PATENT DOCUMENT

Publication Number: US-9941627-B2
Application Number: US-201615181307-A
Country: US
Kind Code: B2

Title: Magnetic surface contacts

Abstract:
This application relates to magnetically actuated electrical connectors. The electrical connectors includes movable magnetic elements that move in response to an externally applied magnetic field. In some embodiments, the electrical connectors includes recessed contacts that move from a recessed position to an engaged position in response to an externally applied magnetic field associated with an electronic device to which the connector is designed to be coupled. In some embodiments, the external magnetic field has a particular polarity pattern configured to draw contacts associated with a matching polarity pattern out of the recessed position.

Claims:
What is claimed is: 
     
       1. A magnetically actuated connector, comprising:
 a connector housing defining a channel; 
 a floating contact disposed within the channel, the floating contact comprising an exterior portion formed of electrically conductive material and an interior portion including a magnet, wherein the floating contact including the electrically conductive material and the magnet is configured to follow a linear path between a first position and a second position within the connector housing in response to a magnetic force; and 
 a flexible circuit including a flexible attachment feature, the flexible attachment feature being electrically coupled to the floating contact and being configured to accommodate movement of the floating contact between the first position and the second position. 
 
     
     
       2. The magnetically actuated connector as recited in  claim 1 , wherein the magnetically actuated connector includes multiple floating contacts and the flexible circuit includes multiple flexible attachment features. 
     
     
       3. The magnetically actuated connector as recited in  claim 2 , further comprising circuitry configured to receive a ground signal through a first floating contact, power through a second floating contact and data through a third floating contact. 
     
     
       4. The magnetically actuated connector as recited in  claim 1 , wherein the floating contact remains in the second position when the magnetically actuated connector is in use. 
     
     
       5. The magnetically actuated connector as recited in  claim 4 , wherein interior surfaces that define the channel guide the floating contact between the first and second positions. 
     
     
       6. The magnetically actuated connector as recited in  claim 4 , wherein in the first position the floating contact is recessed below an exterior surface defined by the connector housing and in the second position the floating contacts are substantially flush with the exterior surface of the connector housing. 
     
     
       7. The magnetically actuated connector as recited in  claim 1 , wherein the exterior portion of the floating contact comprises:
 an electrically conductive shell defining an opening; and 
 a magnetic shunt covering the opening and cooperating with the electrically conductive shell to define the interior portion. 
 
     
     
       8. The magnetically actuated connector as recited in  claim 7 , wherein the magnetic shunt redirects a portion of a magnetic field emitted by the magnet towards an exterior surface of an accessory device associated with the magnetically actuated connector. 
     
     
       9. The magnetically actuated connector as recited in  claim 1 , wherein the flexible attachment feature comprises an inner ring and an outer ring. 
     
     
       10. The magnetically actuated connector as recited in  claim 1 , wherein the floating contact is soldered to a first side of the flexible circuit, the first side being opposite a second side and wherein the magnetically actuated connector further comprises a magnetically attractable substrate coupled with the second side of the flexible circuit. 
     
     
       11. The magnetically actuated connector as recited in  claim 10 , wherein a magnetic attraction between the magnet and the magnetically attractable substrate moves the floating contact from the second position to the first position when the magnetic force is removed. 
     
     
       12. The magnetically actuated connector as recited in  claim 1 , wherein the flexible circuit electrically couples the floating contact with one or more operational components disposed within an associated electronic accessory device. 
     
     
       13. The magnetically actuated connector as recited in  claim 1 , wherein the flexible circuit comprises a flexible printed circuit board, the flexible printed circuit board comprising electrically conductive pathways arranged on a polymeric substrate. 
     
     
       14. An accessory device, comprising:
 a device housing; and 
 a magnetically actuated connector arranged along an exterior surface of the device housing, the magnetically actuated connector comprising: 
 a floating contact having an exterior portion formed of electrically conductive material and an interior portion including a magnet; and 
 a flexible circuit that includes a flexible attachment feature including an inner portion and an outer portion that are concentric, the flexible attachment feature being soldered to the floating contact and being configured to accommodate movement of the floating contact between a first position and a second position. 
 
     
     
       15. The accessory device as recited in  claim 14 , further comprising:
 a protective cover defining a channel therethrough that defines a pathway along which the floating contact moves between the first position and the second position. 
 
     
     
       16. The accessory device as recited in  claim 15 , wherein the channel allows an exterior contact surface of the floating contact to be arranged along an exterior surface of the protective cover when the floating contact is in the second position. 
     
     
       17. The accessory device as recited in  claim 15 , wherein the floating contacts further comprises a magnetic shunt redirecting a magnetic field emitted by the magnet towards an exterior surface of the magnetically actuated connector. 
     
     
       18. An accessory device, comprising:
 a device housing; and 
 a magnetically actuated connector arranged along an exterior surface of the device housing, the magnetically actuated connector comprising:
 an electrical contact having an exterior portion formed at least in part of electrically conductive material and an interior portion that includes a magnet, and 
 an electrically conductive pathway having an inner portion and an outer portion that are concentric, the electrically conductive pathway electrically coupling the electrical contact to circuitry of the accessory device and being configured to accommodate movement of the electrical contact between a first position and a second position. 
 
 
     
     
       19. The accessory device as recited in  claim 18 , wherein the electrically conductive pathway comprises a flexible circuit that is coupled with a magnetically attractable substrate. 
     
     
       20. The accessory device as recited in  claim 19 , wherein the flexible circuit accommodates the movement of the floating contact from the first position to the second position by deforming away from the magnetically attractable substrate. 
     
     
       21. The accessory device as recited in  claim 18 , wherein the magnetically actuated connector comprises a plurality of electrical contacts and wherein the magnetically actuated connector can be attached to an electronic device in two or more orientations.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 USC 119(e) to U.S. Provisional Patent Application No. 62/235,326 filed on Sep. 30, 2015, and entitled “MAGNETIC SURFACE CONTACTS,” the disclosure of which is incorporated by reference in its entirety and for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to a connector for an accessory device capable of exchanging power and data with an electronic device. In particular, the connector includes recessed contacts that are magnetically actuated by magnets associated with contacts of the electronic device. 
     BACKGROUND 
     In an effort to progressively improve the functionality of a portable electronic device, new ways of configuring an accessory device are desirable. A variety of accessory devices are available that can augment the functionality of host electronic devices such as tablet computers, smart phones, laptop computers, etc. These accessory devices often include electronic circuitry and one or more embedded batteries that power the electronic circuitry. In many such devices the batteries can be charged by connecting an appropriate cable to a charging port. Such ports and the contacts positioned therein can be susceptible to damage, etc. Consequently, an accessory device with more robust and/or protected charging contacts is desirable. 
     SUMMARY 
     This disclosure describes various embodiments that relate to a magnetic accessory connector having magnetically actuated electrical contacts. 
     A magnetically actuated connector is disclosed and includes a floating contact having an exterior portion formed of electrically conductive material and an interior portion including a magnet. The magnetically actuated connector also includes a flexible circuit that includes a flexible attachment feature. The flexible attachment feature is electrically coupled to the floating contact and configured to accommodate movement of the floating contact between a first position and a second position. 
     An accessory device is disclosed and includes the following: a device housing; and a magnetically actuated connector arranged along an exterior surface of the device housing. The magnetically actuated connector includes a floating contact having an exterior portion formed of electrically conductive material and an interior portion that includes a magnet. The magnetically actuated connector also includes a flexible circuit having a flexible attachment feature that is soldered to the floating contact and configured to accommodate movement of the floating contact between a first position and a second position. 
     Another accessory device is disclosed and includes the following: a device housing; and a magnetically actuated connector arranged along an exterior surface of the device housing. The magnetically actuated connector includes an electrical contact having an exterior portion formed of electrically conductive material and an interior portion that includes a magnet. The magnetically actuated connector also includes an electrically conductive pathway electrically coupling the electrical contact to circuitry of the accessory device. The electrically conductive pathway is configured to accommodate movement of the electrical contact between a first position and a second position. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  shows various portable electronic devices suitable for use with embodiments disclosed herein; 
         FIGS. 2A-2B  show exploded views of a connector configured to be built into an accessory device; 
         FIG. 3A  shows how floating contacts are assembled together from an electrical contact, a magnet and a magnetic shunt; 
         FIG. 3B  shows the floating contacts assembled and attachment features of a flexible printed circuit board; 
         FIG. 3C  shows a view of the floating contacts soldered to the solder pads arranged on attachment features of the flexible printed circuit board; 
         FIG. 3D  shows a cross-sectional view of a floating contact coupled with a DC shield by way of a flexible PCB in accordance with section line A-A; 
         FIG. 3E  shows a cross-sectional view of another floating contact coupled with a DC shield by way of a flexible PCB in accordance with section line B-B; and 
         FIGS. 4A-4B  show recessed and engaged positions of a connector; 
         FIGS. 5A-5B  show a variety of pogo pins configured to electrically couple with another electrical contact; 
         FIG. 6A  shows a cross-sectional side view of a pogo pin having an integrated movable magnet; 
         FIG. 6B  depicts a pogo pin that differs slightly from the pogo pin depicted in  FIG. 6A  in that the rear housing component utilizes a press-fit feature to couple with the front housing component; 
         FIG. 6C  depicts how an electrical contact can be depressed slightly into the front opening of a housing component on account of a force being exerted on the electrical contact; 
         FIGS. 7A-7B  show first and second positions of an electrical connector  700  utilizing pogo pins similar to those described in  FIGS. 5A-5B ; 
         FIG. 7C  shows an electrical connector utilizing magnetic pogo pins similar to the pins depicted in  FIGS. 6A-6C ; 
         FIGS. 8A-8B  show cross-sectional views of magnetic ball style pogo pins; 
         FIGS. 9A-9B  show top views of a magnetic electrical connector; 
         FIGS. 9C-9D  show cross-sectional side views of the electrical connector depicted in  FIGS. 9A-9B ; 
         FIGS. 10A-10B  show an alternative electrical connector design; and 
         FIGS. 11A-11B  show multiple views of another magnetic connector having a pill-shaped protrusion. 
     
    
    
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The operation and utility of electronic devices can often benefit from interaction with various accessory devices. Input devices can be particularly effective at enhancing utility as they provide new ways and manners for interacting with the device. Unfortunately, these input devices are often electronic in nature and often require cumbersome and easily misplaced charging and/or data cables for applying any number of firmware updates, content loading and charging operations to the accessory device. 
     One solution to this problem is to include a built-in connector with an electronic accessory device that provides a conduit for exchanging power and/or data between the accessory device and another electronic device. In some embodiments, the built-in connector of this accessory device can include a floating contact design. The floating contacts can be positioned in a recessed position when the connector is not in use and in an engaged position when the connector is in use. By stowing the floating contacts in a recessed position when not in use, the electrical contacts of the floating contacts can be prevented from experiencing excessive wear on account of rough or careless handling leading to scratching or degrading of the electrical contacts. The floating contacts can include a magnetic element that drives the floating contacts between the recessed and engaged positions. In some embodiments, the magnetic elements can be attracted to a magnetically attractable element within the accessory device when the connector is not in use. When the connector engages a connector of another electronic device, the connector of the electronic device can include one or more magnetically attractable elements that attract the magnets within the floating contacts with an amount of force sufficient to overcome the magnetic coupling between the magnets and the magnetically attractable element within the accessory device. In this way, the floating contacts can move between the engaged and recessed positions without any expenditure of energy by the accessory device. 
     The accessory device can also include flexible electrically conductive pathways that remain attached to the floating contacts in both the recessed and engaged positions. In some embodiments, the flexible electrically conductive pathways can take the form of one or more flexible circuits. In one particular embodiment, the flexible circuit can take the form of a number of electrically conductive pathways printed upon a polymeric substrate. The polymeric substrate can include a cutout pattern that allows portions of the substrate to accommodate movement of the floating contacts without placing an undue amount of strain on the polymeric substrate. In this way, the electrical coupling between the floating contacts and the flexible circuits can be maintained in both positions. 
     This application also discloses additional embodiments related to moving connector elements. In particular, various pogo pin embodiments are disclosed. Pogo pins typically include a spring-loaded depressible electrical contact. Some of the disclosed pogo pin embodiments include an internal movable magnet that cooperates with a spring to oppose depression of the electrical contact. Additional embodiments are disclosed that include movable magnets that are configured to assist in connection and/or alignment of electrical connectors. 
     These and other embodiments are discussed below with reference to  FIGS. 1-11 ; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
     Floating Contact Embodiments: 
       FIG. 1  shows a perspective view of a portable electronic device  100  suitable for use with embodiments disclosed herein. Portable electronic device  100  can represent a multiplicity of different electronic devices that include a laptop, cell phone, wearable device, tablet device, media device and the like. Portable electronic device  100  can include a display assembly  102  positioned within a front opening defined by device housing  104 . Device housing  104  is also configured to protect various electrical components disposed within device housing  104 . Device housing  104  can also define openings within which contacts making up connector  106  can be positioned. The electrical contacts of connector  106  can be configured to provide a means through which portable electronic device  100  can communicate with and exchange power with various accessory devices. A wide variety of accessory devices can benefit from such a connector including but not limited to a powered cover or case, an external battery pack enclosure, an external keyboard, a stylus, a wireless headset or earbuds, a docking station and the like. 
       FIGS. 2A-2B  show an exploded view of a connector configured to be built into an accessory device.  FIG. 2A  shows protective cover  202 . Protective cover  202  can be formed form an insulating material along the lines of glass fiber reinforced nylon or any rigid polymer. Protective cover  202  could also be formed of insulating materials along the lines of ceramic materials. Protective cover  202  can have an exterior surface with a curvature suited to match a device surface to which it is designed to be coupled with. As depicted, protective cover  202  defines multiple openings  204   a - 204   c  within which electrical contacts of the connector can be positioned. An interior portion of protective cover  202  can define a channel corresponding to each opening that accommodates at least a portion of an electrical contact of connector  200 . The channels defined by protective cover  202  can also help to guide the contacts between recessed and engaged positions. One or more of electrical contacts  206   a - 206   c  can take the form of electrically conductive shells, as depicted. In some embodiments, electrical contacts  206   a - 206   c  can have a minimal thickness configured primarily as an electrically conductive shell for guiding power and data from the electronic device to which it couples and electrically conductive pathways within the accessory device. In some embodiments, electrical contacts  206   a - 206   c  can have an average thickness of about 0.15 mm and be formed from a phosphorous bronze alloy. One reason the thickness of electrical contacts  206   a - 206   c  can be so thin is that the contacts are recessed when not in use which prevents un necessary wear and tear on electrical contacts  206   a - 206   c . Magnets  208   a - 208   c  can take the form of high-strength permanent magnets, such as rare-earth magnets along the lines of neodymium magnets. Magnets  208   a - 208   c  can have a size and shape complementary to an interior geometry of electrical contacts  206   a - 206   c , so that magnets  208  can be coupled with an interior volume defined by electrical contacts  206 . In some embodiments, magnets  208  can be adhesively coupled to an interior surface of a corresponding contact  206 . 
     Connector  200  can also include a number of magnetic shunts  210 . Magnetic shunts  210  can be affixed to a rear-facing portion of a corresponding contact  206 , thereby forming a number of floating contacts that each include contact  206 , magnet  208  and magnetic shunt  210 . Magnetic shunt  210  stays directly behind magnets  208  so that a magnetic fields emitted by magnets  208  are concentrated towards openings  204  defined by protective cover  202 . Magnetic shunts are generally made from a material resistance to the passage of magnetic fields. One common material utilized for magnetic shunts is stainless steel on account of it being able to redirect magnetic fields that would otherwise pass through the magnetic shunt. The magnetic fields emitted by magnets  208  can be arranged in various polarity patterns that help to encourage proper lineup between the floating contacts and corresponding contacts on a portable electronic device. For example, centrally positioned magnets could have one polarity and magnets arranged on the periphery could have an opposite direction polarity. These polarities could be matched with polarities associated with contacts of the portable electronic device. It should be noted that in some embodiments, electrical contacts  206  can include a seal that interacts with protective cover  202  to prevent the intrusion of moisture into an associated accessory device through  200 . For example, each of electrical contacts  206  can include an o-ring that creates an interference fit with a portion of protective cover  202  at least when the floating contacts are in the recessed position. 
     The floating contacts can be soldered to solder pads on flexible printed circuit board (PCB)  212 . The solder pads are situated on portions of a flexible circuit taking the form of flexible PCB  212  that have been partially separated from the rest of flexible PCB  212 . In this way, the portions of the flexible PCB upon which electrical contacts  206  are attached allow substantial movement of electrical contacts  206  away from flexible PCB  212 , so only minor amounts of stress are applied to flexible PCB  212  during movement of the floating contacts. By having three floating contacts, each of the floating contacts can be arranged to provide power, a ground or a data signal. When the central contact is associated with power, connector  200  can be arranged to accept either a ground or a data signal at either of the peripheral contacts. In this way, connector  200  can be coupled to a portable electronic device in either of two different orientations. Flexible printed circuit board  212  can be adhesively coupled with DC shield  214 .  FIG. 2B  shows a connector  250  having a configuration similar to that shown in  FIG. 2A  with the inclusion of a fourth contact depicted as contact  256   d . In some embodiments, the fourth contact  256   d  can provide additional power for connector  250 . In other embodiments, the additional contact  256   d  can provide an additional data port for increasing a transmission speed of data through connector  250 . 
       FIG. 3A  shows how the floating contacts are assembled together from electrical contact  206 , magnet  208  and magnetic shunt  210 . The arrows depicts how magnet  208  is inserted into a rear opening defined by electrical contact  206  and then how magnetic shunt  210  fits between multiple tails  302  of electrical contact  206 .  FIG. 3B  shows the floating contacts assembled and how protrusions  304  of magnetic shunt  210  fit between each of a number of tails  302  of electrical contact  206 . In some embodiments, electrical contact  206  can be adhesively coupled to both magnet  208  and magnetic shunt  210 . 
       FIG. 3B  also shows a detailed view of flexible PCB  212 . Flexible PCB includes multiple electrically conductive pathways that couple the floating contacts with circuitry within the accessory device. Here it can be seen how flexible PCB  212  includes attachment features  306  that take the form of inner and outer rings of material of flexible PCB  212 , which gives each of attachment features  306  a somewhat spiral shaped geometry. In particular, one of attachment features  306  includes outer ring  306 ( 1 ) a  and inner ring  306 ( 1 ) b . Outer ring  306 ( 1 ) a  includes multiple solder pads  308  by which each attachment features  306  can be electrically and mechanically coupled with a floating contact and in particular with tails  302  of the floating contact. Outer ring  306 ( 1 ) a  is coupled to the rest of flexible PCB  212  by inner ring  306 ( 1 ) b , which is in turn attached to the rest of flexible PCB  212  by an attachment member that takes the form of a narrow strip of material. On account of attachment features  306  following a linear path that includes multiple turns, attachment features  306  can allow the floating contacts to transition between engaged and recessed positions while placing minimal stress on attachment features  306  and flexible PCB  212 . This motion is accommodated primarily by the inner ring of each of attachment features  306  since the outer ring is soldered in four places to tails  302  of electrical contacts  206 . When connector  200  transitions between recessed and engaged positions attachment features  306  undergo a telescoping action to accommodate the motion. It should also be noted that while each of attachment features  306  is depicted as being oriented in a different direction, that the flexible connectors could also each be oriented in the same direction or have their orientations vary in different amounts or patterns. 
       FIG. 3C  shows a view of the floating contacts soldered to the solder pads arranged on attachment features  306  of flexible PCB  212 .  FIG. 3C  also shows how flexible PCB  212  can be adhesively coupled with DC shield  214 . DC shield can be formed from any number of magnetically attractable materials. In one particular embodiment DC shield  214  can be formed for stainless steel (SUS)  430 . In another embodiment, DC shield  214  and magnetic shunts  210  can be formed of a cobalt iron alloy. It should be noted that in some embodiments only a periphery of flexible PCB  212  is coupled with DC shield  214 , thereby allowing attachment features  306  to telescope away from DC shield  214  to accommodate movement of the floating contacts. Flexible PCB  212  can be coupled to DC shield  214  in many ways including by a layer of adhesive. In some embodiments, the layer of adhesive forms an insulating layer that electrically isolates flexible PCB  212  from DC shield  214 . 
       FIG. 3D  shows a cross-sectional view of a floating contact coupled with DC shield  214  by way of flexible PCB  212  in accordance with section line A-A. Section line A-A runs across a central portion of the floating contact and consequently magnetic shunt  210  runs across a diameter of electrical contact  206 . In this way magnetic shunt  210  can be well positioned to prevent a magnetic field emitted by magnet  208  from extending towards DC shield  214  and into the accessory device. 
       FIG. 3E  shows a cross-sectional view of another floating contact coupled with DC shield  214  by way of flexible PCB  212  in accordance with section line B-B. In  FIG. 3E  tails  302  of electrical contacts  206  are depicted extending all the way to solder pads  308 . In this way electrical traces on flexible PCB  212  can be electrically coupled to electrical contact  206  by way of solder pads  308  and tails  302 . This allows ground, power or data to pass through electrical contact  206  and over to another electrical device, while bypassing magnet  208  and magnetic shunt  210 . Although a particular configuration of four pads and essentially two rings of the spiral attachment features are depicted the spirals and solder pads can be arranged in many other ways and in many other configurations. For example, in some embodiments when a longer floating contact travel is desired flexible PCB  212  can include three or four spirals or rings allowing flexible attachment features  306  to accommodate a much longer range of travel. Similarly, in some embodiments, electrical contacts  206  may only include three feet soldered to three solder pads of outer ring  306   a  of attachment feature  306 . 
       FIGS. 4A-4B  show recessed and engaged positions of connector  200 .  FIG. 4A  shows how a magnetic force  404  acts between magnet  208  of connector  200  and magnet  402  of the electronic device  400 . In  FIG. 4A  magnet  402  is too far away to overcome the magnetic force  406  that operates between DC shield  214  and magnet  208 .  FIG. 4B  shows how once electrical device  400  and particularly magnet  402  get close enough to magnet  208  magnetic force  404  becomes large enough to overcome magnetic force  406 .  FIG. 4B  also shows the spiral configuration assumed by attachment feature  306  of flexible PCB  212 , which accommodates the floating contacts movement into the engaged position. As depicted, portions of flexible attachment feature  306  (i.e. inner ring  306   b ) deform to accommodate the motion of the floating contact towards electronic device  400 . Once electronic device  400  engages connector  200 , electrical contact  408  of electronic device  400  becomes electrically coupled with electrical contact  206 . It should be noted that while electrical contact is shown as having a convex geometry the geometry can alternatively be concave to match a geometry of electrical contact  408 . It should also be noted that electronic device  400  can have multiple electrical contacts  408 . One electrical contact  408  corresponds to each of electrical contacts  206  of connector  200 . In some embodiments, where electrical contact  206  sticks out past a mating surface defined by protective cover  202  the magnetic coupling may push electrical contact  206  back slightly into connector  200  so that an exterior surface of electronic device  400  can also contact the curved surface defined by protective cover  202 . 
     Pogo Pin Embodiments: 
       FIGS. 5A-5B  show pogo pins configured to electrically couple with another electrical contact.  FIG. 5A  shows a pogo pin  500  with a spring  502  embedded within housing  504 . Spring  502  is configured to allow electrical contact  506  to retract into housing  504  of pogo pin  500 . Pogo pin  500  can also include spring coupling device  508 , which includes a protrusion for mating with spring  502 . The convex surface of spring coupling device  508 , which contacts electrical contact  506 , is designed to encourage misalignment of spring coupling device  508  and electrical contact  506 . This misalignment results in electrical contact  506  being pressed against an interior-facing surface of housing  504 . The electrical contact between electrical contact  506  and housing  504  allows electricity and/or data to be transferred from electrical contact  506  to housing  504  and then out of pogo pin  500  entirely by way of electrically conductive pathway  510 . Electrically conductive pathway  510  can take the form of one or more wires that carry the power and/or signals to another electrical component for further processing. In some embodiments, multiple pogo pins  500  can be used in a single connector to carry different power levels and signal types. It should be noted that the misalignment created by spring coupling device  508  that establishes a solid connection between electrical contacts  506  and housing  504  prevents the unfortunate situation in which electrical contact  506  remains axially aligned with spring  502  and not in significant contact with housing  504 . In the aforementioned axial alignment situation, electricity could be forced to travel through spring  502 , and since spring  502  is not designed to carry electricity the risk of a short circuit and/or damage to the spring increases substantially. The spring shape of spring  502  can also add unwanted inductance to any signal transmitted through spring  502 . It should also be noted that assembly of pogo pin  500  involves inserting the internal components of pogo pin  500  through a front opening defined by housing  504 . 
       FIG. 5B  shows a pogo pin  550  and how a housing  552  of pogo pin  550  can be formed from front housing component  552  and rear housing component  554 . This configuration allows insertion of internal components of pogo pin  550  through a rear facing opening of front housing component  552 . In such a configuration a front opening defined by front housing component  552  can be a rigid opening that need not be configured to accept internal components. Instead the internal components can be inserted through the rear facing opening defined by front housing component  552 . A portion of front housing component  552  can be swaged to produce an annular protrusion configured to engage an annular recess defined by rear housing component  554 . The complementary recess and protrusion allows a straight forward fastener-free coupling between front housing component  552  and rear housing component  554 . Because the internal components don&#39;t need to be inserted through the front opening of front housing component  552 , the front opening through which electrical contact  506  extends can be substantially more rigid, thereby reducing the likelihood of electrical contact  506  inadvertently passing through the front opening. 
       FIGS. 6A-6C  show cross-sectional side views of pogo pins with integrated movable magnets.  FIG. 6A  shows a cross-sectional side view of a pogo pin  600  having an integrated movable magnet  602 . Movable magnet  602  is positioned within an interior volume defined by front housing component  604  and rear housing component  606 . The interior volume can take the form of a channel along which movable magnet  602  can pass. Movable magnet  602  is coupled to spring coupling device  608 , which includes a protrusion that engages one end of spring  610 . When an external magnetic field exerts a force upon movable magnet  602  directed towards electrical contact  612 , movable magnet  602  slides along the channel to compress spring  610  against a rear-facing surface of electrical contact  612 . In this way, movable magnet  602  can be used to augment the force provided by spring  610  when pogo pin  600  is exposed to the external magnetic field. 
       FIG. 6B  depicts a pogo pin  650  that differs slightly from pogo pin  600  in that rear housing component  614  utilizes a press-fit feature to couple with front housing component  656 . In some embodiments, the press-fit feature includes ridges that embed themselves in the interior surface of front housing component  656 , so that a permanent coupling between front housing component  656  and rear housing component  654  is achieved.  FIG. 6B  also depicts connector  670 , with which pogo pin  650  is configured to electrically couple. As depicted in  FIG. 6B , pogo pin  650  is separated from electronic device by a distance sufficient to prevent substantial interaction between movable magnet  652  and external magnet  672 . The polarity of movable magnet  652  can be arranged so that interaction with an external magnet  672  of connector  670  results in a magnetic force that causes movable magnet  652  to compress spring  658  once the distance between magnet  652  and  672  gets small enough, as depicted in  FIG. 6C . Once pogo pin  650  is drawn far enough away from external magnet  672 , spring  658  biases movable magnet  652  back to the position shown in  FIG. 6B . 
       FIG. 6C  also depicts how electrical contact  660  can be depressed slightly into the front opening defined by front housing component  656  on account of physical contact between contact area  674  and electrical contact  660 . The inclusion of movable magnet  652  essentially increases the contact force between electrical contact  660  and contact area  674 , thereby increasing the efficiency of the electrical connection. In some embodiments, a size and/or strength of springs  610  and  658  can be reduced on account of the additional force provided by movable magnets  602  and  652 . While no electrically conductive pathways are depicted in  FIGS. 6A-6C  it should be understood that any of the depicted pogo pins  600 - 650  can be integrated with other electrical components by electrically conductive pathways similar to the ones depicted in  FIGS. 5A-5B . 
       FIGS. 7A-7B  show first and second positions of an electrical connector  700  utilizing pogo pins similar to those described in  FIGS. 5A and 5B . In particular,  FIG. 7A  shows multiple pogo pins  550  protruding from a mating component  704 . While three pogo pins  550  are depicted it should be understood that a larger or smaller amount of pins can be used depending on multiple design factors. Mating component  704  can be formed from a magnetically attractable or in some cases magnetic material. While all of mating component  704  is depicted as having a P1 polarity, it should be understood that mating component  704  can also be magnetized to have multiple poles with different polarities. An exterior facing surface of mating component  704  can be designed to contact and adhere to a connector to which electrical connector  700  is configured to be electrically coupled. Electrical connector  700  can include a series of magnets  706  positioned beneath mating component  704 . Magnets  706  can be configured to attract mating component  704  so it remains in a stowed position (depicted in  FIG. 6A ) regardless of an orientation of electrical connector  700 . 
       FIG. 7B  shows how mating component  704  can move from the stowed position depicted in  FIG. 7A  to a mating position. The movement from the stowed position to the mating position depicted in  FIG. 7B  can be achieved by the application of an external magnetic field to mating component  704 . When the external magnetic field applied to mating component  704  becomes large enough to exceed the strength of the magnetic field emitted by magnets  706 , mating component  704  transitions from the stowed position to the mating position. The mating position can be configured to reduce the escape of stray flux when electrical connector  700  is in use. For example, the protruding portion of mating component  704  can be received into a receptacle connector having a recess that substantially blocks the escape of any magnetic field lines being emitted from mating component  704 . The magnetic attraction between mating component  704  and magnetically attractable or magnetic materials within another connector with which electrical connector  700  is engaged can also improve the mechanical coupling between electrical connector  700  and the other connector (not depicted). 
       FIG. 7C  shows an alternate embodiment in which magnetic pogo pins  650  similar to the pins depicted in  FIGS. 6A-6C  are utilized. It should be noted that the movable magnets within the pogo pins can still be attracted and contribute to compression of corresponding pogo pins. In embodiments where mating component  754  is a multi-pole magnet (as depicted) the movable magnet configuration can work on account of the parallel field lines caused by the multiple adjacent poles cancelling one another out in the region of the pogo pin. Consequently, the movable magnets can still be utilized to augment the strength of the springs. In some embodiments, the polarity of magnets  652  can alternate or vary in another pattern to correspond to a pattern established by the receptacle connector. It should be noted that in addition to mating component  754  being configured to extend out to the mating position, connector  750  can be configured to shift laterally to align with the receptacle connector. In some embodiments, connector  750  could be positioned in a channel allowing the electrical connector to move laterally to accommodate any lateral alignment problems. 
       FIGS. 8A-8B  show cross-sectional views of magnetic ball style pogo pins  800  and  850 .  FIG. 8A  depicts a unibody housing  802  while  FIG. 8B  depicts a two-part housing including front housing component  804  and rear housing component  806 . Both have electrical contacts with ball designs that allows for free rotation of electrical contacts  808  in many different directions. In some embodiments, electrical contacts  808  can take the form of a non-conductive spherical substrate plated in electrically conductive material along the lines of gold or copper. In this way, electricity travelling along the surface of electrical contacts  808  can conduct the electricity efficiently to housing  802  and housing component  604 . The depicted design also includes movable magnet  810  configured to increase a preload generated by internal spring  812 , by virtue of attraction between movable magnet  810  and magnetic ball contact  808 . Pogo pins  800  and  850  also include spring coupling devices  814  with protrusions engaged within internal spring  812 . The protrusion includes a slanting surface that allows a lateral force to be imparted that biases electrical contact  808  towards an internal surface of housing  802  as depicted in  FIG. 8A . The lateral force can be applied to improve the contact force between electrical contact  808  and housing  802 , thereby improving the flow of electricity through pogo pin  800 . 
     Electrical Connector Embodiments: 
       FIGS. 9A-9B  show top views of a magnetic electrical connector  900 . Magnetic electrical connector includes power and/or data circuits  902  that are routed to electrical contacts  904  by electrically conductive pathway  906 . Electrically conductive pathway  906  can be made up of one or more wires that carry discrete signals to and from each of electrical contacts  904 . In some embodiments, connector  900  can be include separate electrically conductive pathways  906  that run to each of electrical contacts  904 . Electrical contacts  904  at least partially surround a movable magnet  908 . Movable magnet  908  can be held in a retracted position (as depicted) by springs or other retaining features (not depicted). When an external magnetic field approaches electrical connector  900  as shown in  FIG. 9B , magnet  908  is drawn towards the end of electrical contacts  904 . This configuration can increase the strength of a magnetic coupling that helps maintain an electrical coupling between electrical connector  900  and another magnetic connector. 
       FIGS. 9C-9D  show cross-sectional side views of electrical connector  900  in accordance with section lines A-A and B-B, respectively. In particular,  FIG. 9C  depicts a retention feature taking the form of spring  906 . In  FIG. 9C  spring  910  is depicted having biased magnet  908  and shunt  912  towards a rear end of electrical contact  904 . Shunt  912  directs a magnetic field emitted by magnet  908  out and away from connector  900  and towards connector  920 . This can increase the range of magnet  908  and reduce the likelihood of that magnetic field from interfering with other electronics associated with connector  900 . 
       FIG. 9D  shows how when connector  900  gets close enough to connector  920  the resulting magnetic force between magnet  908  and connector  920  can exceed the force being applied by spring  910  so that magnet  908  is drawn towards the front of electrical contact  904 . In this way, a magnetic coupling between electrical connector  900  and connector  920  can be maximized when the two connectors are coupled together. 
       FIGS. 10A-10B  show an alternative design taking the form of connector  1000 .  FIG. 10A  depicts connector  1000  and how it includes magnet  1002  and shunt  1004 , which both remain stationary with respect to electrical contact  1006  regardless of the application of an external magnetic field.  FIG. 10B  shows how both electrical contact  1006 , magnet  1002  and shunt  1004  move in response to approaching magnetic connector  1010 . This movement is made possible by a sliding connection between electrical contact  1006  and lead  1008 . The sliding connection can take many forms, including but not limited to a bearing with stops allowing a predefined amount of movement of electrical contact  1004  with respect to lead  1008 . 
       FIGS. 11A-11B  show multiple views of a connector plug  1100  similar to the embodiments depicted in  FIGS. 9A-10B . In particular,  FIG. 11A  shows how connector plug  1100  has a pill-shaped protrusion that includes four electrical contacts  1102  and can be packaged with circuitry allowing for plug  1100  to be electrically coupled with receptacle connector  1152  of electronic device  1150  in either of two orientations. Plug  1100  can also include insulating material  1104  disposed between each electrical contacts  1102 , which are operable to electrically isolate each of electrical contacts  1102  from each other. Similarly, receptacle connector  1154  includes an insulating material pattern corresponding to the arrangement of insulating material  1104 . Both receptacle connector  1152  and plug  1100  can include magnets for facilitating a robust connection between connector plug  1100  and receptacle connector  1152 . As described above, the magnets can be arranged in a complementary array configured to facilitate precise alignment of connector plug  1100  with receptacle connector  1152 . In some embodiments, the pill-shaped protrusion of connector plug  1100  can be configured to extend and retract when approaching and drawing away from receptacle connector  1152 . This can be carried out in many ways, including ways similar to those depicted in  FIGS. 10A-10B . 
       FIG. 11B  shows an example of how a magnetic connector similar to the one depicted in  FIGS. 10A-10B  can be used to provide a magnet and electrical connector behind electrical connector  1102   b . Such a configuration beneficially allows the retraction of magnet  1108  away from electrical connector  1102   b  when the connector is not in use. Such a configuration would reduce the likelihood of magnet  1108  adversely affecting other magnetically sensitive components when connector  1100  is not in active use. This configuration could also prevent connector plug  1100  from inadvertently becoming electrically coupled with another device that doesn&#39;t include magnetically attractable material sufficient to attract magnet  1108 . 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20160613
Publication Date: 20180410
Grant Date: 20180410
Priority Date: 20150930
Inventors: ESMAEILI HANI
JOL ERIC S.
KAMEI IBUKI
WAGMAN DANIEL C.
GOLKO ALBERT J.
AMINI MAHMOUD R.
KASHANI MANI RAZAGHI
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/193", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/5213", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/193", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R11/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/61", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/77", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/91", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R11/30", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/61", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/193", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/5213", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R11/30", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 56740959