104 ,  105 , and posts  106 ,  108 , and  110  enable wing  102  to be conveniently mounted above and/or below a given shell. Thus, wing  102  can be sandwiched between the shells  84 ,  86 . The ability of wing  102  to be mounted above or below an object, and preferably between first and second shells  84 ,  86  provides a variety of different advantages. First, gravity assists in bonding adaptor  82  and the object together during manufacturing and in use. Second, adaptor  82  may be retained between shells  84 ,  86  while shells  84 ,  86  are coupled together. Thus, adaptor  82  may be either bonded ultrasonically or otherwise to one or more shells  84 ,  86 , or may be held mechanically between shells  84 ,  86 . Adaptor  82  is preferably made from a plastic material, such as a nylon, reinforced nylon or other plastic material. 
     With continued reference to FIG. 3, housing shells  84 ,  86  each comprise base plates  85 ,  87 , respectively and a plurality of rails  114 ,  116 ,  118 ,  120  extending along the edges of respective base plates  85 ,  87 . Base plates  85 ,  87  preferably each comprise a substantially planar, metal material, while rails  114 ,  116 ,  118 ,  120  preferably each comprise a plastic material, such as nylon, reinforced nylon or another plastic material. A protective layer  128 ,  130  of an insulating material is disposed on respective plates  85 ,  87  to thereby protect the electrical components of printed circuit board  88  which is sandwiched between shells  84 ,  86 . 
     Mating posts and sockets extend from and are formed within respective mating rails  114 ,  116  and mating rails  118 ,  120  for coupling shells  84 ,  86  to each other. For example, posts  132  mate with sockets  134  when shells  84 ,  86  are coupled. Preferably, shells  84 ,  86  are ultrasonically bonded by ultrasonically bonding mating rails. 
     Rails  114 ,  116 ,  118 ,  120  may be mounted on respective plates  85 ,  87  through a variety of different processes, including mechanically mating the rails and the plates, molding of the plastic rails to the metal plates  85 ,  87 , bending metallic outer flanges  135  partially around the rails, molding portions of rails over tabs (not shown) extending from the plates  85 ,  87  such that the tabs retain the rails on the plates, molding portions of the rails around the comers of the plates (see FIG.  5 ), or combinations thereof. 
     Rail  114  in lower shell  86  includes a lower platform  136  while from rail  116  in upper shell  84  includes an upper platform  138 . Platforms  136 ,  138  preferably comprise a plastic material and receive wing  102  of adaptor  82  therebetween in mating relationship. Apertures  105  (FIGS. 6 b - 6   c ) of wing  102  can be placed on posts  110  extending from platform  136 , after which the sockets  139  of platform  138  are placed on posts  110 , thereby coupling wing  102  securely between rails  114 ,  116 . Posts  106  of wing  102  extend into the recesses  124 ,  126  in platform  138 . As shown, adaptor posts  108 ,  110  may be cylindrical, oblong or rectangular posts, as shown, or a variety of other configurations, including square shapes or other designs. 
     Ultrasonic bonding of adaptor  82  to shells  84 ,  86  may occur during the ultrasonic bonding of shells  84 ,  86  to each other because compression is applied in the same direction during ultrasonic bonding. The posts, e.g.,  132  which couple shells  84 ,  86  to each other are parallel to the posts  108  which couple to adaptor  82 . Furthermore, posts  110  couple shells  84 ,  86  together and couple shells  84 ,  86  to adaptor  82 . Thus as shells  84 ,  86  are being compressed during the ultrasonic bonding thereof, adaptor  82  can be simultaneously compressed between shells  84 ,  86 . Nevertheless, the rails and adaptor may be coupled together through a variety of different means, such as trough the use of a mechanical fit, an adhesive, heat, chemicals, compression fit, screws, or a variety of other means known in the art. 
     In light of the configuration of shells  84 ,  86  and adaptor  82  it is possible to assemble card  80  using an efficient process. In one embodiment, following assembly of media jack  92  such that the cam follower is mounted therein, spring  90  is mounted on spring post  100  through an automated process, after which media jack  92  is mounted onto adaptor  82  through an automated process. 
     FIG. 4 demonstrates that, in one embodiment, the media jack/adaptor component is formed after which the component is placed into shell  86 , followed by circuit board  88 , which is placed in shell  86 , after which shell  84  is placed on top of shell  86 , sandwiching the jack/adaptor combination and circuit board  88  therebetween. In another embodiment, circuit board  88  is placed into shell  86  before the jack adaptor combination is placed in shell  86 . Once the package is assembled, it is possible to ultrasonically bond shells  84  and  86 . In one embodiment, only the rails are ultrasonically bonded and the wing  102  of the adaptor  82  is merely held in place through a mechanical coupling. 
     The combined media jack/adaptor component can be mounted on lower shell  86  through an automated process after which upper shell  84  is mated therewith, also through an automated process. It can be seen from a view of FIG. 4 that the adaptor/media jack combination can be readily mounted onto plates  84 ,  86 , which is a convenient manufacturing option. 
     Thus, in one embodiment, media jack  92  is mounted onto adaptor  82 , which is then sandwiched between shells  84 ,  86 . In another embodiment, however, adaptor  82  is sandwiched between shells  84 ,  86 , after which media jack  92  is pressed through the cavity between shells  84 ,  86  and onto adaptor  82 . 
     With reference now to FIG. 5, circuit board  88 , adaptor  82  and media jack  92  are shown as being disposed within lower shell  86  before shell  84  is placed thereon. Wing  102  of adaptor  82  is coupled to the posts  108 ,  110 , which are disposed through respective apertures. It will be appreciated that in one embodiment posts  108 ,  110  extend integrally from platform  136 . In light of the vertical relationship of posts  108 ,  110  through apertures  104 ,  105 , adaptor  82  is held between shells  84 ,  86 . 
     A variety of different means for providing communication between media jack  92  and circuit board  88  may be used in the present invention, such as flexible ribbon cable  16  of FIG. 1 or an electric or infrared sensor positioned between media jack  92  and circuit board  88 . 
     With reference now to FIGS. 6 a  through  6   c , adaptor  82  is shown. As mentioned above, adaptor  82  comprises an adaptor body  94  having a track  96  for slidably receiving a media jack  92 . Track  96  has first and second opposing slots  140 ,  142  in which tabs of media jack  92  slide. Slot  140  is defined in part by ridges  144 ,  146  of body  94 . Slot  142  is defined in part by similar ridges  148 ,  150  on an opposing side of body  94 . Tabs of media jack  92  may also be positioned outside of slots  140 ,  142  such that media jack  92  is movably mounted on track  96  and held in place by the tabs inside and outside of slots  140 ,  142 . The tabs of jack  92  may be similar or identical to tabs  28 ,  29 ,  32  and  31  discussed above with regard to FIG. 1 a , for example. 
     Cam track  98  is configured within the body  94  of adaptor  82 . The advantage of configuring the cam track  98  within body  94  is that a variety of different cam followers may be employed when coupled to media jack  92  or another media jack. 
     Cam track  98  and an associated cam follower are collectively an example of means for arresting the movement of media jack  92  along track  96 . Cam track  98  movably receives a cam follower such as cam follower  23  shown in FIG. 1 or a variety of different cam followers known in the art or yet to be produced. 
     For example, in one embodiment, the cam follower comprises a cam follower described in United States patent application to Madsen, et al., entitled “System and Apparatus for Retaining Position of Cam Follower,” filed on Nov. 30, 1998, Ser. No. 09/201,682 with the United States Patent Office, which is incorporated herein by reference. 
     In addition, a variety of different media jacks may be employed in the present invention such as the media jacks disclosed in the above referenced patent application to Madsen, et al entitled “System and Apparatus for Retaining Position of Cam Follower.” A hole in media jack  92  restrains one end of the cam follower while track  98  allows the opposing end of the cam follower to slide thereon. A cable is another example of a media jack which could be pushed onto an adaptor such as adaptor  82  and lock in a selectively moving or a static position. 
     Track  96  further has stops  152 ,  154  in respective opposing slots  140 ,  142  thereof for arresting the movement of media jack  92  past the end of track  96 . Preferably, each stop  152 ,  154  is angled so as to serve initially as a ramp as the media jack  92  is initially placed onto the track  92 . Each stop  152 ,  154  serves as another example of means for arresting the movement of the media jack along track  96 . 
     There are a variety of other examples of means for arresting the movement of the media jack along track  96 . Cam track  98  is an example of a groove for selectively arresting the movement of jack  92  when it is desired to orient jack in a retracted position. Another example of a means for arresting the movement of jack  92  is a groove formed within body  98  which selectively receives a spring-loaded latch. An example of such a latching mechanism is a one-sided barb which slides or otherwise moves into the groove and then can be removed through the use of a button which is pushed in order to unlatch the latch from the groove. Examples of other arresting means are disclosed in a U.S. patent application entitled “Multiple Use Port and Devices Interfacable Therewith,” filed on Nov. 30, 1998, Ser. No. 09/201,647, which is incorporated herein by reference. 
     Another example of the means for arresting movement of a media jack is the use of tabs oriented on the media jack which prevent the media jack from moving once all of the tabs on the jack are initially moved over stops  150 ,  152 . In this embodiment, the means for arresting the movement of the media jack allows a single one-way sliding movement onto the adaptor. As an example of this embodiment, a front and back set of tabs are disposed on the media jack and the media jack is locked in place after both sets of tabs are pushed over the stops  152 ,  154 . Another example of a means for arresting the movement of a media jack is a protuberance extending from the body of the adaptor. 
     FIG. 7 shows an extended view of a retractable media jack  92  extending from plates  84 ,  86  of communications card  80 . In the embodiment shown, an aperture  156  exists between shells for the placement of a coupler coupled to the circuit board, for example. Also as shown in FIG. 7, shells  84 ,  86  define a plane. The means for coupling wing  102  to at least one of the shells  84 ,  86 , (e.g., apertures  104 ,  105  and posts  108 ,  110 ) and preferably both shells, extends transversely to the plane of the shells  84 ,  86 . 
     A communications card incorporating the adaptor  82  and shells  84 ,  86  of the present invention is easily automatible and can be fitted to multiple devices or applications. The adaptor  82  can fit in or on a variety of different objects. It can be attached to a communications card, internally within a laptop or other computer or any other number of electronic devices. In addition, adaptor  82  can fit into a cellular phone, on a table, or on a variety of areas, as opposed to being dependent upon a certain kind of frame. With the newly invented adaptor and shell system, the number of required parts is fewer, product cost is less and manufacturing is substantially less complicated than in previous systems. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrated and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.