PATENT DOCUMENT

Publication Number: US-9780484-B2
Application Number: US-201213584769-A
Country: US
Kind Code: B2

Title: Magnetic arrangements and labels for connectors

Abstract:
Magnetic connectors that may be readily manufactured and provide a high landed force and labels for magnetic connectors that may protect magnets or magnetic elements in the connectors, provide an aesthetically pleasing appearance, and improve the magnetic performance of the connectors. In various examples, power and signal paths may be formed using contacts that are separate from magnets or magnetic elements, paths may be formed using magnets or magnetic elements, or paths may be formed using a combination of contacts and magnets and magnetic elements. The magnets may have various arrangements. One or more magnets may be used in conjunction with magnetic elements. The interface surface of these magnets and magnetic elements may have various contours, such as flat, spline, or involute.

Claims:
What is claimed is: 
     
       1. A method of assembling a connector comprising:
 providing a first magnet and a second magnet; 
 orienting the first magnet and the second magnet such that their magnetic field lines are in opposing directions; 
 placing the first magnet and the second magnet in a housing; and 
 attaching a label to the first magnet and attaching the label to the second magnet near an opening in the housing such that the label is positioned between the first magnet and a corresponding connector and between the second magnet and the corresponding connector when the connector and the corresponding connector are mated, the label comprising:
 a first magnetically conductive portion; 
 a second magnetically conductive portion; 
 a magnetically less conductive portion between the first magnetically conductive portion and the second magnetically conductive portion; and 
 an opening forming a passage through the label. 
 
 
     
     
       2. The method of  claim 1  wherein attaching the label comprises attaching a label using a layer of adhesive to attach the label to the first magnet and to attach the label to the second magnet. 
     
     
       3. The method of  claim 1  wherein the first and second magnetically conductive portions are steel. 
     
     
       4. The method of  claim 1  wherein attaching the label comprises attaching a label formed of a resin that contains magnetically conductive particles. 
     
     
       5. The method of  claim 1  wherein the first magnetically conductive portion is at least approximately aligned with the first magnet, and the second magnetically conductive portion is at least approximately aligned with the second magnet. 
     
     
       6. The method of  claim 5  wherein the label has a thickness between 0.05 and 0.2 mm, such that stray flux is reduced, but a magnetic field at a front of the label is not reduced beyond a desirable level, and the magnets are physically protected. 
     
     
       7. The method of  claim 5  wherein the label has a thickness between 0.05 and 0.2 mm. 
     
     
       8. The method of  claim 5  wherein the label is formed of resin containing magnetically conductive particles in the first magnetically conductive portion and the second magnetically conductive portion. 
     
     
       9. The method of  claim 8  wherein the label has substantially no magnetically conductive particles in the magnetically less conductive portion. 
     
     
       10. The method of  claim 1  wherein the label is at least substantially formed of polycarbonate containing iron powder. 
     
     
       11. The method of  claim 5  wherein the label is formed of polycarbonate containing iron powder in the first magnetically conductive portion and the second conductive portion. 
     
     
       12. The method of  claim 11  wherein the label has substantially no iron powder in the magnetically less conductive portion. 
     
     
       13. The method of  claim 5  wherein the label is attached to the first and second magnets by a magnetic field. 
     
     
       14. The method of  claim 5  wherein the adhesive is glue. 
     
     
       15. The method of  claim 5  wherein the label is attached by being applied as a coating to a surface of the first magnet and the second magnet. 
     
     
       16. The method of  claim 5  wherein the first magnetically conductive portion conveys power and the second magnetically conductive portion conveys ground. 
     
     
       17. The method of  claim 5  wherein the connector is a receptacle. 
     
     
       18. The method of  claim 17  further comprising:
 providing a third magnet and a fourth magnet; 
 orienting the third magnet and the fourth magnet such that their magnetic field lines are in opposing directions; 
 placing the third magnet and the fourth magnet in the housing. 
 
     
     
       19. The method of  claim 18  wherein attaching the label further comprises attaching the label further comprising:
 a third magnetically conductive portion at least approximately aligned with the third magnet, 
 a fourth magnetically conductive portion at least approximately aligned with the fourth magnet; and 
 a second magnetically less conductive portion between the third magnetically conductive portion and the fourth magnetically conductive portion. 
 
     
     
       20. The method of  claim 19  wherein at least one conductive portion may convey power and at least one conductive portion may convey ground. 
     
     
       21. The method of  claim 20  wherein at least one conductive portion may convey a signal. 
     
     
       22. A connector comprising:
 a first magnet; 
 a second magnet, the first magnet and the second magnet oriented such that their magnetic field lines are in opposing directions; 
 a housing supporting the first magnet and the second magnet; 
 a label attached to the first magnet and the second magnet near an opening in the housing such that the label is positioned between the first magnet and a corresponding connector and between the second magnet and the corresponding connector when the connector and the corresponding connector are mated, the label comprising:
 a first magnetically conductive portion; 
 a second magnetically conductive portion; 
 a magnetically less conductive portion between the first magnetically conductive portion and the second magnetically conductive portion; and 
 an opening forming a passage through the label. 
 
 
     
     
       23. The connector of  claim 22  further comprising a layer of adhesive between the label and the first magnet and between the label and the second magnet. 
     
     
       24. The connector of  claim 22  wherein the first and second magnetically conductive portions are steel. 
     
     
       25. The connector of  claim 22  wherein the label comprises a label formed of a resin that contains magnetically conductive particles. 
     
     
       26. The connector of  claim 22  wherein the first magnetically conductive portion is at least approximately aligned with the first magnet and the second magnetically conductive portion is at least approximately aligned with the second magnet. 
     
     
       27. The connector of  claim 26  wherein the label has a thickness between 0.05 and 0.2 mm, such that stray flux is reduced, but a magnetic field at a front of the label is not reduced beyond a desirable level, and the magnets are physically protected. 
     
     
       28. The connector of  claim 26  wherein the label has a thickness between 0.05 and 0.2 mm. 
     
     
       29. The connector of  claim 26  wherein the label is formed of resin containing magnetically conductive particles in the first magnetically conductive portion and the second magnetically conductive portion. 
     
     
       30. The connector of  claim 29  wherein the label has substantially no magnetically conductive particles in the magnetically less conductive portion. 
     
     
       31. The connector of  claim 22  wherein the label is at least substantially formed of polycarbonate containing iron powder. 
     
     
       32. The connector of  claim 26  wherein the label is formed of polycarbonate containing iron powder in the first magnetically conductive portion and the second conductive portion. 
     
     
       33. The connector of  claim 32  wherein the label has substantially no iron powder in the magnetically less conductive portion. 
     
     
       34. The connector of  claim 26  wherein the label is attached to the first and second magnets by a magnetic field. 
     
     
       35. The connector of  claim 26  wherein the label is glued to the first and second magnets by a layer of adhesive. 
     
     
       36. The connector of  claim 26  wherein the label is attached by being applied as a coating to a surface of the first magnet and the second magnet. 
     
     
       37. The connector of  claim 26  wherein the first magnetically conductive portion conveys power and the second magnetically conductive portion conveys ground. 
     
     
       38. The connector of  claim 26  wherein the connector is a receptacle. 
     
     
       39. The connector of  claim 38  further comprising:
 a third magnet and a fourth magnet oriented such that their magnetic field lines are in opposing directions, 
 wherein the third magnet and the fourth magnet are supported by the housing. 
 
     
     
       40. The connector of  claim 39  wherein the label further comprises:
 a third magnetically conductive portion at least approximately aligned with the third magnet, 
 a fourth magnetically conductive portion at least approximately aligned with the fourth magnet; and 
 a second magnetically less conductive portion between the third magnetically conductive portion and the fourth magnetically conductive portion. 
 
     
     
       41. The connector of  claim 40  wherein at least one conductive portion may convey power and at least one conductive portion may convey ground. 
     
     
       42. The connector of  claim 41  wherein at least one conductive portion may convey a signal. 
     
     
       43. The connector of  claim 26  wherein the opening is located between the first magnetically conductive portion and the second magnetically conductive portion of the label. 
     
     
       44. The connector of  claim 43  further comprising a plurality of contacts, wherein the opening allows access to the contacts by the corresponding connector. 
     
     
       45. A connector comprising:
 a first magnet; 
 a second magnet, the first magnet and the second magnet oriented such that their magnetic field lines are in opposing directions; 
 a housing supporting the first magnet and the second magnet; 
 a label attached to the first magnet and the second magnet near an opening in the housing such that the label is positioned between the first magnet and a corresponding connector and between the second magnet and the corresponding connector when the connector and the corresponding connector are mated, the label comprising:
 a first magnetically conductive portion; 
 a second magnetically conductive portion separate from the first magnetically conducive portion; and 
 a magnetically less conductive portion between and separating the first magnetically conductive portion and the second magnetically conductive portion.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional patent application No. 61/522,620, filed Aug. 11, 2011, which is incorporated by reference. 
    
    
     BACKGROUND 
     The number and types of electronic devices available to the public has increased tremendously the past few years, and this increase shows no signs of abating. Devices such as portable computing devices, tablet, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors and other devices have become ubiquitous. 
     These devices often receive power and share data using various cables. These cables may have connector inserts, or plugs, on each end. The connector inserts may plug into connector receptacles on electronic devices, thereby forming one or more conductive paths for signals and power. 
     These inserts and receptacles may be magnetic, where an insert is held in place in a receptacle by magnetic attraction. To avoid inadvertent disconnections, it may be undesirable for an insert to be easily removed from a receptacle. Accordingly, it may be desirable to provide configurations for magnets in these connectors that provide a high holding power. To reduce costs, it may be desirable that the connectors be simple to manufacture. 
     Also, these connector inserts may be left in place for long periods of time. In other applications though, a cable may be disconnected from an electronic device on a regular basis. This may lead to wear, damage, or abrasions on or in the connector inserts and receptacles. For these reasons, it may be desirable to protect the connectors from wear and other damage. 
     A user&#39;s experience in connecting and disconnecting these cables may do a lot to inform the user&#39;s opinion of the device itself. Accordingly, it may be desirable to provide connectors that function well and provide an improved performance. 
     Thus, what is needed are magnet configurations for connectors that provide a high holding force and are simple to manufacture, and labels that may further improve holding power, protect the connectors, and improve connector performance. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide arrangements for magnets for connectors that have a high holding strength and are easy to manufacture, and labels that further improve holding power, protect the connectors, and improve connector performance. 
     Various embodiments of the present invention may provide magnetic connectors that provide various electrical pathways. In some embodiments of the present invention, paths for power and ground supplies may be provided by a magnetic connector. In other embodiments, one or more signal lines for data communication, connection detection, or other purpose, may be included. These one or more signal lines may be electronic or optical. In various embodiments of the invention, combinations of some or all of these signals may be conveyed in some or all of these ways. 
     In various embodiments of the present invention, these pathways may be provided using one or more contacts on a connector insert that aligns with a corresponding connector on a connector receptacle. For example, these pathways may be provided using contacts surrounded by one or more magnets or magnetic elements. In other embodiments of the present invention, the magnets or magnetic elements may be used to provide power and signal pathways. In still other embodiments of the present invention, one or more contacts and one or more magnets or magnetic elements may be used to provide power or signal pathways. 
     In various embodiments of the present invention, different types and numbers of magnets or magnetic elements may be used. An illustrative embodiment of the present invention may provide a magnetic connector system where one or more magnets are located in a connector receptacle, while one or more attraction plates, which may be made of a ferro-magnetic material, may be located in a corresponding connector insert. In other embodiments of the present invention, one or more magnets may be located in a connector insert and one or more attraction plates may be located in a corresponding connector receptacle. In still other embodiments, one or more magnets may be located in both a connector insert and a connector receptacle. 
     Embodiments of the present invention may provide connectors having magnets and magnetic elements in various arrangements. One illustrative embodiment of the present invention may provide a number of magnets, where one or more magnets include openings to allow passageways for one or more power, ground, or signal contacts. One specific embodiment provides three magnets, where a central magnet has a bay-type opening to form a passageway for one or more contacts. In another embodiment of the present invention, these three magnets may be formed using a single magnet. 
     In another embodiment of the present invention, one magnet may be used. Flux from the one magnet may be guided along two or more poles or magnetic elements to provide a magnetic attraction. The one magnet and magnetic elements may be located in a connector receptacle or a connector inserts. The magnetic elements may convey power or signals, or they may be electrically isolated, where separate contacts may convey power or signals. 
     These various arrangements may provide a high holding strength, also referred to as a high landed force. For example, the one magnet arrangement may provide a high landed force with a simple connector design. 
     Embodiments of the present invention may provide magnetic arrangements having various surface contours. For example, the surface may have a contour that is flat, spline, involute, rounded, or have it may have other contours. 
     These contours and high-landed forces may provide a connector system where a connector insert may be “blind mated” to a connector receptacle. That is, the connector insert and connector receptacle may be configured such that when the connector insert is brought into close proximity to the connector receptacle in approximately a correct orientation, the magnetic attraction between the connector insert and the connector receptacle is such that the connector insert may be pulled into contact with the connector receptacle. As part of this blind mating, the physical features of the connector insert and the connector receptacle may be such that they pose little or no obstacle to the formation of this connection. This may provide an easy way for a user to make a connection of a cable to a device. Specifically, the user merely brings the connector insert in approximately a correct orientation and into proximity of the connector receptacle. From there, the magnetic attraction between the connector insert and the connector receptacle brings them into contact. 
     Another illustrative embodiment of the present invention may provide a label for a magnetic connector that may protect magnets in the connector, provide an aesthetically pleasing appearance, and improve the magnetic performance of the connector. 
     A specific embodiment of the present invention may provide a label that protects magnets in a connector. The connector may be a connector receptacle or connector insert. This label may protect the magnets by providing a more durable surface than brittle magnets would otherwise provide. This better-wearing, more robust surface may protect the magnets from damaging impacts and abrasions. The label may have sufficient thickness to provide adequate protection for the magnets, while not being excessively thick and thereby effectively magnetically isolating the magnets. 
     Another illustrative embodiment of the present invention may provide a label that provides an aesthetically pleasing appearance. Various embodiments of the present invention may achieve this by hiding the magnets. In various embodiments of the present invention, the labels may have a finish that matches another part of the connector, a device housing for the device that includes the connector, or other desirable finish. For example, illustrative embodiments of the present invention may provide labels having a brushed aluminum-appearing finish, a plastic-appearing finish, or other type of finish. 
     Another illustrative embodiment of the present invention may provide a label for a magnetic connector that may improve connector performance by reducing an air gap between magnetic elements in a connector receptacle and connector insert. In various embodiments of the present invention, this may be achieved by forming some or all of the label from magnetically conductive material. In a specific embodiment of the present invention, an air gap between magnets in a connector receptacle and an attraction plate in a connector insert is reduced by employing a magnetically conductive label. 
     Another illustrative embodiment of the present invention may provide a label for a connector receptacle having a number of magnets with their poles arranged in different orientations. In a specific embodiment of the present invention, this label may be formed as a substantially contiguous piece of magnetically conductive material. This label may improve connector performance by limiting stray magnetic flux when the connector is not connected. This limited stray flux may help to reduce inadvertent attraction of magnetic material when the connector is not connected. It may also reduce the chance of inadvertent de-magnetization of credit cards and loss of other magnetic information when they are brought into proximity of the connector. 
     Another illustrative embodiment of the present invention may provide a label for a connector receptacle having a number of magnets with their poles arranged in different orientations. In a specific embodiment of the present invention, this label may be formed as multiple sections of magnetically conductive material, each section corresponding to a magnet. This arrangement may reduce the shorting of flux among the magnets. This may in turn increase magnetic attraction between magnetic elements in a connector receptacle and an attraction plate in a connector insert. Increasing magnetic attraction in this way may allow the use of magnets having a reduced cost or size, thereby reducing connector costs. 
     Embodiments of the present invention may provide labels that are formed of various materials. In a specific embodiment of the present invention, the label may be formed of magnetic steel or other magnetically conductive or ferro-magnetic material. Another specific embodiment of the present invention may provide a label that is formed of a resin that contains magnetic particles. 
     Embodiments of the present invention may provide labels that may be attached in various ways. For example, the labels may be attached using glue or other adhesive. In other embodiments of the present invention, the labels may rely on magnetic attraction, that is, the label may be magnetically held to the magnets. In other embodiments of the present invention, labels may be held on mechanically, for example by using clips or tension between a feature on the connector and the label. In one specific embodiment of the present invention, a connector receptacle may include a mesa or raised portion on which one or more contacts may reside. A label may be fitted around the mesa, using the raised portion to hold the label in place. In still other embodiments of the present invention, the label may be formed as a coating, film, or layer over the magnets. 
     Embodiments of the present invention may provide labels where magnetically conductive areas are arranged in different ways. For example, when magnetic elements are used to convey power or signals, the label may have isolated magnetically (and electrically) conductive areas to avoid shorts between magnetic elements that are conveying different power supplies or signals. Magnetic elements that convey the same power supply or signal may share a conductive area. In these situations, the label both conducts electricity and is used to provide magnetic holding power. 
     Where the magnet elements do not convey power or signals, and instead separate contacts are used, the magnet elements may share magnetically conductive areas, or they may be separated. In other embodiments, some combination of these may be employed. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system including a connector system that may be improved by the incorporation of an embodiment of the present invention; 
         FIG. 2  illustrates a connector insert and connector receptacle according to an embodiment of the present invention; 
         FIG. 3  illustrates another connector insert and connector receptacle according to an embodiment of the present invention; 
         FIG. 4  illustrates a side view of a magnetic connector system according to an embodiment of the present invention; 
         FIG. 5  illustrates two arrangements of magnets according to embodiments of the present invention; 
         FIG. 6  illustrates a portion of a connector according to an embodiment of the present invention; 
         FIG. 7  illustrates an oblique view of magnets and magnetic elements that may be employed by a connector receptacle according to an embodiment of the present invention; 
         FIG. 8  illustrates the magnets and magnetic elements of  FIG. 7  connecting to a magnetic element or attraction plate; 
         FIG. 9  illustrates a label according to an embodiment of the present invention; 
         FIGS. 10A and 10B  illustrate the operation of a magnetic label according to an embodiment of the present invention; 
         FIGS. 11A and 11B  illustrate the operation of a magnetic label according to an embodiment of the present invention; 
         FIGS. 12A and 12B  illustrate the operation of a magnetic label according to an embodiment of the present invention; and 
         FIGS. 13A and 13B  illustrate the operation of a magnetic label according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates an electronic system including a connector system that may be improved by the incorporation of an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     This figure includes a laptop computer  110  that may receive power from power adapter  120 . Specifically, power adapter  120  may provide power to laptop computer  110  through cable  130  and a connector system, including connector insert  132  and connector receptacle  112 . In various embodiments of the present invention, connector insert  132  and connector receptacle  112  may be various types of connectors. In some embodiments of the present invention, connector insert  132  and connector receptacle  112  are magnetic connectors. That is, one or more magnets may be located in one or both of connector insert  132  and connector receptacle  112 . An attraction plate or other magnetically-conductive portion may be included in either or both connector insert  132  or connector receptacle  112 . In a specific embodiment of the present invention, connector receptacle  112  may include one, two, three, four, or more than four magnets. Some or all of these magnets may have opposing polarities. In this specific embodiment of the present invention, connector insert  132  may include an attraction plate. 
     The attraction plate in connector insert  132  may be magnetically attracted to magnets in connector receptacle  112 . Specifically, magnetic field lines originating in a first one of the magnets in connector receptacle  112  may pass through the attractor plate in connector insert  132  and terminate in the first one or a second magnet in connector receptacle  112 . 
     While in this specific embodiment of the present invention electronic device  110  is a laptop computer, other electronic devices such as portable computing devices, tablet, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors and other devices, may be improved by the incorporation of embodiments of the present invention. Also, while connector insert  132  and connector receptacle  112  convey power, in other embodiments of the present invention, connector insert  132  and connector receptacle  112  may convey data, status, control, and other types of signals, as well as bias, power, ground, and other types of voltages. For example, a connection status signal may be conveyed using these connectors. These signals and voltages may convey signals according to one or more interfaces, such as Universal Serial Bus (USB), High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), DisplayPort, Thunderbolt, or other types of interface. 
     During use, it may be desirable that connector insert  132  not be easily disconnected from receptacle  112 . Accordingly, embodiments of the present invention may provide a connector system having a high holding strength or landed force. Embodiments of the present invention may further provide inserts and receptacles that are simple to manufacture. 
     Also, during a device&#39;s lifetime, connector insert  132  may be connected to, and disconnected from, connector receptacle  112  numerous times. This may lead to wear and damage to connector receptacle  112 . Also, it may be desirable for connector receptacle  112  to have an aesthetically-pleasing appearance. Moreover, the connection and disconnection of connector insert  132  from connector receptacle  112  may go a long way in informing a user&#39;s opinion of device  110 , and therefore the likelihood of the user making a similar purchase in the future. Accordingly, embodiments of the present invention may provide labels that may protect these connectors, provide an aesthetically-pleasing appearance, and improve connector performance. In various embodiments of the present invention, these labels may also limit stray flux when a connection is not made and improve holding strength or landed force when a connection is made. An example of a connector that may be improved by embodiments of the present invention is shown in the following figure. 
       FIG. 2  illustrates a connector insert and connector receptacle according to an embodiment of the present invention. Connector receptacle  112  may be located on housing  210  of a device. Connector receptacle  112  may include a recessed portion  220  surrounding a raised portion or mesa  230 . One or more contacts  232  may be arranged on mesa  230 . 
     Connector insert  132  may include attraction plate  240 . The attraction plate  240  may surround a recessed portion  242 . One or more contacts  244  may be located in recessed portion  242 . One or more contacts  244  may be arranged to mate with contacts  232  when connector insert  132  is mated with connector receptacle  112 . Mesa  230  on connector receptacle  112  may be arranged to fit in recessed portion  242  in connector insert  132 . Attraction plate  240  on connector insert  132  may be formed to fit in recess  220  in connector receptacle  112 . 
     Connector receptacle  112  may include one or more magnets or magnetic elements near an opening in housing  210 . Specifically, one or more magnets or magnetic elements may be located at or near recessed surface  220 . Left unprotected, these magnets or magnetic elements may be damaged by impacts or abrasions caused by the insertion of connector insert  132 . Accordingly, embodiments of the present invention may provide a label to protect these magnets or magnetic elements. Also, since more than one magnet or magnetic elements may be used, one or more seams between magnets or magnetic elements may be visible. Accordingly, labels according to embodiments of the present invention may cover these seams so that they cannot be seen. Also, such labels may match housing  210  in appearance for an improved look. 
     In this example, power and signal paths may be formed over contacts  232  and  244 . In other embodiments of the present invention, power and signal paths may be formed using one or more magnets or magnetic elements. In still other embodiments of the present invention, power and signal paths may be formed using contacts and magnets or magnetic elements. An example where magnets or magnetic elements are used to convey signals is shown in the following figure. 
       FIG. 3  illustrates another connector insert and connector receptacle according to an embodiment of the present invention. Connector receptacle  112  may be located on housing  210  of an electronic device. Connector receptacle may include one or more magnets or magnetic elements  332 . These magnets or magnetic elements  332  may convey power or signals. Magnets or magnetic elements  332  may be isolated by isolation areas  330 . A label (now shown) may cover one or more magnets or magnetic elements  332  for protection and to increase holding power and reduce stray flux. 
     Connector insert  132  may include magnets or magnetic elements  344 , which may be separated by isolation areas  342 . Magnets or magnetic elements (or attraction plates)  344  may be arranged to mate with magnets or magnetic elements  332  of receptacle  112  when insert  132  is mated with receptacle  112 . Also, magnets or magnetic elements  344  may be arranged to fit in the recess in receptacle  112  when insert  132  is mated with receptacle  112 . 
     Embodiments of the present invention may further improve the performance of these connector systems by providing a magnetically-conductive label. By making some or all of the label magnetically conductive, an air gap between magnets in receptacle  112  and the attraction plate  240  in connector insert  132  may be reduced. This label may thus reduce stray flux when a connection is not made, and may improve the landed force when a connection is made between insert  132  and receptacle  112 . An example of a connector system according to an embodiment of the present invention that employs such a label is shown in the following figure. 
       FIG. 4  illustrates a side view of a magnetic connector system according to an embodiment of the present invention. This magnetic system includes portions of connector insert  132  and connector receptacle  112 . Connector receptacle  112  may include one or more magnets  410 , which may be covered by label  420 . Connector insert  132  may include an attraction plate  240 . Magnetic field lines originating in magnet  410 A may pass through label  420  and attraction plate  240  and terminate in second magnet  410 B. 
     More specifically, magnetic field lines originating in a North pole of magnet  410 A may pass through label  420  and attraction plate  240  and terminate at a South pole of magnet  410 B. In various embodiment of the present invention, magnets  410 A and  410 B may be formed of various materials, such as NdFeB, N50, or N52. Again, they may be arranged in various configurations. Examples of some arrangements are shown in the following figure. 
       FIG. 5  illustrates two arrangements of magnets according to embodiments of the present invention. Magnetic arrangement  510  includes magnets  512 ,  514 , and  516 . These magnets may be arranged in a linear fashion as shown. The polarities of these magnets may alternate, for example, North, South, and then North again. Magnet  514  may include bay  520 . Bay  520  may provide a passage for one or more contacts to form electrical connections. Magnets  512 ,  514 , and  516  may also be used to form electrical connections. In various embodiments of the present invention, these magnets may be located in either or both a connector receptacle and a connector insert. 
     Magnetic arrangement  560  includes magnetic portions  552 ,  554 , and  556 . Magnetic portions  552 ,  554 , and  556  may be formed of a single piece. Magnetic portion  554  may include bay  560 . Bay  560  may provide a passage for one or more contacts to form electrical connections. Magnetic portions  552 ,  554 , and  556  may also be used to form an electrical connection. In various embodiments of the present invention, these magnet portions may be located in either or both a connector receptacle and a connector insert. 
     In various embodiments of the present invention, a single magnet may be used in conjunction with magnetic elements. These magnetic elements may be formed using a ferro-magnetic material. These designs may provide a connector system that is readily manufactured and provides a high-landed force. They may also include a label as shown above. An example is shown in the following figure. 
       FIG. 6  illustrates a portion of a connector according to an embodiment of the present invention. This arrangement may be used in either connector receptacles or connector inserts, or both, consistent with embodiments of the present invention. In this example, a single magnet  610  is employed. A first magnetic element  620  may extend from a North side of magnet  610  to an opening, which in this case is covered by label  420 . A second magnetic element  630  may extend from a South side of magnet  610  to the opening. Magnetic field lines originating at a North side of magnet  610  may pass through magnetic element  620 , through the opening, through the second magnetic element  630 , to the South side of magnet  610 . Some of the flux at the opening may pass through label  420 . This flux is shown as flux  650 . Other flux, shown here as flux  660  and  661 , may pass through the air in front of the opening. The structure may be at least partially located in housing  640 . Again, this configuration may provide a simple magnetic connector that is readily assembled. This configuration may also provide a high-landed force. 
     In this example, a magnet  610  is used. In this and other embodiments of the present invention, the included magnet may generally be thought of as a magnetic flux source. Accordingly, other magnetic flux sources, such as electromagnets, and other structures presently available or available in the future may be used as magnetic flux sources. 
     Again, embodiments of the present invention may provide paths for power and ground. They may instead provide paths for other signals, such as communication or connection detection signals. They may also provide paths for some combination of power, ground, and signals. Again, these signals may be conveyed (provided or received) using contacts, magnets, magnetic elements, or some combination thereof. In these examples, contacts may be located completely or at least partially between the magnet  610  and the opening in the housing  640 , and between the first magnetic element  620  and the second magnetic element  620 . In other embodiments of the present invention, contacts may be located elsewhere. 
     In other embodiments of the present invention, the first magnetic element  620  and the second magnetic element  630  may provide paths for power and ground. In this case, when a corresponding connector makes contact, current may flow through the first magnetic element  620  and the second magnetic element  630 . In still other embodiments of the present invention, contacts may be included and one or more power, ground, and signals may be conveyed by one or more of the first magnetic element  620  and the second magnetic element  630 . 
       FIG. 7  illustrates an oblique view of magnets and magnetic elements that may be employed by a connector receptacle according to an embodiment of the present invention. This figure includes one or more magnets  610  and one or more magnetic elements  333  that provide surfaces for contacts  332 . An insulating layer  330  may insulate various magnetic elements  333  from each other and from magnets  610 . Magnetic elements  333  may be used to convey power and ground. Magnetic elements  333  may also be used to convey one or more signals, such as signals for communication, connection detection, or for other purposes. 
     In a specific embodiment of the present invention, magnetic elements  333  may form contacts in a connector receptacle, such as contacts  332  in connector receptacle  112 , though they may form contacts in a connector insert. In this specific embodiment of the present invention, these contacts may convey power and ground. A signal may also be included. In one arrangement, the top row of contacts  332  may be used, in order (either right-to-left, or left-to-right), for power, signal, and ground. The lower row of contacts  332  may be used, again in order, for ground, signal, and power. In this arrangement, each power and ground contact and corresponding magnetic elements  332  should be electrically isolated from each other, for example by insulating layer  330 . This arrangement may provide an advantage in that a corresponding connector insert may be inserted in one of two possible orientations while still making a proper electrical connection. 
     In other embodiments of the present invention, a top row of contacts to  332  may be used, in order, for power, signal, and ground. The lower row of contacts  332  may be used, again in order, for power, signal, and ground. In this arrangement, corresponding power, signal, and ground contacts do not need to be isolated from each other. Unfortunately, in this arrangement, a connector insert may either be inserted only one way, or the receptacle needs to detect the polarity of the connection made and adjust accordingly. 
     In still other embodiments of the present invention, contacts for conveying one or more of power, ground, or signals may be completely or at least partially located between the magnet or magnets  610  and a front of the connector (though they may extend beyond the front of the connector), and between the magnetic elements  333 . In other embodiments of the present invention, these contacts may be located elsewhere in the connector. These contacts may be arranged in a row, as in  FIG. 2 , or they may have other configurations. 
     In one specific embodiment of the present invention, more than one magnet, for example, three magnets  610 , may be used, as shown. In other embodiments of the present invention, other numbers of magnets, for example, two, four, or more than four magnets and corresponding magnetic elements may be used. These magnets may be at least approximately aligned with the various contacts  332 . Magnets  610  may be arranged in an alternating North-South-North, or South-North-South arrangement. This may make the corresponding two rows of contacts  332  to have the same alternating arrangement, that is, one row may have a polarity of North-South-North, while the other has a polarity of South-North-South. As in each of these examples, contacts  332  may be actual contacts to convey power, ground, signals, or some combination thereof. In such a configuration, these elements may be used both for magnetic hold, as well as to convey power, ground, and signals. 
     In other embodiments of the present invention, contacts  332  may be used for magnetic hold, while other contacts, which again may be located between rows of contacts  332  or at other locations, may be used for power, ground, signals, or some combination thereof. For example, contacts, such as those shown in  FIG. 2 , may be included. Other features, such as mesa  230  in  FIG. 2 , may be included as well. In still other embodiments, other combinations that use contacts  332  as well as other contacts may be employed. For example, contacts  332  may be used for power and ground, while separate signal contacts may be included, for example between rows of contacts  332 . 
       FIG. 8  illustrates the magnets and magnetic elements of  FIG. 7  connecting to a magnetic element or attraction plate  344 . 
     In various embodiments of the present invention, the surfaces formed by contacts  332  and insulating layer  330  may have various shapes or contours. For example, this shape may be flat. In the examples shown in  FIGS. 7 and 8 , the surface may have a spline or involute contour. These shapes may assist in preventing binding between a connector insert in a connector receptacle. These shapes may further assist in blind mating between a connector insert and a connector receptacle. 
     Again, embodiments of the present invention may provide a connector system where a connector insert may be “blind mated” to a connector receptacle. That is, the connector insert and connector receptacle may be configured such that when the connector insert is brought into close proximity to the connector receptacle in approximately a correct orientation, the magnetic attraction between the connector insert and the connector receptacle is such that the connector insert may be pulled into contact with the connector receptacle. 
     This may provide an easy way for a user to make a connection of a cable to a device. Specifically, the user may simply bring the connector insert in approximately a correct orientation and into proximity of the connector receptacle. From there, the magnetic attraction between the connector insert and the connector receptacle may bring them into contact. 
     To facilitate this blind mating, the physical features on the connector insert and connector receptacle may be such that there may be few or no obstacles to the formation of the connection. For example, the opening on attraction plate  240  of connector insert  132  may be such that it readily accepts mesa  230  on connector receptacle  112 . Similarly, attraction plate  240  (or contacts  344 ) of connector insert  132  may be such that it readily fits in the opening of receptacle  112 . 
     Again, embodiments of the present invention may provide a label over a surface of these various magnets or magnetic elements. These labels may improve the durability, appearance, and functionality of connector systems. An example of label  420  is shown in the following figure. 
       FIG. 9  illustrates a label according to an embodiment of the present invention. In one embodiment of the present invention, a substantial portion of label  420  may be formed of a contiguous piece of magnetically conductive material. In other embodiments of the present invention, label  420  may include one or more magnetically conductive portions separated by non or less-magnetically conductive areas or dividers. 
     In the example shown, label  420  includes upper magnetically conductive portion  910  and lower magnetically conductive portion  920 . Upper magnetically conductive portion  910  may be at least approximately aligned with magnets  410 A in  FIG. 4 , while lower magnetically conductive portion  920  may be at least approximately aligned with magnet  410 B in  FIG. 4 . A magnetically less conductive portion  930  may isolate upper magnetically conductive portion  910  from lower magnetically conductive portion  920 . One or more openings, such as opening  940 , may be included to allow passage of contacts or contact structures, such as mesa  230  in  FIG. 2 . 
     In various embodiments of the present invention, three, four, or more magnets or magnetic elements may be employed by connector receptacle  112 . In such cases, label  420  may be subdivided further into smaller magnetically conductive areas. For example, label  420  may be arranged to have four magnetically conductive areas. In a specific embodiment of the present invention, one of these areas may be located in each corner of label  420 . When label  420  covers a connector such as the connector shown in  FIG. 7  and the contacts  332  convey power, ground, and signals, or some combination thereof, label  420  may be arranged to have six (or some other appropriate number) magnetically conductive areas that are electrically isolated from each other. When label  420  covers a connector such as the connector in  FIG. 7  and the contacts  332  are used for magnet hold but not to convey power, ground, and signals, or some combination thereof, label  420  may be arranged to have two magnetically conductive areas that are electrically isolated from each other. In other embodiments, label  420  may be formed as a single magnetically conductive area, where the opening may have an opening for a mesa or contacts, such as mesa  230  in  FIG. 2 . These one or more electrically isolated conductive areas may thus form paths for power, ground, signals, or a combination thereof. Accordingly current may flow through the label when power, ground, or other signals are actually conveyed. Similarly, when the label covers a number of magnets and the magnets are used to convey power, ground, or signals, current may flow through the label. In such a situation, the label may be used for both its magnetic hold and current carrying capability. 
     Again, in other embodiments of the present invention, magnetically less conductive portion  930  may be absent, and magnetically conductive portions  910  and  920  may be joined as a single magnetically conductive area. Such a label may be used where the magnets or magnetic elements are not used to convey more than one power, ground, or signal line. Again, label  420  may also include opening  940 , for example, to allow passage of one or more contacts, such as contacts  232  in  FIG. 2 . Opening  940  may be arranged to accept or fit over mesa  230 , as shown in  FIG. 2 . In other embodiments of the present invention, opening  940  may be absent. 
     In various embodiments of the present invention, label  420  may be formed of various materials. For example, label  420  may be formed of steel, such as magnetic steel, or other ferro-magnetic material. In another embodiment of the present invention, label  420  may be formed of a resin that may contain magnetically conductive particles. For example, label  420  may be formed of a polycarbonate with iron powder. Magnetically less conductive portion  930  may be formed by an absence of such particles. 
     Again, label  420  may have an appearance to match a device housing, such as device housing  210  in  FIG. 2 . In other embodiments of the present invention, other finishes or appearances may be used. 
     Label  420  may be a fixed to magnets  410 A and  410 B in various ways. For example, label  420  may be glued or held to magnets  410  using an adhesive. In other embodiments of the present invention, label  420  may be magnetically held to magnets  410 A and  410 B. In other embodiments of the present invention, opening  940  may fit snugly around mesa  230 , such that label  420  is held in place. In still other embodiments the present invention, other mechanisms, such as clips, may be used to fix a label  420  in place. In still other embodiments of the present invention, the label may be formed as a coating, film, or layer over the magnets. 
     By forming label  420  from magnetically conducive material, an air gap between magnets  410 A and  410 B and attraction plate  240  is reduced. This may increase hold power of the magnets and improve connector performance, particularly compared to using a non-magnetically conductive label. 
     Again, in various embodiments of the present invention, label  420  may be at least substantially formed of a magnetically conductive material. Such a label may limit stray flux present near an opening of a connector receptacle. This may help to avoid magnetic attraction of stray magnetically conductive particles. Also, limiting stray flux may protect credit card and other magnetically stored information. Further, by forming label  420  from a magnetically conductive material, an air gap that may otherwise exist (if label  420  is non-magnetic) is reduced or eliminated. This may increase a holding power of magnets  410 A and  410 B. By increasing the hold power of magnets  410 A and  410 B, magnets  410 A and  410 B may be made smaller, or less-expensive magnets may be used. An example is shown in the following figures. 
       FIGS. 10A and 10B  illustrate the operation of a magnetic label according to an embodiment of the present invention. As shown in  FIG. 10A , magnetic field lines may originate in a North pole of magnet  410 A and terminate in a South pole of magnet  410 B. Label  420  may act as a shunt, such that some of the magnetic flux may pass through label  420 . That is, label  420  may magnetically saturate. This is shown here as flux  1010 . Other portions of the magnetic flux may pass outside of label  420  as stray flux. This is shown here as magnetic flux  1020 . Increasing flux  1010  may reduce stray flux  1020 . Again, by reducing stray magnetic flux  1020 , stray particles may be picked up to a lesser extent, and credit card and other magnetically stored information may be protected. Magnets  410 A and  410 B may be located in housing  1060 . In various embodiments of the present invention, some or all of housing  1060  may be formed with, or part of, device enclosure  210 , which encloses an electronic device housing the connector receptacle. 
     In  FIG. 10B , attraction plate  240  may be brought into proximity with label  420 . Accordingly, magnetic field lines  1020  pass through attraction plate  240 , thereby holding attraction plate  240  in place against label  420 . In this way, connector insert  132  may be held in place against connector receptacle  112 . 
     Again, in other embodiments of the present invention, magnetically less conductive portions may be used in label  420 . These magnetically less conductive portions may be used to reduce flux  1010 . By reducing flux  1010 , flux  1020  can be increased, thereby improving the hold power of magnets  410 . By increasing the hold power of magnets  410 , magnets  410  may be made smaller, less-expensive magnets may be used, the hold power may be increased, or some combination thereof. An example is shown in the following figures. 
       FIGS. 11A and 11B  illustrate the operation of a magnetic label according to an embodiment of the present invention. As shown in  FIG. 11A , magnetic field lines again may originate in a North pole of magnet  410 A and terminate in a South pole of magnet  410 B. Because of the presence of magnetically less conductive portion  930 , magnetic flux  1010  is reduced. (A dashed line may be used to symbolically indicate this reduction.) For this reason, magnetic flux  1020  is increased (as illustrated here by the inclusion of magnetic field line  1021 ). 
     In  FIG. 11B , attraction plate  240  may be brought into proximity with label  420 . Again, flux lines  1020  and  1021  pass through attraction plate  240 . This increased flux  1020  and  1021  increases the hold power of magnets  410 A and  410 B. This in turn allows magnets  410 A and  410 B be to be smaller in size, it may allow less expensive magnets to be used, the hold power to be increased, or some combination thereof. 
     While the above example shows multiple magnets in a receptacle mating with an attraction plate of an insert, in other embodiments of the present invention, other arrangements are possible. For example, the receptacle may include an attraction plate while the insert includes one or more magnets. Further, in other embodiments of the present invention, magnets may be located in both the insert and receptacle. 
     Again, in other embodiments of the present invention, one magnet may be used in either the receptacle or insert. Magnetic elements may be used to provide magnetic North and South poles at an interface between a receptacle and insert. As before, these magnetic elements may be covered with a label. The label may be fully conductive, or it may be separated by isolation areas to avoid electrical connections between the contacts formed by the magnetic elements. Examples are shown in the following figures. 
       FIGS. 12A and 12B  illustrate the operation of a magnetic label according to an embodiment of the present invention. As shown in  FIG. 12A , magnetic field lines may originate in a North pole of magnet  610 , pass through magnetic elements  332 , and terminate in a South pole of magnet  610 . Label  420  may act as a shunt, such that some of the magnetic flux may pass through label  420 . That is, label  420  may magnetically saturate. This is shown here as flux  1210 . Other portions of the magnetic flux may pass outside of label  420  as stray flux. This is shown here as magnetic flux  1220 . Increasing flux  1210  may reduce stray flux  1220 . Again, by reducing stray magnetic flux  1220 , stray particles may be picked up to a lesser extent, and credit card and other magnetically stored information may be protected. Magnet  610  and magnetic elements  332  may be located in housing  1260 . In various embodiments of the present invention, some or all of housing  1260  may be formed with, or part of, device enclosure  210 , which encloses an electronic device housing the connector receptacle. 
     In  FIG. 12B , attraction plate  240  may be brought into proximity with label  420 . Accordingly, magnetic field lines  1220  pass through attraction plate  240 , thereby holding attraction plate  240  in place against label  420 . In this way, connector insert  132  may be held in place against connector receptacle  112 . 
     Again, in other embodiments of the present invention, magnetically less conductive portions may be used in label  420 . These magnetically less conductive portions may be used to reduce flux  1210 . By reducing flux  1210 , flux  1220  can be increased, thereby improving the hold power of magnet  610 . By increasing the hold power of magnet  610 , magnet  610  may be made smaller, a less-expensive magnets may be used, the hold power may be increased, or some combination thereof. An example is shown in the following figures. 
       FIGS. 13A and 13B  illustrate the operation of a magnetic label according to an embodiment of the present invention. As shown in  FIG. 13A , magnetic field lines again may originate in a North pole of magnet  610 , pass through magnetic elements  332 , and terminate in a South pole of magnet  610 . Because of the presence of magnetically less conductive portion  930 , magnetic flux  1210  may be reduced. (A dashed line may be used to symbolically indicate this reduction.) For this reason, magnetic flux  1220  is increased (as illustrated here by the inclusion of magnetic field line  1221 ). 
     In  FIG. 13B , attraction plate  240  may be brought into proximity with label  420 . Again, flux lines  1220  and  1221  pass through attraction plate  240 . This increased flux  1220  and  1221  increases the hold power of magnet  610 . This in turn may allow magnet  610  to be smaller in size, it may allow less expensive magnets to be used, and it may allow the hold power to be increased, or some combination thereof. 
     In various embodiments of the present invention, label  420  may have various thicknesses. In various embodiments of the present invention where label  420  is a contiguous piece of magnetically conductive material, a thickness of label  420  may be limited such that not all, or an excessive amount, of magnetic flux from magnets  410 A and  410 B or  610  is shorted through label  420 , though label  420  may be thick enough to reduce stray flux. In other words, the label may be thick enough to reduce stray flux, but thin enough to not pass so much of the flux as to weaken the magnetic field beyond a desirable point. With this thickness, the label may be saturated by the magnetic field. In other embodiments of the present invention, label  420  may be thick enough to physically protect magnets  410 A and  410 B or magnetic elements  332 . In a specific embodiment of the present invention, label  420  may have a thickness of 0.2 mm. An additional layer of adhesive may be approximately 0.05 mm thick. In other embodiments of the present invention, other thicknesses may be used. For example, label  420  may be in the range of 0.1 to 0.3 mm thick, though label  420  may be thinner than 0.1 mm or thicker than 0.3 mm. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20120813
Publication Date: 20171003
Grant Date: 20171003
Priority Date: 20110811
Inventors: DIFONZO JOHN C.
ANASTAS GEORGE V.
NARAJOWSKI DAVID
HAMEL BRADLEY J.
DEGNER BRETT WILLIAM
LIGTENBERG CHRIS
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R43/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/26", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 48945928