Patent Description:
Serial bus standards specify requirements for compliant connectors. For example, the Universal Serial Bus (USB) standard requires an interface (the portion of the connector that connects with a mating USB compliant connector) with four conductors and a shell. The USB standard also specifies that the four conductors carry signals that are serial digital communications. The serial digital communications are susceptible to signal integrity issues such as noise, cross talk, degradation due to impedances, or the like. To ensure that the signal integrity issues are minimized, the USB standard also requires that the conductors in the interface meet specified dimensions. However, from the interface to, for example, a circuit board, manufacturers can bend the conductors to meet non-standard specifications (e.g., customer's circuit board layout, chassis design, etc.) as long as the signal integrity requirements in the serial bus standards are met.

To meet the signal integrity requirements, the manufacturers typically bend the conductors in a planar curve to interface with the circuit board. The spacing may vary between the conductors along the lengths of the conductors. For example, in a portion along the conductors that is exposed, the spacing might be wider than the portion that is surrounded by a polymer (e.g., PTFE) insulator. Also, the distances along the surface of the insulator between the conductors, and the conductors and the shell, can vary. These issues can be problematic with respect to safety considerations, such as clearance or creepage distance.

Creepage distance is defined as the distance along the surface of the insulator between each of the conductors. Creepage distance is a concern because creepage distance can be the distance at which a discharge occurs between conductors for a given voltage. Discharges between conductors are undesirable due to safety issues. Although designers of circuit boards regularly specify creepage distance in board layouts, the distance between conductors in standardized serial bus connectors are typically specified to ensure signal integrity. That is, the standardized serial bus connectors are <NUM> designed to maximize data transmission rates while meeting basic safety standards. As a result, the standard serial bus connectors are not well suited for enhanced safety standards (e.g., IEC <NUM>-<NUM> (Increased Safety)) that are required in many industrial applications.

<CIT> discloses an exemplary serial bus connector.

<FIG> and <FIG> show an exemplary standard serial bus connector <NUM>. As shown in <FIG>, the standard serial bus connector <NUM> is a USB-A connector that includes conductors <NUM> that are disposed inside a shell <NUM>. The conductors <NUM> extending from the standard serial bus connector <NUM> are arranged in a parallel configuration. Due to the parallel configuration, the smallest creepage distance is between the conductors <NUM> and the shell <NUM>. As a result, if a discharge occurs, it will likely occur between the conductors <NUM> and the shell <NUM>. The pin-to-pin spacing in the parallel configuration also does not meet spacing requirements of the enhanced safety standard. Furthermore, when mounted to a PCB, the spacing is further reduced by the PCB annular rings necessary for soldering. <FIG> shows an exploded view of the standard serial bus connector <NUM> that includes an insulating body <NUM>. As can be seen, the spacing between the conductors <NUM> vary along the lengths of the conductors <NUM>. The conductors <NUM> are more likely to discharge at the minimum spacing or clearance between the exposed portions of the conductors <NUM>. The minimum creepage distance and clearance are less than those required by the enhanced safety standard. As a result, the spacing between the conductors <NUM>, as well as between the conductors <NUM> and the shell <NUM>, do not meet the enhanced safety standard requirements.

Designing proprietary connectors that meet the enhanced safety standard requirements is prohibitively expensive. For example, the proprietary design does not just require a new connector design but also corresponding inventory buildup of cables, connectors, or the like, that are able to interface with the proprietary connector. Accordingly, there is a need for an enhanced safety serial bus connector that is able to interface with standard cables or connectors.

An enhanced safety serial bus connector is provided. The enhanced safety serial bus connector comprises a shell with a first end and a second end, the first end being a terminal end of the shell and having a terminal centerline, and the second end being the lead end of the shell. The enhanced safety serial bus connector further comprises an insulating body disposed inside the shell and extending from approximately the first end to the second end and a plurality of conductors substantially disposed in the insulating body and extending from the first end to the second end, the plurality of conductors having contacts that are proximate the first end, and having contact centerlines that are substantially parallel to the terminal centerline. The plurality of conductors are arranged at the first end in a substantially planar configuration and include inner conductors and outer conductors, an inner contact width of the inner conductors being less than an outer contact width of the outer conductors. Each conductor of the plurality of conductors is spaced apart from an adjacent conductor with substantially the same creepage distance, equal to or greater than about <NUM>.

A method of forming the above mentioned enhanced safety serial bus connector is provided. According to an aspect, the method comprising forming a shell comprised of a first end and a second end; the first end being a terminal end of the shell and having a terminal centerline and the second end being the lead end of the shell. The method further comprises forming a plurality of conductors extending from the first end to the second end and arranged at the first end in a substantially planar configuration, wherein each conductor of the plurality of conductors is spaced apart with substantially the same creepage distance, equal to or greater than about <NUM>, wherein the plurality of conductors includes inner conductors and outer conductors, wherein the step of forming the plurality of conductors comprises forming the conductors with the inner conductor width of the inner conductors being less than the outer conductor width of the outer conductors.

According to an aspect, an enhanced safety serial bus connector (<NUM>), comprises: a shell (<NUM>) with a first end (<NUM>10a) and a second end (<NUM>10b); the first end (<NUM>10a) being a terminal end of the shell (<NUM>) and having a terminal centerline (CL); and the second end (<NUM>10b) being the lead end of the shell (<NUM>); an insulating body (<NUM>) disposed inside the shell (<NUM>) and extending from approximately the first end (110a) to the second end (110b); and a plurality of conductors (<NUM>) substantially disposed in the insulating body (<NUM>) and extending from the first end (<NUM>10a) to the second end (<NUM>10b), the plurality of conductors (<NUM>) having contacts (<NUM>) that: are proximate the first end (110a); and have contact centerlines (X, Y) that are substantially parallel to the terminal centerline (CL); wherein the plurality of conductors (<NUM>) are arranged at the first end (110a) in a substantially planar configuration and include inner conductors (130a, 130b) and outer conductors (130c, 130d), an inner contact width (WI) of the inner conductors (130a, 130b) being less than an outer contact width (WO) of the outer conductors (130c, 130d); characterised in that each conductor (130a-130d) of the plurality of conductors (<NUM>) is spaced apart from an adjacent conductor (130a-130d) with substantially the same creepage distance, equal to or greater than about <NUM>.

Preferably, the plurality of conductors (<NUM>) are comprised of four conductors (130a-130d), the four conductors (130a-130d) being comprised of the two inner conductors (130a-130b) with the inner contact centerlines (X) spaced from the terminal centerline (CL) by approximately <NUM>, and the two outer conductors (130c-130d) with the outer contact centerlines (Y) spaced from the terminal centerline (CL) by approximately <NUM>.

Preferably, the plurality of conductors (<NUM>) are comprised of four conductors (130a-130d), the four conductors (130a-130d) being comprised of the two inner conductors (130a-130b) with the inner contact width (WI) of approximately <NUM>, and the two outer conductors (130c-130d) with the outer contact width (WO) of approximately <NUM>.

Preferably, the plurality of conductors (<NUM>) are uniformly distributed in a surface of the insulating body (<NUM>), and extend from the surface of the insulating body (<NUM>) substantially perpendicular to the surface of the insulating body (<NUM>).

Preferably, the surface of the insulating body (<NUM>) is a lead facing surface (124a) and wherein the plurality of conductors (<NUM>) are uniformly distributed in the lead facing surface (124a).

According to an aspect, a method of forming the enhanced safety serial bus connector (<NUM>) comprises forming a shell (<NUM>) comprised of a first end (110a) and a second end (<NUM>10b): the first end (<NUM>10a) being a terminal end of the shell (<NUM>) and having a terminal centerline (CL); and the second end (<NUM>10b) being the lead end of the shell (<NUM>); and forming a plurality of conductors (<NUM>) extending from the first end (110a) to the second end (110b) and arranged at the first end (110a) in a substantially planar configuration, wherein each conductor (130a-130d) of the plurality of conductors (<NUM>) is spaced apart from an adjacent conductor (130a-130d) with substantially the same creepage distance, equal to or greater than about <NUM>, wherein the plurality of conductors (<NUM>) includes inner conductors (130a, 130b) and outer conductors (130c, 130d); wherein the step of forming the plurality of conductors (<NUM>) comprises forming the conductors (<NUM>) with the inner conductor width (WI) of the inner conductors (130a, 130b) being less than the outer conductor width (WO) of the outer conductors (130c, 130d).

Preferably, the method of forming the enhanced safety serial bus connector (<NUM>) further comprises encapsulating the plurality of conductors (<NUM>) with the insulating body (<NUM>).

Preferably, the step of encapsulating the plurality of conductors (<NUM>) comprises uniformly distributing the plurality of conductors (<NUM>) in a surface of the insulating body (<NUM>).

Preferably, the step of encapsulating the plurality of conductors (<NUM>) comprises extending the plurality of conductors (<NUM>) from a surface of the insulating body (<NUM>) in a direction that is substantially perpendicular to the surface of the insulating body (<NUM>).

<FIG> and the following description depict specific examples to teach those skilled in the art how to make and use the best mode of embodiments of an enhanced safety serial bus connector. For the purpose of teaching inventive principles, some conventional aspects have been simplified or omitted. Those skilled in the art will appreciate variations from these examples that fall within the scope of the present claims.

Those skilled in the art will appreciate that the features described below can be combined in various ways to form multiple variations of the enhanced safety serial bus connector. As a result, the embodiments described below are not limited to the specific examples described below, but only by the claims.

<FIG> shows a perspective view of an enhanced safety serial bus connector <NUM> according to an embodiment. As shown, the enhanced safety serial bus connector <NUM> includes a shell <NUM> with a first end 110a and a second end 110b. In the embodiment shown, the first end 110a is a terminal end of the shell <NUM> and the second end 110b is the lead end of the shell <NUM>. An insulating body <NUM> is disposed inside the shell <NUM> and extends from the first end 110a to the second end 110b. In alternative embodiments, the insulating body may not extend from the first end 110a to the second end 110b. Additionally or alternatively, the insulating body may be a coating or any other appropriate configuration of insulating material. In the embodiment shown, the enhanced safety serial bus connector <NUM> also includes a plurality of conductors <NUM> that are partially disposed in the insulating body <NUM>. The plurality of conductors <NUM> also extend from the first end 110a to the second end 110b. As will be explained in the following, the enhanced safety serial bus connector <NUM> shown in <FIG> substantially conforms to the serial bus standard.

The serial bus standard can be one of the USB standards, such as the USB <NUM> and USB <NUM> standards, although alternative embodiments can include other standards. The serial bus standard may include spacing specifications for conductors in a compliant serial bus connector. The serial bus standard may also define the voltage on the conductors. The voltage defined by the serial bus standard can be correlated with a minimum enhanced safety distance by referring to an enhanced safety standard. The enhanced safety standard can be any standard that is not met by the spacing specifications in the serial bus standard. For example, the standard serial bus connectors that are compliant with the USB serial bus standard do not meet the IEC <NUM>-<NUM> standard for minimum enhanced safety distance requirement. For conductors carrying five volts, the enhanced safety standard may require a creepage distance of <NUM> or more. The standard serial bus connector <NUM>, therefore, complies with the serial bus standard, but does not comply with the enhanced safety standard.

The enhanced safety serial bus connector <NUM> does not comply with the spacing specifications defined by the serial bus standard. Instead, the spacing between each of the plurality of conductors <NUM>, as well as between the plurality of conductors <NUM> and the shell <NUM>, are equal to or greater than the minimum enhanced safety distance. For example, the spacing between each of the plurality of conductors <NUM> may be about <NUM>, which meets the enhanced safety standard and is greater than the spacing in the USB standard serial bus connector of <NUM>. The enhanced safety serial bus connector <NUM> may nevertheless meet other requirements of the serial bus standard, such as compatibility with mating connectors, transmission rates, signal integrity, electromagnetic compatibility (EMC) requirements, or the like. Accordingly, the enhanced safety serial bus connector <NUM> may substantially conform to the serial bus standard while still complying with the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard, as will be described in more detail in the following.

<FIG> shows a plan view of the enhanced safety serial bus connector <NUM>. The interface end of the enhanced safety serial bus connector <NUM> is depicted. The enhanced safety serial bus connector <NUM> is shown as including the shell <NUM> with the first end 110a and the second end 110b in a USB-A style configuration. Also shown are the insulating body <NUM> and the plurality of conductors <NUM>. The plurality of conductors <NUM> is comprised of a first conductor 130a, a second conductor 130b, a third conductor 130c, and a fourth conductor 130d. Although four conductors 130a-130d are shown, more or fewer conductors may be employed in alternative embodiments. In the embodiment of <FIG>, the four conductors 130a-130d are arranged at the first end 110a in a substantially planar configuration with inner conductors 130a, 130b and outer conductors 130c, 130d.

The shell <NUM> also includes coupling tabs <NUM>. Although not shown in <FIG>, a USB standard male plug can be inserted into the shell <NUM> at the first end 110a and pressed against the coupling tabs <NUM>. The coupling tabs <NUM> are configured to press against the USB standard male plug to electrically couple the shell <NUM> to a shell on the USB standard male plug. The coupling tabs <NUM> may also mechanically couple and retain the USB standard male plug in the shell <NUM>. In addition, the plurality of conductors <NUM> can interface with corresponding conductors in the USB standard male plug. Accordingly, the enhanced safety serial bus connector <NUM> may meet transmission rates, signal integrity, EMC requirements, and other specifications in the serial bus standard. However, the plurality of conductors <NUM> are also spaced apart with a distance that is equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard, as will be explained in more detail in the following.

<FIG> shows a sectional view of the enhanced safety serial bus connector <NUM> taken at section <NUM>-<NUM> shown in <FIG>. The enhanced safety serial bus connector <NUM> includes the shell <NUM> with the first end 110a discussed in the foregoing. Due to the sectioning, the second end 110b is not shown. The shell <NUM> is also shown with the terminal centerline CL and the coupling tabs <NUM> described in the foregoing. The insulating body <NUM> is disposed in the shell <NUM> and surrounds the second conductor 130b. As can be seen in <FIG>, the shell <NUM>, the insulating body <NUM>, and the second conductor 130b are cross-sectioned.

As can be appreciated from <FIG>, the plurality of conductors <NUM> are in a coplanar curve at the interface end of the enhanced safety serial bus connector <NUM>. As can also be appreciated, the plurality of conductors <NUM> bend from the coplanar curve to a distributed configuration in the insulating body <NUM>. More particularly, the first conductor 130a, the second conductor 130b, and the fourth conductor 130d are uniformly distributed in the insulating body <NUM>. The third conductor 130c is not shown due to the sectioning, but is also uniformly distributed. The uniform distribution can ensure that the spacing between each of the plurality of conductors <NUM> is equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

<FIG> shows an exploded perspective view of the enhanced safety serial bus connector <NUM>. The enhanced safety serial bus connector <NUM> with the shell <NUM>, the insulating body <NUM>, and the plurality of conductors <NUM> is discussed in the foregoing. The insulating body <NUM> and the plurality of conductors <NUM> are shown as disposed away from the shell <NUM> for clarity.

The shell <NUM> includes the first end 110a and the second end 110b as well as ground posts <NUM>. The ground posts <NUM> can be adapted to interface and be soldered with, for example, ground traces in a circuit board. Alternative embodiments can include tabs, ridges, or other means of coupling the shell <NUM> to the board or other components. The shell <NUM> may provide grounding for the enhanced safety serial bus connector <NUM>. For example, the shell <NUM> may be comprised of a conductor, such as a tin-coated copper, that ensures the signals carried by the plurality of conductors <NUM> are not distorted, coupled to noise sources, or the like. The spacing between each of the plurality of conductors <NUM>, as well as the spacing between the plurality of conductors <NUM> and the shell <NUM>, may be determined by the insulating body <NUM>.

The insulating body <NUM> is shown as being comprised of a terminal portion <NUM> and a lead portion <NUM>. The terminal portion <NUM> is shown as disposed away from the lead portion <NUM> for clarity. The terminal portion <NUM> is adapted to couple to the lead portion <NUM>. The terminal portion <NUM> is also shown as including a first contact groove 122a, a second contact groove 122b, a third contact groove 122c, and a fourth contact groove 122d. The contact grooves 122a-122d can have dimensions that ensure that the spacing between each of the plurality of conductors <NUM> is equal to or greater than the minimum enhanced safety distance requirement. The insulating body <NUM> can also mechanically support the plurality of conductors <NUM>.

The plurality of conductors <NUM> includes contacts <NUM> and leads <NUM>. The contacts <NUM> are adapted to electrically couple to corresponding contacts in the USB standard male connector described in the foregoing. The each of the plurality of conductors <NUM> are adapted to fit within the contact grooves 122a-122d when the enhanced safety serial bus connector <NUM> is assembled. The dimensions of the contact grooves 122a-122d can be selected such that the contacts <NUM> are pressed against the corresponding contacts in the USB standard male plug with a desired force. Selecting the desired force may include considerations of the pressure that allows a desired transmission rate, which may be a transmission rate specified by the serial bus standard, for the dimensions of the contacts <NUM>. The dimensions of the plurality of conductors <NUM> can be determined when the plurality of conductors <NUM> are formed prior to being encapsulated by the insulating body <NUM>, as will be described in the following with reference to <FIG> and <FIG>.

<FIG> shows the lead portion <NUM> encapsulating the plurality of conductors <NUM>. The lead portion <NUM> is shown with a lead facing surface 124a. As can be seen, the plurality of conductors <NUM> extending from the lead facing surface 124a are substantially perpendicular to the lead facing surface 124a. Each of the plurality of conductors <NUM>, which are shown as the first through the fourth conductors 130a-130d, include the contacts <NUM>. In the embodiment shown, the contacts <NUM> comprise the first through the fourth contacts 132a-132d. The lead portion <NUM> also includes an interface facing surface 124b that is adapted to interface with the terminal portion <NUM> of the insulating body <NUM>. An end plate 124c is shown as formed integrally in the interface facing surface 124b.

The leads <NUM> extend from the interface facing surface 124b in a direction that is substantially perpendicular to the interface facing surface 124b. As can also be seen, the leads <NUM> are oriented in a direction perpendicular to the contacts <NUM>. For example, the contacts <NUM> extend parallel to the terminal centerline CL. The leads <NUM> extend perpendicular to the terminal centerline CL. As can also be seen, the leads <NUM> are uniformly distributed within the lead facing surface 124a of the insulating body <NUM>. That is, in contrast to the parallel arrangement of the conductors <NUM> in the prior art, the plurality of conductors <NUM> are uniformly distributed within the lead facing surface 124a. The uniform distribution of the plurality of conductors <NUM> can ensure that the distances between each of the plurality of conductors <NUM>, as well as between the plurality of conductors <NUM> and the shell <NUM>, is equal to or greater than a minimum enhanced safety distance requirement for the voltage defined by the serial bus standard. For example, the distances between each of the leads <NUM> can be determined by the spacing between annular rings on a circuit board such that the creepage distance between the annular rings is equal to or greater than the minimum enhanced safety distance requirement. As can be appreciated, the distances between each of the plurality of conductors <NUM> can be determined when the plurality of conductors <NUM> are formed.

<FIG> shows the plurality of conductors <NUM> without the insulating body <NUM>. The plurality of conductors <NUM> include the first through fourth conductors 130a-130d. Also shown are the contacts <NUM>, which include the first through fourth contacts 132a-132d. The plurality of conductors <NUM> are also shown with the leads <NUM>, which includes the first through fourth leads 134a-134d. The contacts <NUM> are shown as coupled to an assembly strip <NUM>. The assembly strip <NUM> is shown in phantom lines to illustrate that the assembly strip <NUM> may be discarded after the plurality of conductors <NUM> are formed.

As can be seen, each of the plurality of conductors <NUM> are spaced from an adjacent conductor 130a-130d. The spacing between each of the plurality of conductors <NUM> may substantially conform to spacing requirements of the serial bus standard, which can define the voltage on the plurality of conductors <NUM>. The spacing between each of the plurality of conductors <NUM> can also be equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard. For example, the spacing between each of the plurality of conductors <NUM> may be <NUM>, which meets the enhanced safety standard and is greater than the spacing in the USB standard serial bus connector of <NUM>. As can be appreciated, the spacing between each of the plurality of conductors <NUM> can be determined when the plurality of conductors <NUM> are formed, which can include the spacing between each of the plurality of conductors <NUM> at the interface of the enhanced safety serial bus connector <NUM>.

<FIG> shows a block diagram of the interface of the enhanced safety serial bus connector <NUM> and the standard serial bus connector <NUM> to compare the spacing at the interface. The enhanced safety serial bus connector <NUM> is shown as coaxially aligned with the standard serial bus connector <NUM>. The terminal centerline CL extends from the enhanced safety serial bus connector <NUM> and over the standard serial bus connector <NUM>. The conductors <NUM> in the standard serial bus connector <NUM> are shown as having inner contact centerlines PX and outer contact centerlines PY. As can be appreciated, the conductors <NUM> have the same width, which may be <NUM>.

As shown in <FIG>, the plurality of conductors <NUM> in the enhanced safety serial bus connector <NUM> include the four conductors 130a-130d. The plurality of conductors <NUM> include inner conductors 130a-130b with inner contact centerlines X. The plurality of conductors <NUM> also include outer conductors 130c-130d with outer contact centerlines Y. It can be seen that the inner contact centerlines X in the enhanced safety serial bus connector <NUM> are further away from the terminal centerline CL than the prior art inner contact centerlines PX. In addition, the inner conductors 130a-130b have an inner contact width WI that is smaller than the outer contact width WO.

As can also be seen by comparing the standard serial bus connector <NUM> and the enhanced safety serial bus connector <NUM>, although the inner contact width WI may not be in compliance with the serial bus standard, the inner two of the conductors <NUM> of the standard serial bus connector <NUM> and the inner conductors 130a-130b of the enhanced safety serial bus connector <NUM> have some overlapping surfaces. As a result, the plurality of conductors <NUM> can interface with corresponding conductors in a USB standard male interface. Accordingly, the enhanced safety serial bus connector <NUM> can substantially conform to the spacing requirements of the serial bus standard.

Although the outer conductors 130c-130d are shown as having the same width and displaced from the centerline CL by approximately the same distance, outer conductors in alternative embodiments may have different widths and be spaced differently than the outer two of the conductors <NUM>. In the embodiment shown, the widths of the conductors <NUM> in the standard serial bus connectors <NUM> may be <NUM> wide. The outer conductors 130c-130d in the enhanced safety serial bus connector <NUM> can also be about <NUM>. However, the inner conductors 130a-130b can be <NUM> wide, which is less than the width of the inner two of the conductors <NUM>. In some embodiments, the outer conductors 130c-130d can be <NUM> wide. As a result, the spacing between the plurality of conductors <NUM> may be equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

For example, in the embodiment shown, the serial bus standard may require voltages on the plurality of conductors <NUM> to be five volts. An enhanced safety standard for the five volts on the conductors may require that the creepage distance between each of the plurality of conductors <NUM> be equal to or greater than about <NUM>. The different distances of the contact centerlines X, Y in the enhanced safety serial bus connector <NUM> and the contact centerlines PX, PY in the standard serial bus connector <NUM>, as well as the difference between the widths of the conductors <NUM> in the standard serial bus connector <NUM> and the widths WI,WO of the plurality of conductors <NUM>, can allow the spacing between each of the enhanced safety serial bus connector <NUM> to be equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

In addition, the distances between the terminal centerline CL and the contact centerlines X, Y may not be within the range specified by the serial bus standard that defines a voltage on the plurality of conductors <NUM>. For example, the distance of the prior art inner contact centerline PX of the inner two of the conductors <NUM> from the terminal centerline CL in the standard serial bus connector <NUM> may be explicitly limited to <NUM> ± <NUM> (<NUM> to <NUM>). The distance of the inner contact centerline X of the inner conductors 130a-130b in the enhanced safety serial bus connector <NUM> may be specified <NUM> ± <NUM> (<NUM> to <NUM>). Similarly, the widths of each of the plurality of conductors <NUM> may not be within the range specified by the serial bus standard. For example, the inner conductors 130a-130b may be specified at <NUM> ± <NUM> (<NUM> to <NUM>). The outer conductors 130c-130d can have widths of <NUM> ± <NUM> (<NUM> to <NUM>). The serial bus standard may require that the widths of the conductors <NUM> be <NUM> ± <NUM> (<NUM> to <NUM>). Accordingly, the distances between the terminal centerline CL and the contact centerlines X, Y, as well as the widths WI, WO of each of the plurality of conductors <NUM>, may not be within the ranges specified by the serial bus standard.

Although the dimensions of the plurality of conductors <NUM> may not be within the ranges specified by the serial bus standard, the enhanced safety serial bus connector <NUM> can substantially conform to spacing requirements of the serial bus standard that defines the voltage on the plurality of conductors <NUM>. For example, even though the dimensions of the plurality of conductors <NUM> may not be the same as the conductors <NUM>, the contacts <NUM> may nevertheless couple to the USB standard male plug. As a result, the enhanced safety serial bus connector <NUM> can meet the enhanced safety distance requirement while still substantially complying with the serial bus standard. For example, the enhanced safety serial bus connector <NUM> may substantially conform to the serial bus standard by allowing the data to transmit between, for example, the USB standard male connector and the enhanced safety serial bus connector <NUM>. With the interface of the enhanced safety serial bus connector <NUM> described, we now turn to the lead portion of the enhanced safety serial bus connector <NUM>.

<FIG> shows a plan view of the enhanced safety serial bus connector <NUM>. As shown, the enhanced safety serial bus connector <NUM> includes the plurality of conductors <NUM>, which is comprised of the first through fourth conductors 130a-130d. The shell <NUM> surrounds the insulating body <NUM>. The shell <NUM> also includes the ground posts <NUM>. As shown in <FIG>, the second end 110b of the shell <NUM> illustrates the creepage distances between each of the plurality of conductors <NUM>, as well as the creepage distances between each of the plurality of conductors <NUM> and the ground posts <NUM>. The terminal centerline CL is shown as extending through the center of the enhanced safety serial bus connector <NUM> at both the first end 110a and the second end 110b.

As can be seen, the plurality of conductors <NUM> are uniformly distributed in the insulating body <NUM> at the second end 110b. As a result, the creepage distances between each of the plurality of conductors <NUM> is substantially the same. The creepage distances being substantially the same can ensure that the minimum spacing is equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard. However, in alternative embodiments, the creepage distances between each of the plurality of conductors <NUM> may not be substantially the same, but still meet the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

As can also be appreciated, the second end 110b also has creepage distances between each of the plurality of conductors <NUM> and the ground posts <NUM>. For example, the distances between the third conductor 130c and the ground posts <NUM> that are proximate the third conductor 130c are about the same. The distances between each of the plurality of conductors <NUM> and the proximate ground posts <NUM> can also ensure that the creepage distance is equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

The enhanced safety serial bus connector <NUM> can be formed by a variety of methods. For example, as shown in <FIG>, the plurality of conductors <NUM> may be formed when the assembly strip <NUM> is, for example, moved through one or more forming tools or any other appropriate device that can form the plurality of conductors <NUM>. Prior to forming the plurality of conductors <NUM>, the assembly strip <NUM> may be comprised of a blank strip of material. A flat stamped version of the plurality of conductors <NUM> can be formed by stamping the assembly strip <NUM> as the assembly strip <NUM> is, for example, moved through the one or more forming machines. The flat stamped plurality of conductors <NUM> can be bent into the shape shown in <FIG> by, for example, sequentially bending each of the plurality of conductors <NUM>. However, other methods may be employed to form the plurality of conductors <NUM>.

The plurality of conductors <NUM> can be inserted into an injection molding machine that encapsulates a portion of the plurality of conductors <NUM>. For example, the plurality of conductors <NUM>, which are flat stamped and bent into the shape as shown in <FIG>, can be encapsulated by the lead portion <NUM> of the insulating body <NUM> with an injection molding machine. Accordingly, the plurality of conductors <NUM> extending from the lead facing surface 124a can be uniformly distributed prior to being encapsulated by the shell <NUM>. The insulating body <NUM> can be sufficiently rigid to ensure that, during subsequent manufacturing processes, the plurality of conductors <NUM> remain uniformly distributed. For example, when the shell <NUM> is encapsulated around the insulating body <NUM>, the insulating body <NUM> can prevent the encapsulation from displacing the plurality of conductors <NUM>.

When the shell <NUM> is encapsulated over the insulating body <NUM>, the distances between the shell <NUM> and the plurality of conductors <NUM> can also be equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard. For example, the lead facing surface 124a of the insulating body <NUM> can be sized to ensure that the creepage distances between each of the plurality of conductors <NUM> and the ground posts <NUM> is equal to or greater than the minimum enhanced safety distance requirement for the voltage defined by the serial bus standard.

The embodiments described above provide an enhanced safety serial bus connector <NUM>. As explained above, the enhanced safety serial bus connector <NUM> may substantially conform to the serial bus standard. For example, the enhanced safety serial bus connector <NUM> may include a plurality of conductors <NUM> where each of the conductors 130a-130d are spaced apart from an adjacent conductor 130a-130d with a distance that substantially conforms to spacing requirements of the serial bus standard. As a result, the contacts <NUM> can transmit data with a USB standard male plug connector at a rate specified by the serial bus standard while still meeting the enhanced safety distance requirement.

The enhanced safety serial bus connector <NUM> can both substantially conform to the spacing requirements of the serial bus standard and comply with the minimum enhanced safety distance requirement. For example, the plurality of conductors <NUM> may include contact widths WI, WO that are less than the width specified by the serial bus standard. The plurality of conductors <NUM> can also be spaced from the terminal centerline CL at distances that are greater than corresponding distances defined in the serial bus standard. Additionally or alternatively, each of the plurality of conductors <NUM> can also be uniformly distributed in a surface of an insulating body <NUM>. Accordingly, the creepage distance between each of the plurality of conductors <NUM> may be greater than the minimum enhanced safety distance.

As a result of having the plurality of conductors <NUM> that are spaced apart with a distance that substantially conforms to the spacing requirements of the serial bus standard, existing manufacturing tools can be used to form the enhanced safety serial bus connector <NUM>. This can reduce the costs of implementing the enhanced safety serial bus connector <NUM> over a completely new proprietary design. In addition, the enhanced safety serial bus connector <NUM> is compatible with standard connectors that are in compliance with the serial bus standard. This ensures that existing inventory of cables and connectors can still be used while the enhanced safety serial bus connector <NUM> complies with the enhanced safety standard. Accordingly, the enhanced safety serial bus connector <NUM> can be inexpensively designed and incorporated into industrial products that meet the enhanced safety standard.

The detailed descriptions of the above embodiments are not exhaustive descriptions of all embodiments contemplated by the inventors to be within the scope of the following claims.

Indeed, persons skilled in the art will recognize that certain elements of the above-described embodiments may variously be combined or eliminated to create further embodiments, and such further embodiments fall within the scope of the following claims.

It will also be apparent to those of ordinary skill in the art that the above-described embodiments may be combined in whole or in part to create additional embodiments within the scope of the following claims.

Claim 1:
An enhanced safety serial bus connector (<NUM>), comprising:
a shell (<NUM>) with a first end (<NUM>10a) and a second end (110b);
the first end (<NUM>10a) being a terminal end of the shell (<NUM>) and having a terminal centerline (CL); and
the second end (<NUM>10b) being the lead end of the shell (<NUM>);
an insulating body (<NUM>) disposed inside the shell (<NUM>) and extending from approximately the first end (<NUM>10a) to the second end (110b); and
a plurality of conductors (<NUM>) substantially disposed in the insulating body (<NUM>) and extending from the first end (<NUM>10a) to the second end (110b), the plurality of conductors (<NUM>) having contacts (<NUM>) that:
are proximate the first end (<NUM>10a); and
have contact centerlines (X, Y) that are substantially parallel to the terminal centerline (CL);
wherein the plurality of conductors (<NUM>) are arranged at the first end (<NUM>10a) in a substantially planar configuration and include inner conductors (130a, 130b) and outer conductors (130c, 130d), an inner contact width (WI) of the inner conductors (130a, 130b) being less than an outer contact width (WO) of the outer conductors (130c, 130d); characterised in that each conductor (130a-130d) of the plurality of conductors (<NUM>) is spaced apart from an adjacent conductor (130a-130d) with substantially the same creepage distance, equal to or greater than about <NUM>.