PATENT DOCUMENT

Publication Number: US-8888537-B2
Application Number: US-201213678959-A
Country: US
Kind Code: B2

Title: Audio jack with multiple points of contact

Abstract:
An improved electronic audio receptacle connector employs contacts that have multiple points of contact with a mating audio plug. The contacts each have multiple segments, each segment having a plurality of transverse fingers that interface with a conductive portion of the audio plug. The multiple points of contact improve the reliability of the receptacle connector. The housing of the receptacle connector may be made of two portions mated along an interface. The two portions may have features along the interface to impede moisture ingression and to interlock them together.

Claims:
What is claimed is: 
     
       1. An electrical audio receptacle connector comprising:
 a receiving face with a front opening to receive a plug portion of a mating audio plug connector and a rear face disposed opposite of the receiving face; 
 a housing that extends between the receiving face and the rear face, the housing defining a cavity that communicates with the front opening; and 
 a plurality of contacts, each of the plurality of contacts having an internal portion disposed within the cavity and an external portion disposed outside of the housing; 
 wherein the internal portion comprises a segment having a longitudinal rail and a plurality of transverse fingers attached to the longitudinal rail, the fingers arranged to contact a conductive portion of the plug portion of the mating audio plug; and 
 wherein the housing has a base portion aligned with and mated to a lid portion along two or more interfaces that interlock along their entire length forming a liquid tight seal. 
 
     
     
       2. The electrical audio receptacle connector set forth in  claim 1  wherein the internal portion of each of the plurality of contacts comprises a pair of parallel longitudinal rails; and
 wherein the plurality of transverse fingers are disposed between, and attached to the pair of parallel longitudinal rails. 
 
     
     
       3. The electrical audio receptacle connector set forth in  claim 1  wherein the plurality of transverse fingers are substantially planar. 
     
     
       4. The electrical audio receptacle connector set forth in  claim 1  wherein the plurality of transverse fingers are substantially arcuate. 
     
     
       5. The electrical audio receptacle connector set forth in  claim 1  wherein the longitudinal rail is substantially straight. 
     
     
       6. The electrical audio receptacle connector set forth in  claim 1  wherein the longitudinal rail is substantially circular. 
     
     
       7. The electrical audio receptacle connector set forth in  claim 1  wherein the longitudinal rail is arcuate. 
     
     
       8. The electrical audio receptacle connector set forth in  claim 1  wherein the internal portion comprises a first segment that is substantially straight and a second segment that is substantially straight and connected to the first segment at an angle of approximately 90 degrees. 
     
     
       9. The electrical audio receptacle connector set forth in  claim 8  wherein the internal portion comprises a third segment that is substantially straight and is connected to the second segment at an angle of approximately 90 degrees. 
     
     
       10. The electrical audio receptacle connector set forth in  claim 9  wherein the internal portion comprises a fourth segment that is substantially straight and is connected to the third segment at an angle of approximately 90 degrees;
 wherein the four segments of the longitudinal rail form a substantially square internal portion. 
 
     
     
       11. The electrical audio receptacle connector set forth in  claim 1  wherein the two or more interfaces are adhered to one another. 
     
     
       12. The electrical audio receptacle connector set forth in  claim 11  wherein the lid portion comprises tabs along the interface and the base portion comprises tab receiving features along the interface. 
     
     
       13. An electrical audio receptacle connector comprising:
 a receiving face with a front opening to receive a plug portion of a mating audio plug connector and a rear face disposed opposite of the receiving face; 
 a housing that extends between the receiving face and the rear face, the housing defining a cavity that communicates with the front opening; 
 wherein the housing has a base portion and a lid portion that are joined along an interlocking liquid tight interface; and 
 a plurality of contacts, each of the plurality of contacts having a plurality of transverse fingers disposed within the cavity and arranged to contact a conductive portion of the plug portion of the mating audio plug. 
 
     
     
       14. The electrical audio receptacle connector set forth in  claim 13  wherein the base portion has a slot disposed along the interface and the lid portion has a rail disposed along the interface; and
 wherein the rail is engaged in the slot along the interface. 
 
     
     
       15. An electrical audio receptacle connector for receiving an audio plug connector, the receptacle connector comprising:
 a liquid tight body having an opening that communicates with a cavity having height, width and depth dimensions; 
 a plurality of contacts positioned within and spaced apart along the depth of the cavity, each of the plurality of contacts having four primary contact portions and a lead portion, the four primary contact portions including first and second opposing contact surfaces and third and fourth opposing contact surfaces that combine to form an aperture through which the audio plug connector can be inserted, the first and second opposing contact surfaces extending in the height dimension on opposite sides of the cavity and the third and fourth opposing contact surfaces extending in the width dimension on opposite sides of the cavity, and wherein the lead portion extends from one of the four primary contact portions out of the body through a liquid tight seal enabling the contact to be soldered to a substrate. 
 
     
     
       16. The electrical audio receptacle connector set forth in  claim 15  wherein each of the plurality of contacts includes opposing rails and each primary contact portion includes one or more transverse fingers. 
     
     
       17. The electrical audio receptacle connector set forth in  claim 16  wherein the transverse fingers are curved inward towards a line that longitudinally bisects a center of the cavity. 
     
     
       18. The electrical audio receptacle connector set forth in  claim 15  wherein each primary contact portion includes at least three transverse fingers. 
     
     
       19. The electrical audio receptacle connector set forth in  claim 15  wherein each of the plurality of contacts has four segments at 90 degree intervals and each segment has multiple individual contact points. 
     
     
       20. The electrical audio receptacle connector set forth in  claim 15  wherein each of the plurality of contacts has a generally square cross-sectional shape. 
     
     
       21. The electrical audio receptacle connector set forth in  claim 15  wherein each of the plurality of contacts has a generally circular cross-sectional shape. 
     
     
       22. The electrical audio receptacle connector set forth in  claim 15  wherein the plurality of contacts consist of first, second, third and fourth contacts wherein the first contact conducts left audio signals, the second contact conducts right audio signals, the third contact conducts ground signals and the fourth contact conducts microphone signals. 
     
     
       23. An electrical audio receptacle connector for receiving an audio plug connector, the receptacle connector comprising:
 a body having an opening that communicates with a cavity having height, width and depth dimensions, the body having a base portion and a lid portion that combine to form a liquid-tight tube like structure with the lid portion and the base portion joined along an interlocking interface that extends along at least one half of the depth of the body; 
 a plurality of contacts positioned within and spaced apart along the depth of the cavity, each contact having at least one contact surface configured to electrically couple to a contact of the audio plug connector during a mating event and a lead that extends out of the base portion of the body where the body forms a liquid-tight seal at an interface between each lead and the base portion of the body. 
 
     
     
       24. The electrical audio receptacle connector set forth in  claim 23  wherein the lid portion is adhered to the base portion along the interface. 
     
     
       25. The electrical audio receptacle connector set forth in  claim 23  wherein the lid portion and the base portion have interlocking geometry disposed along the entire interlocking interface. 
     
     
       26. The electrical audio receptacle connector set forth in  claim 23  wherein each of the plurality of contacts includes opposing rails and each primary contact surface includes one or more transverse fingers. 
     
     
       27. The electrical audio receptacle connector set forth in  claim 26  wherein each primary contact surface includes at least three transverse fingers. 
     
     
       28. The electrical audio receptacle connector set forth in  claim 23  wherein each of the plurality of contacts has four segments at 90 degree intervals each of which has multiple individual contact points.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to electrical audio connectors and in particular to electrical audio connectors that can be mounted to a substrate, such as a printed circuit board (PCB), within an electronic device. A wide variety of electronic devices are available for consumers today that use a wide variety of connectors to facilitate communication with other devices and/or accessories. 
     As an example, audio jack receptacle connectors are sometimes positioned at one or more of the external surfaces of an electronic device and mounted to a PCB within the device. As smart-phones, media players, charging stations and other electronic devices become more indispensable to their operators, the devices are with their operators more frequently and are more likely to be exposed to harsh environments that may damage the connectors and/or the device. For example, audio plug connectors are often unplugged from the electronic device and may be physically damaged or contaminated with non-conductive debris. Further, the electronic device itself may be exposed to liquid which may enter the device through the connector opening. Either of these scenarios may result in a failure of the electronic device to operate properly. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention pertain to receptacle connectors, such as audio receptacle connectors, used in a variety of electronic devices. Some embodiments of the invention provide a contact system that has multiple contact points for redundancy and that assists with balancing forces during a mating event. Other embodiments of the invention use over-molding or other injection molding techniques to improve the water proofing characteristics of an audio jack receptacle connector or other type of connector. Still other embodiments include multiple contact points and improved water proofing characteristics. 
     Contacts within the connector may provide contact points at multiple locations around a circumference of a plug connector. In some embodiments the locations are spaced evenly apart in one or more 90 degree segments along the entire 360 degree circumference of the plug. In some embodiments the internal portion of the contact may have four segments arranged in a square pattern covering the 360 degree circumference of the plug. In other embodiments the internal portion of the contact may have only one segment covering a 90 degree portion of the circumference of the plug. In further embodiments the contact may have one segment arranged in a circle covering the entire 360 degree circumference of the plug. In still further embodiments, one or more segments may have an outside portion positioned external to the connector housing for connecting the contact to a PCB or other structure. 
     In some embodiments, each contact segment may comprise a pair of parallel longitudinal rails having a plurality of transverse fingers disposed between the pair of rails and attached to the pair of parallel longitudinal rails. The fingers may be arranged to interfere with a conductive portion of the plug portion of mating audio plug. More specifically, a single contact may comprise a plurality of fingers, all of which may contact a single conductive portion of the plug, providing redundant contacts. 
     Some embodiments of the housing of the receptacle connector may be made from a base portion and a lid portion that are joined along an interface. In some embodiments, the housing may have features such as tabs on the lid and corresponding tab recesses on the base portion that help hold the housing together. In further embodiments, the housing may have features along the interface that make the housing impervious to liquid. One embodiment comprises a base portion with a slot along the interface and a lid portion with a rail along the interface, wherein the rail is engaged in the slot along the interface. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a diagram that illustrates an example of an audio plug. 
         FIG. 1B  is a diagram that illustrates an example of an audio plug. 
         FIG. 2  is a diagram that illustrates an exploded front perspective view of an electrical audio receptacle connector with contacts comprising multiple points of contact in accordance with an embodiment of the invention. 
         FIG. 3A  is a diagram that illustrates a front perspective view of an electrical audio receptacle connector with contacts comprising multiple points of contact in accordance with an embodiment of the invention. 
         FIG. 3B  is a diagram of an embodiment that illustrates a housing interface feature in accordance with an embodiment of the invention. 
         FIG. 3C  is a diagram of an embodiment that illustrates a housing interface feature in accordance with an embodiment of the invention. 
         FIG. 3D  is a diagram of an embodiment that illustrates a housing interface feature in accordance with an embodiment of the invention. 
         FIG. 4  is a diagram that illustrates a perspective view of an audio plug engaged with an electrical audio receptacle connector with the connector housing removed in accordance with an embodiment of the invention. 
         FIG. 5  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 6  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 7  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 8  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 9  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 10  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 11  is a diagram that illustrates a perspective view of a contact in accordance with an embodiment of the invention. 
         FIG. 12  is a diagram that illustrates a plan view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 13  is a diagram that illustrates a plan view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 14  is a diagram that illustrates a plan view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 15  is a diagram that illustrates a plan view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 16  is a diagram that illustrates a plan view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 17  is a diagram that illustrates a perspective view of a contact segment in accordance with an embodiment of the invention. 
         FIG. 18  is a process by which a connector with contacts comprising multiple points of contact can be made in accordance with an embodiment of the invention. 
         FIG. 19  is a process by which a connector with contacts comprising multiple points of contact can be made in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Certain embodiments of the present invention relate to electrical connectors assembled to PCBs that may be employed in electronic devices. While the present invention can be useful to produce connector assemblies for a wide variety of electronic devices, some embodiments of the invention are particularly useful for producing audio connector assemblies for electronic devices that require improved reliability, as described in more detail below. 
     Embodiments of the present invention may include a receptacle connector for receiving an audio connector or plug, e.g., a standard audio connector or plug. Standard audio plugs are available in three sizes according to the outside diameter of the plug: a 6.35 mm (¼″) plug, a 3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. The plugs include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions or “rings” located between the tip and sleeve, resulting in the connectors often being referred to as TRS (tip, ring and sleeve) connectors. 
       FIGS. 1A and 1B  illustrate examples of audio plugs  110  and  120  having three and four conductive portions, respectively. As shown in  FIG. 1A , plug  110  includes a conductive tip  112 , a conductive sleeve  116  and a conductive ring  114  electrically isolated from the tip  112  and the sleeve  116  by insulating rings  117  and  118 . The three conductive portions  112 ,  114 ,  116  are for left and right audio channels and a ground connection, respectively. Plug  120 , shown in  FIG. 1B , includes four conductive portions: a conductive tip  122 , a conductive sleeve  126  and two conductive rings  124 ,  125  and is thus sometime referred to as a TRRS (tip, ring, ring, sleeve) connector. The four conductive portions  122 ,  124 ,  125  and  126  are electrically isolated by insulating rings  127 ,  128  and  129  and are typically used for left and right audio, ground and microphone signals, respectively. 
     When plugs  110  and  120  are 3.5 mm miniature connectors, the outer diameter of conductive sleeve  116 ,  126  and conductive rings  114 ,  124 ,  125  is 3.5 mm and the insertion length of the connector is 14 mm. For 2.5 mm subminiature connectors, the outer diameter of the conductive sleeves is 2.5 mm and the insertion length of the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MP3 players and smart phones as well as other electronic devices. 
     Plugs  110  and  120  may interface with a receptacle connector mounted in an electronic device. The contacts are one of the most critical components of the connectors. The contacts are the portions of the receptacle connector and the plug that physically touch when the connectors are engaged and are responsible for conducting the electrical signals between the mated connectors. Not only must these contacts survive sometimes thousands of mates and de-mates, they must also withstand the rigors of today&#39;s consumer, remaining with them throughout the day as they travel in and out of fitness centers, kitchens, offices, factories, automobiles, and many other places. Many of these locations provide opportunities for exposure to chemicals or connector damage that pose little or no risk to the consumer, but present a harsh environment for the contacts. For example, connectors regularly come into contact with food, sweat, and other elements that may corrode or contaminate the materials that make up the connector contacts. In addition, electronic devices may be exposed to liquids such as a bathtub or rain, which may penetrate the device and destroy it. 
     To further illustrate embodiments of the invention, various examples of electrical audio connectors that include improved reliability and/or improved resistance to liquid ingression that may be made in accordance with the present invention are discussed below; however these embodiments should in no way limit the applicability of the invention to other connectors. 
       FIG. 2  is a simplified exploded perspective view of an audio receptacle connector  200 , in accordance with one embodiment of the invention. Receptacle connector  200  may include a body having an opening  255  that communicates with a cavity  265  having height, width and depth dimensions. Receptacle connector  200  may have a receiving face  250  with front opening  255  to receive a plug portion of a mating audio plug connector  120  (see  FIG. 1B ) and rear face  260  disposed opposite of the receiving face. Housing  205 ,  210  may extend between receiving face  250  and rear face  260  and define a cavity  265  that communicates with front opening  255 . A plurality of contacts  222   a ,  224   a ,  225   a ,  226   a , may be positioned within and spaced apart along a depth of the cavity and each may have an internal portion  222   b ,  224   b ,  225   b ,  226   b  disposed within cavity  265  and external portions  222   c ,  224   c ,  225   c ,  226   c  disposed outside of housing  205 ,  210 . External portions  222   c ,  224   c ,  225   c ,  226   c  may be configured to mount receptacle connector  200  to a printed circuit board or similar structure and provide an electrical path from contacts  222   a ,  224   a ,  225   a ,  226   a  to the electronic device. 
     In some embodiments, housing  205 ,  210  may comprise two pieces, including a base portion  205  and a lid portion  210 . In further embodiments, base portion  205  may be formed separately and contacts  222   a ,  224   a ,  225   a ,  226   a  may be subsequently inserted into the base portion. In other embodiments, base portion  205  may be formed around the contacts using, for example, an insert-molding process. In one embodiment an insert-molding process comprises placing the contacts in a portion of a molding die, closing the die, and injecting molten polymer around at least a portion of the contacts. In some embodiments, lid portion  210  may be formed separately using, for example, an injection molding process, while in other embodiments the lid portion may be formed around contacts  222   a ,  224   a ,  225   a ,  226   a  using, for example, an insert-molding process. In one embodiment an injection molding process comprises forming a cavity in a die, injecting molten polymer into the cavity, and removing the formed component from the die. In further embodiments, housing  205 ,  210  may be one piece and formed, for example, by insert-molding around contacts  222   a ,  224   a ,  225   a ,  226   a . In yet further embodiments, receiving face  250  of housing  205 ,  210  may have a face plate or bezel configured to engage with and form a liquid-tight seal to the electronic device. 
     In embodiments where base portion  205  is separate from lid portion  210 , the lid portion may be equipped with one or more tabs  290 , and base portion may be equipped with one or more tab recesses  295  where the tabs and tab recesses are configured to align and/or interlock the components together. In further embodiments, where lid portion  210  may be molded separately and pressed into place, tabs  290  and tab recesses  295  may be, for example, a clearance fit, an interference fit or snap-fit. Other embodiments may use different interlock features, such as, for example, pins and holes, latch features or adhesive. Interlock features may also be used in embodiments where lid portion  210  is insert-molded onto base portion  205 . In these embodiments, during the molding of lid portion  210 , molten plastic may flow into tab recesses  295  in base portion  205 , and serve as an interlock between the two components. 
     Some embodiments may benefit from receptacle connector  200  inhibiting liquid ingression into the electronic device through the connector. The housing configurations discussed above may be employed in some embodiments to make a liquid-tight connector that may have a tube like structure with a lid portion  210  and a base portion  205  having a plurality of contacts that extend through the base. The tube like structure may have a first interface  330  running the length of one side, a second interface  331  running the length of a second side, and a third interface  332  between the first and second interfaces. The interfaces may be configured to be substantially liquid-tight.  FIG. 3A  shows the housing fully assembled with base portion  205  of the housing aligned and mated to lid portion  210  along interfaces  330 ,  331 ,  332 . In some embodiments, insert-molding lid portion  210  onto base portion  205  may adhere the two components together along interfaces  330 ,  331 ,  332  which may form a liquid-tight connector  200 . Other embodiments may use different interface designs to form a liquid-tight connector. For example,  FIG. 3B  shows an enlarged view of one embodiment of interface  330 ,  331 ,  332  taken in region  335  where lid portion  210  may be glued and adhered to base portion  205 .  FIG. 3C  illustrates an embodiment having a rail  370  disposed on lid portion  210  and slot  375  disposed on base portion  205 .  FIG. 3D  illustrates a further embodiment having a half dove tail feature  380  employed along interface  330 ,  331 ,  332 . Interface features illustrated in  FIGS. 3C and 3D  may be called interlocking geometry and they may be disposed along the entire interface  330 ,  331 ,  332  or only a portion thereof. Myriad designs can be employed along interface  330 ,  331 ,  332  to form a liquid-tight receptacle connector. For example, further embodiments may use an externally applied sealant or tape along interface  330 ,  331 ,  332 . 
     In some embodiments a liquid tight seal may be formed at an interface between each contact external portion  222   c ,  224   c ,  225   c ,  226   c  and the body. In further embodiments, this may be accomplished by insert-molding contacts  222   a ,  224   a ,  225   a ,  226   a  into base portion  205  of housing. In other embodiments, this may be performed by adding a sealant or epoxy to the interface of base portion  205  of housing and external portion  222   c ,  224   c ,  225   c ,  226   c  of contacts. In further embodiments, a liquid tight seal may be formed by employing an interference fit between base portion  205  of housing and external portion  222   c ,  224   c ,  225   c ,  226   c  of contacts. Myriad methods can be used to form a liquid tight seal between base portion  205  of housing and external portion  222   c ,  224   c ,  225   c ,  226   c  of contacts. 
       FIG. 4  illustrates one embodiment of receptacle connector  200  (see  FIG. 2 ) engaged with example plug  120 . In this illustration, lid portion  210  (see  FIG. 2 ) and base portion  205  of housing have been removed for clarity, and example plug  120  is shown engaged with contacts  222   a ,  224   a ,  225   a ,  226   a . Each contact  222   a ,  224   a ,  225   a ,  226   a  may be aligned with a conductive portion of plug  120 . For example, in one embodiment, first contact  222   a  may be aligned with conductive tip  122  to conduct left audio signals, second contact  224   a  may be aligned with conductive ring  124  to conduct right audio signals, third contact  225   a  may be aligned with conductive ring  125  (see  FIG. 1B ) to conduct ground signals, and fourth contact  226   a  may be aligned with conductive sleeve  126  to conduct microphone signals. While the invention has been described with respect to jacks for standard TRRS audio connectors, it can be used with other types of connectors. 
     As illustrated in  FIG. 5 , contact  222   a  has been removed from receptacle connector  200  (see  FIG. 2 ) and will be used to show features that may be applicable to any of contacts  222   a ,  224   a ,  225   a  or  226   a . Contact  222   a  may have internal portion  222   b  that may comprise multiple primary contact segments  505 ,  510 ,  515 ,  520 . For example, internal portion  222   b  of contact  222   a  may have first segment  505  that may be substantially straight and second segment  510  that may be also substantially straight and may be connected to the first segment at an angle of approximately 90 degrees. Contact  222   a  may further have third segment  515  that may be substantially straight and may be connected to second segment  505  at an angle of approximately 90 degrees. Contact  222   a  may further have fourth segment  520  that may be substantially straight and may be connected to third segment  515  at an angle of approximately 90 degrees. The four segments  505 ,  510 ,  515 ,  520  of internal portion  222   b  of contact  222   a  may form a substantially square cross-sectional shape such that when combined, they form an aperture through which audio plug connector  120  (see  FIG. 1B ) can be inserted. Each contact  222   a  may have first and second opposing contact surfaces and third and fourth opposing contact surfaces. The first and second opposing surfaces may extend in the height dimension on opposite sides of cavity  265  (see  FIG. 2 ) and the third and fourth opposing surfaces may extend in the width dimension on opposite sides of the cavity. The end of segment  520  may be attached to segment  505 , or base portion  205  (see  FIG. 2 ) of housing may hold segment  520  in place. First segment  505  of contact  222   a  may have outside portion  222   c , sometimes called a lead, that may be disposed outside of housing  205 ,  210  (see  FIG. 2 ) and used to electrically couple the contact to a printed circuit board or other structure. 
     Further, each segment  505 ,  510 ,  515 ,  520  of contact  222   a  may comprise a pair of parallel longitudinal rails  550 ,  560  having a plurality of transverse fingers  555  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Fingers  555  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . More specifically, a single contact  222   a  may each comprise a plurality of fingers  555 , all of which may contact a single conductive portion of plug  120  (see  FIG. 1B ). When plug  120  (see  FIG. 1B ) is engaged with contact  222   a , one or more portions of contact may deflect to accommodate the generally larger geometry of the plug. In some embodiments one or more transverse fingers  555  may deflect. In another embodiment, one or more longitudinal rails  550 ,  560  may deflect. In other embodiments, one or more segments  505 ,  510 ,  515 ,  520  may deflect. In further embodiments any combination of the above may deflect to accommodate plug  120  (see  FIG. 1B ). 
     Some contacts in some embodiments may be considered to have two levels of redundancy. First, each segment  505 ,  510 ,  515 ,  520  may have a plurality of fingers  555  that may act as a redundant electrical connection between contact  222   a  and the respective single conductive portion of plug  120  (see  FIG. 1B ). Second, each contact may have more than one segment disposed around the circumference of plug  120  (see  FIG. 1B ), where each segment may act as a redundant electrical connection between contact  222   a  and the respective single conductive portion of the plug. For example, contact  222   a  illustrates four fingers  555  disposed on each of the four segments  505 ,  510 ,  515 ,  520  of the contact. This may result in sixteen separate contacts with conductive tip  122  of plug  120  (see  FIG. 4 ). Some embodiments may have both levels of redundancy (e.g.,  FIGS. 5-7 ) while other embodiments may have just one level of redundancy (e.g.  FIG. 8 ). Contact  222   a  in  FIG. 5  has four segments at 90 degree intervals, each of which may have multiple individual contact points. 
     In some embodiments, redundant electrical connections may improve the reliability and/or performance of receptacle connector  200  (see  FIG. 2 ). For example, if a portion of conductive tip  122  (see  FIG. 2 ) of plug  120  is damaged or contaminated with a non-electrically conductive substance, the plurality of fingers  555  increases the likelihood that at least one of the fingers will make electrical contact with the conductive tip of the plug. Fingers  555  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). 
     Further, each of contacts  222   a ,  224   a ,  225   a ,  226   a  may be designed to be wiping contacts that, during every mate and de-mate cycle, the contact of either the plug or the receptacle is forcibly pushed against the opposing contact during insertion and withdrawal of the plug. This results in a wiping action that helps breaks through any nonconductive surface corrosion and oxidation on the contact surface helping retain intimate metal-to-metal contact between the plug contacts and the receptacle contacts. 
     Other embodiments, as illustrated in  FIG. 6 , may have contacts  622   a  with internal portion  622   b  comprising segments  605 ,  610 ,  615 ,  620 . Each segment may have a pair of parallel longitudinal rails  650 ,  660  and a plurality of transverse fingers  655  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Longitudinal rails  650 ,  660  may be somewhat arcuate, or non-linear in shape. Fingers  655  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  655  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). The end of segment  620  may be attached to segment  605 , or base portion  205  (see  FIG. 3A ) of housing may hold segment  620  in place. One segment  605  of contact  622   a  may have outside portion  622   c  that may be used to electrically couple the contact to a printed circuit board or other structure. 
     Other embodiments, as illustrated in  FIG. 7 , may have contacts  722   a  with internal portion  722   b  comprising a single segment  705  formed in a generally circular shape. Segment  705  may comprise a pair of parallel longitudinal rails  750 ,  760  having a plurality of transverse fingers  755  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Longitudinal rails  750 ,  760  may be somewhat arcuate in shape, forming the generally circular cross-sectional shape of contact  722   a . Fingers  755  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  755  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). The end of segment  705  may be attached to the beginning of segment  705 , or the base portion  205  (see  FIG. 3A ) of housing may hold the end of segment  705  in place. Segment  705  of contact  722   a  may have outside portion  722   c  that may be used to electrically couple the contact to a printed circuit board or other structure. Contacts  222   a ,  622   a  and  722   a  are for illustrative purposes only and other contact shapes and geometries may be employed in further embodiments. For example, further embodiments may have other designs such as, hexagonal, octagonal, triangular or oval shapes comprising one or more segments. 
     Other embodiments, as illustrated in  FIG. 8 , may have contacts  822   a  with internal portion  822   b  comprising a single segment  805  formed in a generally straight shape. Segment  805  may comprise a pair of parallel longitudinal rails  850 ,  860  having a plurality of transverse fingers  855  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Longitudinal rails  850 ,  860  may be substantially straight. Fingers  855  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  855  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). The base portion  205  (see  FIG. 3A ) of housing may hold segment  805  in place. Segment  805  of contact  822   a  may have an outside portion  822   c  that may be used to electrically couple the contact to a printed circuit board or other structure. 
     Further embodiments, as illustrated in  FIG. 9 , may have contacts  922   a  with two halves  980 ,  990 , each similar to contact  822   a  in  FIG. 8 . Each half,  980 ,  990  may have an internal portion  922   b  comprising a single segment  905 ,  910  respectively, formed in a generally straight shape. Segments  905 ,  910  may each comprise a pair of parallel longitudinal rails  950 ,  960  having a plurality of transverse fingers  955  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Longitudinal rails  950 ,  960  may be substantially straight. Fingers  955  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  955  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). The base portion  205  (see  FIG. 3A ) of housing may hold segments  905 ,  910  in place. Segments  905 ,  910  of contact  922   a  may have outside portions  922   c  that may be used to electrically couple the contact to a printed circuit board or other structure. 
     Still further embodiments, as illustrated in  FIG. 10 , may have contacts  1022   a  comprising two components  1080 ,  1090 . In some embodiments, the two components  1080 ,  1090  may be formed, joined and subsequently installed in base portion  205  (see  FIG. 3A ) of housing. In other embodiments, component  1090  may be installed in base portion  205  (see  FIG. 3A ) of housing, then the second component  1080  may be joined to the first  1090 . The lid portion  210  (see  FIG. 3A ) of housing may then be subsequently assembled. In other embodiments, base portion  205  of housing may be insert-molded around component  1090  and component  1080  may be subsequently joined to component  1090 . Joining may be performed, for example, by welding, soldering or using a conductive adhesive. Once the two components  1080 ,  1090  are joined, contact  1022   a  may resemble contact  222   a  and perform similarly. Thus, when fully assembled, contact  1022   a  may have four segments, where each segment  1005 ,  1010 ,  1015 ,  1020  of contact  1022   a  may comprise a pair of parallel longitudinal rails  1050 ,  1060  having a plurality of transverse fingers  1055  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Fingers  1055  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  1055  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). The base portion  205  (see  FIG. 3A ) of housing may hold segments  1005 ,  1010 ,  1015 ,  1020  in place. Segment  1005  of contact  1022   a  may have outside portion  1022   c  that may be used to electrically couple the contact to a printed circuit board or other structure. 
     Other embodiments, as illustrated in  FIG. 11 , may have contacts  1122   a  with internal portion  1122   b  comprising segments  1105 ,  1110 ,  1115 . Each segment may have a pair of parallel longitudinal rails  1150 ,  1160  and a plurality of transverse fingers  1155  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. Fingers  1155  may be arranged to interfere with conductive portions  126 ,  125 ,  124 ,  122  (see  FIG. 1B ) of the plug portion of mating audio plug  120 . Fingers  1155  may be generally flat, or arcuate wherein they may be curved inward towards a line that longitudinally bisects the center of cavity  265  (see  FIG. 2 ). Segments  1105 ,  1115  of contact  1122   a  may have outside portions  1122   c  that may be used to electrically couple the contact to a printed circuit board or other structure. Contacts  822   a ,  922   a ,  1022   a  and  1122   a  are for illustrative purposes only and other contact shapes and geometries may be employed in further embodiments. 
     Referring back to  FIG. 5 , the internal portion  222   b  of contact  222   a  may be comprised of segments  505 ,  510 ,  515 ,  520 . Segments  505 ,  510 ,  515 ,  520  may be of myriad designs. In one embodiment, illustrated in  FIG. 12 , segment  1205  may comprise a pair of parallel longitudinal rails  1250 ,  1260  having a plurality of transverse fingers  1255  disposed between the pair of rails and attached to the pair of parallel longitudinal rails. In this embodiment, the width of the transverse rails  1255  may be slightly less than the width of the longitudinal rails  1250 ,  1260 . Comparatively, in  FIG. 13 , the width of transverse rails  1355  of segment  1305  are somewhat wider than that of the longitudinal rails  1350 ,  1360 . Thus the deflection of segment  1205  when engaged with plug  120  (see  FIG. 1B ) may be different than the deflection of segment  1305 . The width of both the longitudinal and the transverse rails may be varied to change the performance of the contact. For example, the narrow transverse rails of segment  1205  may allow each rail to deflect easier, applying a lower normal force on the plug contact, whereas the wider rails of segment  1305  may apply a higher normal force on the plug contact. 
     Further embodiments, as illustrated in  FIGS. 14 and 15 , may also change the performance of the contacts. For example segment  1405  illustrated in  FIG. 14  has transverse fingers  1455  that are tapered towards longitudinal rails  1450 ,  1460 , whereas segment  1505  illustrated in  FIG. 15  has transverse fingers  1555  that are tapered towards the center of the fingers. Each segment design may have particular benefits for a particular application and myriad designs can be used in further embodiments. Some embodiments, such as segment  1605  illustrated in  FIG. 16 , may only have one rail  1650 . Thus the transverse fingers  1655  may only be attached to one rail and may be cantilevered. Further embodiments, such as illustrated in  FIG. 17 , may have segments  1705  with no rails or transverse fingers at all and may be dished, or deformed  1730  such that when plug  122  (see  FIG. 1B ) is inserted, the dished portion of the segment may deflect. 
     Myriad contact designs may be employed in further embodiments. Any of the contact designs and segment designs discussed above may be employed as shown, or in other combinations. Further, different contact designs may be employed within a given connector. For example, a receptacle connector  200  may have one of contact  222   a , one of contact  622   a , one of contact  722   a  and one of contact  822   a . Various combinations of contacts can be used in other embodiments. Additionally, different segment designs can be employed within a given receptacle connector  200 . For example, a receptacle connector may have one of contact  222   a  with a segment design as illustrated in  FIG. 12 , and one of contact  622   a  with a segment design as illustrated in  FIG. 14 . Some embodiments may employ contacts that may have different normal forces. For example, some embodiments may place a contact with a higher normal force as the last contact to be engaged by plug  120  (see  FIG. 1B ), providing the user tactile feedback indicating full engagement of the plug. 
     Contacts may be made from any electrically conductive material, such as, for example, copper, brass, phosphor-bronze, steel or other materials. In some embodiments, contacts may also be plated with one or more metals. In one embodiment, each contact may be plated first with nickel, then with gold. Myriad methods can be used to manufacture the contacts. Housing  205 ,  210  (see  FIG. 2 ) may be made from any non-electrically conductive material. In some embodiments the housing may be made from plastic and may be injection molded. In other embodiments the housing may be made from plastic and may be insert-molded. Myriad methods can be used to manufacture housing  205 ,  210  (see  FIG. 2 ). 
     An exemplary simplified process  1800  for manufacturing a receptacle connector assembly with contacts comprising multiple points of contact, in accordance with embodiments described herein, is depicted in  FIG. 18 . In step  1805  a blank leadframe material may be provided. The leadframe material may comprise, for example, copper, brass, iron, phosphor-bronze, beryllium-copper, or other metallurgical alloys. In step  1810  the leadframe material may be shaped into contacts. The contacts can be made into myriad shapes without departing from the invention. In step  1815  a base portion of the plastic housing may be provided. In step  1820  the contacts may be installed in the lower housing. The contacts may have an inner portion disposed within the housing and an outer portion disposed outside of the housing. In step  1825  the housing lid may be installed. In step  1830  the receptacle connector may be completed, and is ready to be installed on a PCB. 
     An alternative exemplary simplified process  1900  for manufacturing a receptacle connector assembly with contacts comprising multiple points of contact, in accordance with embodiments described herein, is depicted in  FIG. 19 . In step  1905  a blank leadframe material may be provided. The leadframe material may comprise, for example, copper, brass, iron, phosphor-bronze, beryllium-copper, or other metallurgical alloys. In step  1910  the leadframe material may be shaped into contacts. The contacts can be made into myriad shapes without departing from the invention. In step  1915  a base portion of the plastic housing may be insert-molded around the contacts. The contacts may have an inner portion disposed within the housing and an outer portion disposed outside of the housing. In step  1920  the housing lid may be insert-molded around the contacts. In alternative embodiments, the housing lid may be molded separately and subsequently mated with the base portion of the housing. In step  1925  the receptacle connector may be completed, and is ready to be installed on a PCB. 
     In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the invention, and what is intended by the applicants to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.

Metadata:
Filing Date: 20121116
Publication Date: 20141118
Grant Date: 20141118
Priority Date: 20121116
Inventors: DO TRENT K.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/187", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/506", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/506", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 50728343