Patent Publication Number: US-7707719-B2

Title: Method for protecting contacts within a connector assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a Divisional of U.S. utility application entitled “Connector Insert for Preventing Contamination” having Ser. No. 11/015,403, filed on Dec. 17, 2004 now U.S. Pat. No. 7,217,146, which is entirely incorporated herein by reference. 

   TECHNICAL FIELD 
   The present invention relates to the field of connectors and, more particularly, relates to preventing contamination of the contacts of the connector during the manufacturing process. 
   BACKGROUND OF THE INVENTION 
   Electronic devices typically include various types of receptacle-type connector assemblies which are installed during the manufacturing of the electronic device. For example, a computer or set-top box may include 1394 ports, sometimes referred to as “firewire” ports, or USB ports. Also, a newer connector, referred to as a HDMI (High Definition Multimedia Interface) connector assembly, integrates audio and video information into a single digital interface to be used with, for example, digital video disc (DVD) players, digital television (DTV), high definition TV (HDTV), set-top boxes, and other audio and/or video devices. Connectors such as these include contacts within the receptacle housing of the connector assembly. These contacts are typically made of gold and may easily become contaminated during the manufacturing of the electronic device. The HDMI connector, in particular, allows contamination to pass into the receptacle housing of the connector assembly through openings in the bottom of the receptacle housing. These openings in the bottom of the receptacle housing define resilient tabs that are utilized to retain the corresponding plug-type connector within the receptacle housing. This contamination often occurs from liquid flux, paste or solder that seeps, bubbles, wicks or splashes into the connector assembly through these openings or elsewhere in the receptacle housing while the connector assembly is soldered to an electrical board. 
   Consequently, these electronic devices fail because of the contaminated connector assemblies. The contaminated connector assemblies require replacing by hand which results in a costly rework of the electronic device. Therefore, what is needed is a means to protect the connector assembly&#39;s contacts from contamination during the manufacturing process. 

   
     BRIEF DISCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a perspective view of one embodiment of an insert configured to be received within the receptacle housing of a connector assembly. 
       FIG. 2  illustrates the insert of  FIG. 1  received within the connector assembly according to the present invention. 
       FIG. 3  illustrates is a cross-section view of the insert within the connector assembly taken along lines  3 - 3  of  FIG. 2   
       FIG. 4  illustrates an end view of one embodiment of the insert of the present invention. 
       FIG. 5  illustrates a bottom view of one embodiment of the insert of the present invention. 
   

   DETAILED DESCRIPTION 
   The present invention will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which an exemplary embodiment of the invention is shown. This invention may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, the embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The present invention is described more fully hereinbelow. 
     FIG. 1  illustrates a perspective view of one embodiment of an insert  10  to be received and retained within a receptacle housing  12  of a connector assembly  14 . The connector assembly  14  in  FIGS. 1-3  generally depict a HDMI connector assembly which is for illustrative purposes only. The insert  10  of the present invention may be used with any type of connector assembly where it is desirable to prevent contacts within a receptacle housing from becoming contaminated.  FIGS. 2 and 3  illustrate the insert  10  received and retained within the receptacle housing  12  of the connector assembly  14  to prevent contamination of electrical contacts  20 . 
   As best shown in  FIG. 1 , the electrical contacts  20  are positioned along both sides of a central tongue portion  24 . The tongue portion  24  is interposed between the contacts  20 . The distal ends of the contacts  20  correspond with the distal end of the tongue portion  24 . The receptacle housing  12  also includes a plurality of outwardly extending feet  26  which are utilized to secure the connector assembly  14  to an electrical board (not shown). Once these feet  26  are positioned in corresponding openings in an electrical board during the manufacturing process, the electrical board is passed through a hot bath of solder where the solder and liquid flux may pass through openings  30  defined on the top and bottom of the receptacle housing  12  of the connector assembly  14 . Typically, these openings  30  define resilient tabs  32  which are used to retain the corresponding plug-type connector (not shown) within the receptacle housing  12  of the connector assembly  14 . However, contamination other than solder and liquid flux may contaminate the contacts  20  which may pass into the receptacle housing  12  through other means during the manufacturing process as well as during shipment of the electrical devices. 
   The insert  10  may itself be referred to as a plug or connector, but the insert  10  does not have electrical components to make an electrical connection with any connector assembly such as connector assembly  14 . The insert  10  is preferably made of Pollybutylene Terephalateor, commonly referred to as PBT (30% glass filled), with a UL rating of UL94V-0, or some other suitable material such as a heat resistant plastic. As best shown in  FIG. 4 , at least part of a body portion  40  of the insert  10  is configured or keyed to be received within the receptacle housing  12  and also has a central opening  42  configured or keyed to protect at least portions of the contacts  20  around the central tongue portion  24 . Preferably, the exterior of the body portion  40  conforms to the inner confines of the receptacle housing  12  and the opening  42  of the body portion  40  conforms to the contacts  20 . 
   In one embodiment, the body portion  40  obstructs contaminates from passing through the openings  30  as well as through the front face of the connector assembly  14  when the body portion  40  is within the receptacle housing  12 . In another embodiment, the body portion  40  is configured to be received and retained only within a lower portion of the receptacle housing  12  below the tongue portion  24  such that any openings  30  on the bottom of the receptacle house  12  are blocked to prevent contamination, while any openings  30  on the top of the receptacle housing  12  above the tongue portion  24  remain unobstructed. 
   For example, in one embodiment, if the connector assembly  14  is a HDMI connector, the bottom edges of the body portion  40  are truncated or arched inward as best seen from the end view shown in  FIG. 4 . The bottom edges of the opening  42  are preferably also truncated or arched inward in order to accommodate the contacts  20  and tongue portion  24  while the exterior of the insert  10  mattingly corresponds with the interior of the receptacle housing  12 . However, the opening  42  and the exterior of the body portion  40  of the insert  10  may be configured differently depending upon the type of the connector assembly the insert is intended to be used with. 
   In one embodiment for use with a HDMI connector assembly, the body portion  40  has a height x of approximately 0.175 inches which allows the insert  10  to be received and retained within the receptacle housing  12  in a secure manner. The depth of the opening  42  through the body portion  40  could be any depth suitable for receiving the contacts  20  and central tongue portion  24 . For example, the depth of the opening  42  could be approximately 0.275 inches. Also, for example, the height y of the opening  42  could be approximately 0.054 inches in order to satisfactorily accommodate the contacts  20  and the central tongue portion  24 .  FIG. 4  best illustrates the proximal end of the insert  10  having height x and an opening with height y. 
     FIGS. 4 and 5  also illustrate a width w of the body portion  40 . In one embodiment, such as when the insert  10  is used with a HDMI connector, the overall width of the body portion  40  is approximately 0.547 inches. The opening  42 , on the other hand, has a width z as shown in  FIG. 4  which is approximately 0.452 inches. 
   In one embodiment, when the insert  10  is received and retained within the receptacle housing  12  of the connector assembly  14 , the body portion  40  has a length which allows it to extend outward from the face of the connector assembly  14  as shown in  FIGS. 1-3 . This allows the insert  10  to be more easily withdrawn from the connector assembly  14  by allowing the body portion  12  itself to be grasped by hand or by a tool. Preferably, however, the insert  10  also includes an elongated portion  46  as best shown in  FIG. 5  which outwardly extends from the body portion  40  to facilitate withdrawal of the insert  10  from the connector assembly  14 . The elongated portion  46  may be any length, but is preferably a length which permits itself to be grasped by hand or by a tool.  FIG. 5  also illustrates the elongated portion  46  having a width d relative the body portion  40 . The width d could be, for example, approximately 0.25 inches. The elongated portion  46  may be also utilized for facilitating the insertion of the insert  10  within the receptacle housing  12  in a secured manner. 
   In another embodiment, the insert  10  may include only the body portion  40  and therefore have no elongated portion  46 . In such case, the body portion  40  may include a recessed portion or other means suitable for allowing the body portion  40  to be hooked or otherwise grasped with a tool so that the insert  10  may be withdrawn from the connector assembly  14 . In yet another embodiment, the insert may include a withdraw strap that outwardly extends from the body portion  40 . In any case, to facilitate a low profile design, nothing extends significantly beyond the exterior of the connector assembly  14 , such as an electrical cord, when the connector assembly  14  with insert  10  is installed in an electrical device. 
   The elongated portion  46  may include one or more friction bearing surfaces to further facilitate the withdrawal of the insert  10  from the connector assembly  14 . For example, one or more divots  48  on the surface of the elongated portion  46  may allow the insert  10  to be more easily grasped by the fingers.  FIGS. 1-3  and  5  show a pair of divots  48  displaced from one another, on one side of the elongated portion  46 , and adjacent the distal end of the elongated portion  46 . 
   The foregoing has broadly outlined some of the more pertinent aspects and features of the present invention. These should be construed to be merely illustrative of some of the more prominent features and applications of the invention. Other beneficial results can be obtained by applying the disclosed information in a different manner or by modifying the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding of the invention may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope of the invention defined by the claims.