PATENT DOCUMENT

Publication Number: US-9357654-B2
Application Number: US-201414195823-A
Country: US
Kind Code: B2

Title: Low-profile plug with cam and flexible circuit board

Abstract:
A cable assembly including a connector insert to fit in a connector receptacle in an electronic device, where a back surface of the connector insert is substantially flush with an outside of an enclosure for the electronic device. One example may provide a cable assembly that includes a connector insert formed by wrapping a flexible circuit board at least partially around a housing. The flexible circuit board may be routed against an underside of the electronic device such that it does not obstruct a user, consume space in a display area, or have an undesirable appearance.

Claims:
What is claimed is: 
     
       1. A connector insert comprising:
 a housing having a first recess; 
 a flexible circuit board at least partially wrapped around the housing; 
 an integrated circuit coupled to the flexible circuit board and located in the first recess; and 
 a plurality of contacts formed on the flexible circuit board and arranged to mate with a plurality of contacts in a receptacle of an electronic device. 
 
     
     
       2. The connector insert of  claim 1  wherein the housing is metallic. 
     
     
       3. The connector insert of  claim 1  wherein the plurality of contacts are located on a first end portion of the flexible circuit board, the housing further has a second recess, and the first end portion of the flexible circuit board is located in the second recess. 
     
     
       4. The connector insert of  claim 1  further comprising a pull tab attached to the flexible circuit board. 
     
     
       5. The connector insert of  claim 1  further comprising a pull tab attached to the connector insert. 
     
     
       6. A connector insert comprising:
 a housing having a first recess and a second recess; 
 a flexible circuit board at least partially wrapped around the housing; 
 a component attached to the flexible circuit board and located in the first recess; and 
 a plurality of contacts located on a first end portion of the flexible circuit board and arranged to mate with a plurality of contacts in a receptacle of an electronic device, wherein the first end portion of the flexible circuit board is located in the second recess. 
 
     
     
       7. The connector insert of  claim 6  wherein the component attached to the flexible circuit board comprises an integrated circuit. 
     
     
       8. The connector insert of  claim 6  further comprising a pull tab attached to the flexible circuit board. 
     
     
       9. A method of manufacturing a connector insert comprising:
 forming a plurality of contacts on a first side at a first end portion of a flexible circuit board, the plurality of contacts arranged to mate with a plurality of contacts in a receptacle of an electronic device; 
 attaching a first component to a second side of a flexible circuit board; 
 aligning a housing over the first component such that the first component fits in a first recess of the housing; 
 at least partially wrapping the flexible circuit board around the housing; and 
 fitting the first end portion of the flexible circuit board in a second recess in the housing. 
 
     
     
       10. The method of  claim 9  further comprising:
 attaching a pull tab to the first side of the flexible circuit board. 
 
     
     
       11. The method of  claim 9  wherein the housing is metallic. 
     
     
       12. A cable assembly including a connector insert arranged to have a low-profile when inserted into an electronic device, the cable assembly comprising:
 a housing having a first recess, the housing formed to fit in a receptacle in the electronic device and having a back surface arranged to be substantially flush with an outside surface of an enclosure for the electronic device; 
 a flexible cable at least partially wrapped around the housing; and 
 a plurality of contacts formed on a first end portion of the flexible cable and arranged to mate with a plurality of contacts in the receptacle, the first end portion located in the first receptacle. 
 
     
     
       13. The cable assembly of  claim 12  wherein the housing is metallic. 
     
     
       14. The cable assembly of  claim 12  wherein the housing comprises a second recess, and wherein an integrated circuit is attached to the flexible cable and is located in the first recess. 
     
     
       15. The cable assembly of  claim 12  further comprising a pull tab attached to the flexible cable. 
     
     
       16. The cable assembly of  claim 12  further comprising a pull tab attached to the connector insert. 
     
     
       17. The cable assembly of  claim 12  wherein the flexible cable is a flexible circuit board. 
     
     
       18. A cable assembly including a connector insert arranged to have a low-profile when inserted into an electronic device, the cable assembly comprising:
 a housing having a first recess, the housing formed to fit in a receptacle in the electronic device and having a back surface arranged to be substantially flush with an outside surface of an enclosure for the electronic device; 
 a flexible circuit board at least partially wrapped around the housing; 
 an integrated circuit attached to the flexible circuit board and located in the first recess; and 
 a plurality of contacts formed on the flexible circuit board and arranged to mate with a plurality of contacts in the receptacle. 
 
     
     
       19. The cable assembly of  claim 18  wherein the plurality of contacts are located on a first end portion of the flexible circuit board. 
     
     
       20. The cable assembly of  claim 19  wherein the housing includes a second recess and the first end portion of the flexible circuit board is located in the second recess. 
     
     
       21. The cable assembly of  claim 20  further comprising a pull tab attached to the flexible circuit board.

Description:
BACKGROUND 
     The amount of data transferred between electronic devices has grown tremendously the last several years. Large amounts of audio, streaming video, text, and other types of data content are now regularly transferred among desktop and portable computers, media devices, handheld media devices, displays, storage devices, and other types of electronic devices. Power supply voltages and ground may be transferred with this data. 
     Power and data may be conveyed over cables that may include wire conductors, fiber optic cables, or some combination of these or other conductors. Cable assemblies may include a connector insert at one or both ends of a cable, though cable assemblies may be connected or tethered to an electronic device in a dedicated manner. The connector inserts may be inserted into receptacles in the communicating electronic devices. 
     Many of these electronic devices are now being used in retail or other environments where customers and others interact directly with them. These devices may include touch or other types of screens that provide information about various items, products, or services. These screens may also allow users to explore databases to find further information, to request help, to place orders, or to interact in other ways. 
     Again, conventional cable assemblies include a connector insert at an end of a cable. The connector insert includes an insert portion to fit in a connector receptacle in an electronic device. A housing of the connector insert attaches to the insert portion and does not fit into the connector receptacle, but rather extends orthogonally to an exterior surface of the electronic device. The cable may extend from the housing, also in a direction orthogonal to the exterior surface of the electronic device. 
     While this housing may be very convenient in that is allows a user to easily insert and remove the connector insert, it may obstruct a user interacting with the electronic device. It may also consume space in a display area and have an undesirable appearance. 
     Thus, what is needed are cable assemblies including connector inserts that do not obstruct a user, do not consume space in a display area, and do not have an undesirable appearance. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide cable assemblies that do not obstruct a user, do not consume space in a display area, and do not have an undesirable appearance. An illustrative embodiment of the present invention may provide a cable assembly including a connector insert to fit in a connector receptacle in an electronic device, where a back surface of the connector insert is substantially flush with an outside of an enclosure for the electronic device. One such illustrative embodiment of the present invention may provide a cable assembly that includes a flexible circuit board at least partially wrapped around a cam or housing. The flexible circuit board may be routed against an underside of the electronic device such that it does not obstruct a user, does not consume space in a display area, and does not have an undesirable appearance. 
     An illustrative embodiment of the present invention may include flexible cable at least partially wrapped around a cam or other housing. The flexible cable may be a flexible circuit board, ribbon connector, or other flexible cable. The flexible cable may be substantially flat to aid in keeping the cable out of sight of a user. The flexible cable may have an end portion, with a number of contacts printed or otherwise formed on a first side of the end portion of the flexible cable. The contacts may be electrically connected to conductors in the flexible cable. 
     One or more circuits or components may be attached to a second side of the flexible cable. In this way, the flexible cable may provide part of an enclosure for the circuits or components. These circuits may include active devices, passive components, integrated circuits, relays, switches, microelectromechanical devices (MEMs), or other electronic or mechanical components. These components may include circuits for power, identification, authorization, theft-prevention, and other functions. The components may be electrically connected to one or more conductors in the flexible cable and the contacts. 
     These components may be enclosed between the flexible cable and a housing, such as a cam or other type of housing. The housing may be metallic, though in various embodiments of the present invention it may be plastic, resin, ceramic, or other material or combination of these and other materials. The housing may have a first recess and the components may be located in the first recess. The housing may have a second recess and the end portion of the flexible cable may be located in the second recess. The housing or cam may help to enclose and protect the components, act as a plug head, and have a rear portion that conforms to an outside of a device enclosure. 
     The end portion of the flexible cable may be secured to the housing in the second recess. The end portion may be glued, taped, fixed with adhesive, or otherwise secured in place. The flexible cable may be wrapped at least partially around the housing or cam. This may allow contacts to be on a first side of the flexible cable and may allow the flexible cable to contact and enclose the components and exit the electronic device along its underside. 
     Again, the housing may have a back end arranged to be substantially flush with an outside of an enclosure for the electronic device. This, combined with the use of a flexible cable that may be discreetly routed, may provide a cable assembly that is unobtrusive, does not consume display area, and does not have an undesirable appearance. When a cable insert according to an embodiment of the present invention is inserted in an electronic device, the cable assembly may provide a connector insert and flexible cable that are not readily viewable by a user while that user is looking at a screen of the electronic device. 
     Contacts on the end portion of the flexible cable may engage or mate with connectors in the receptacle of the electronic device. Specifically, the housing may be arranged such that the contacts on the first side of the end portion of the flexible cable mate with contacts in the connector receptacle on the electronic device. These connections may be used to convey data, power, startup or configuration information, or other types of signals between the electronic device and one or more other electronic devices or networks. 
     While these cables may be useful in retail environments where they may rarely be disconnected, it may be desirable to disconnect them on occasion. It may be desirable that these cables not be removed by someone simply grabbing the flexible cable, as this may damage the cable assembly. Accordingly, embodiments of the present invention may include a pull tab for use in disconnecting and removing the cable assembly. This pull tab may be fixed using glue, tape, or adhesive, or otherwise attached to the first side of the flexible cable. 
     An illustrative embodiment of the present invention may provide a method of forming a cable assembly. This method may include forming a plurality of contacts on a first side at a first end portion of a flexible circuit board. A first component may be attached to a second side of a flexible circuit board. A housing may be aligned over the first component such that the first component fits in a first recess of the housing. A flexible circuit board may be at least partially wrapped around the housing. A pull tab may be attached to the first side of the flexible circuit board to enable the removal of the housing when it is inserted in a receptacle of an electronic device. 
     Embodiments of the present invention may be used in connector inserts and receptacles for cables that may connect to various types of devices, such as portable computing devices, tablets, desktop computers, laptops, all-in-one computers, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, and chargers, and other devices. These connector inserts may provide pathways for signals and power compliant with various standards such as Universal Serial Bus (USB), a High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), power, Ethernet, DisplayPort, Thunderbolt, Lightning and other types of standard and non-standard interfaces. 
     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 a cable assembly according to an embodiment of the present invention; 
         FIG. 2  illustrates a cable assembly according to an embodiment of the present invention; 
         FIG. 3  illustrates a cable assembly inserted into an electronic device in accordance with an embodiment of the present invention; 
         FIG. 4  illustrates a flexible cable according to an embodiment of the present invention; 
         FIG. 5  illustrates an intermediate step in the manufacturing of a cable assembly according to an embodiment of the present invention; 
         FIG. 6  illustrates a cam or housing  210  according to an embodiment of the present invention; 
         FIG. 7  illustrates a completed cable assembly according to an embodiment of the present invention; 
         FIG. 8  illustrates a close-up view of a connector insert portion according to an embodiment of the present invention; and 
         FIG. 9  illustrates another close-up view of a connector insert portion according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates a cable assembly according to 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 cable assembly including connector insert portion  110  and flexible cable  120 . Connector insert portion  110  may be configured to be inserted in receptacle  112  and may have a back that is arranged to fit approximately flush with an outside of an enclosure of electronic device  140 . Flexible cable  120  may include a wider portion  122 . To assist in removal of connector insert portion  110 , a pull tab  130  may be included. Connector insert portion  110  may be removed by pulling on pull tab  130  in a direction approximately orthogonal to a surface of the device enclosure for the electronic device  140 . 
     Again, connector insert portion  110  may be arranged to be substantially flush with a surface of device enclosure  140 . Flexible cable  120  may be routed underneath the electronic device and away from connector insert portion  110 . Pull tab  130  may similarly be folded underneath the electronic device. This may provide a cable assembly that is not visible to a user who is viewing a screen on the electronic device. (In this figure, the screen may be facing downward towards a surface on which the electronic device is resting.) 
     Traces or conductors in flexible cable  120  may attach to contacts on connector insert portion  110 . These contacts may mate or form electrical connections with contacts in the connector receptacle  112 . In this way, power, data, and other signals may be transferred between the electronic device and one or more other electronic devices. 
     In this specific example, flexible cable  120  may be a flexible circuit board, though in other embodiments of the present invention it may be a ribbon cable or other type of flexible cable. 
       FIG. 2  illustrates a cable assembly according to an embodiment of the present invention. In this example, flexible cable  120  may be wrapped at least partially around a cam or housing  210 . Cam or housing  210  may include a first recess. One or more electronic components  220  may be located in this recess. These components may include active devices, passive components, integrated circuits, relays, switches, microelectromechanical devices (MEMs), or other electronic or mechanical components. These components may include circuits for power, identification, authorization, theft-prevention, and other functions. 
     One or more contacts  124  may be printed or otherwise formed on flexible cable  120 . These contacts may be printed on a first side of a first end portion of flexible cable  120 . The end portion of flexible cable  120  may fit in a second recess in housing  210 . The first end portion of flexible cable  120  may be glued, attached with adhesive or tape, or otherwise fixed to cam or housing  210 . Pull tab  130  may be attached to insert portion  110 . For example, pull tab  130  may be glued, fixed with adhesive or tape, or otherwise attached to a first surface of flexible cable  120 . 
     Again, when connector insert portion  110  is inserted into a receptacle, contacts  124  may mate with corresponding contacts in a connector receptacle. Also, flexible cable  120  may be routed away and underneath the electronic device  140  such that the cable assembly is not visible to a user viewing a screen on the electronic device. An example is shown in the following figure. 
       FIG. 3  illustrates a cable assembly inserted into an electronic device in accordance with an embodiment of the present invention. Again, connector insert portion  110  may include one or more electrical components  220 . These electrical components  220  may be housed in a recess in housing or cam  210 . Flexible cable  120  may be at least partially wrapped around cam or housing  210 . Pull tab  130  may be included to assist in the removal of connector insert portion  110  from electronic device  140 . Again, a rear of housing  210  may be arranged to fit substantially flush with an outside surface of an enclosure for electronic device  140 . 
     One or more contacts  124  formed on flexible cable  120  may mate with corresponding contacts  324  in the connector receptacle  112 . These connections may convey power, data, startup or configuration information, or other signals between this electronic device  140  and one or more other electronic devices. More specifically, contacts  124  may electrically connect to contacts at a distant end of flexible cable  120 . Contacts  124  and distant contacts (not shown) may electrically connect to each other or to components  220 . An example of one flexible cable  120  is shown in the following figure. 
       FIG. 4  illustrates a flexible cable according to an embodiment of the present invention. This flexible cable  120  may include a number of contacts  124  on an end portion of flexible cable  120 . Pull tab  130  may also be attached to flexible cable  120 . Distant end portion  128  may include a number of contacts  410 ,  412 ,  414 , and  416 . These contacts may convey data and power between electronic device  140  and one or other electronic devices. In a specific embodiment of the present invention, contacts  410  may be a D− contact and contact  412  may be a D+ contact. These contacts may convey a Universal Serial Bus or other differential signal. Contact  414  may be a VBUS contact, while contact  416  may be a ground contact. This second set of contacts may supply power to electronic device  140 . A second side of flexible cable  120  may include a contact area  420 , where one or more components may be attached. Traces may connect these components to one or more contacts  124 , as well as one or more contacts on distant end portion  128 . 
     Connector assemblies consistent with embodiments of the present invention may be manufactured in various ways. An example is shown in the following figure. 
       FIG. 5  illustrates an intermediate step in the manufacturing of a cable assembly according to an embodiment of the present invention. One or more contacts  124  may be formed on an end portion of flexible cable  120 . Pull tab  130  may be attached to the top surface of flexible cable  120 . One or more electrical components  220  may be attached to a second side of flexible cable  120 . A cam or housing may be placed over electrical components  220 . Flexible cable  120  may be at least partially wrapped around this cam or housing. An example of such a cam or housing is shown in the following figure. 
       FIG. 6  illustrates a cam or housing  210  according to an embodiment of the present invention. Cam or housing  210  may include a first recess  610 . One or more electrical components  220  may be located in first recess  610 . In one example, components  220  may be sealed in a structure that is arranged to fit in first recess  610 . This may provide improved heat dissipation for components  220 . Cam or housing  210  may protect electrical components  220  and provide a mechanical support for flexible cable  120 . Cam or housing  210  may include a second recess  620 . An end portion of flexible cable  120  supporting contacts  124  may be located in second recess  620 . This end portion may be glued, fixed with adhesive or tape, or otherwise secured to second recess  620 . In other embodiments of the present invention, a lip or edge around the recess  620  may be used to secure the flexible cable  120  in place. Cam or housing  210  may further include side indentations  630 , which may be grasped by a user during insertion into electronic device. 
       FIG. 7  illustrates a completed cable assembly according to an embodiment of the present invention. Again, flexible cable  120  may be at least partially wrapped around housing  210  to form connector insert portion  110 . Pull tab  130  may be attached to connector insert portion  110  to assist in the removal of connector insert portion  110  from an electronic device. An end portion of flexible cable  120  may support a number of contacts that may be electrically connected to contacts  124  on connector insert portion  110  and to one or more electrical components  220  inside housing  210 . 
       FIG. 8  illustrates a close-up view of a connector insert portion according to an embodiment of the present invention. Again, a number of contacts  124  may be located on an end portion of flexible cable  120 . Flexible cable  120  may include a wider portion  122 . Flexible cable  120  may be at least partially wrapped around housing  210 . A pull tab  130  may be included. 
       FIG. 9  illustrates another close-up view of a connector insert portion according to an embodiment of the present invention. Again, connector insert portion  110  may include housing  210 . Pull tab  130  may also be included. 
     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: 20140303
Publication Date: 20160531
Grant Date: 20160531
Priority Date: 20140303
Inventors: NG NATHAN
YUAN PAUL
KIM MIN CHUL
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/303", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R31/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/056", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/056", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/056", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R31/06", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R31/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4913", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/303", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 54007188