PATENT DOCUMENT

Publication Number: US-11424573-B2
Application Number: US-202017031106-A
Country: US
Kind Code: B2

Title: Magnetic connectors with self-centering floating contacts

Abstract:
Connectors that have a low profile, can form strong and reliable connections despite connection alignment errors, and can be readily manufactured. One example can provide a connector receptacle having a magnetic array arranged to provide a strong attachment that allows the use of a low profile connector receptacle and connector insert. The magnetic array can include magnets and magnetic elements, where the magnetic elements can be magnetically conductive pole-pieces. Each pole piece can have magnets at two of its sides. Another example can provide contacts for a connector insert that can have more than one contacting surface to connect to a contact of a connector receptacle.

Claims:
What is claimed is: 
     
       1. A connector insert comprising:
 an attraction plate having a passage forming a front opening; 
 a housing located in the passage; 
 a board comprising a plurality of pads; 
 a plurality of contacts located in the housing, each contact in the plurality of contacts comprising:
 an anchor at a first end, the anchor soldered to a corresponding pad on the board; 
 a forked portion, the forked portion including an upper beam and a lower beam, the upper beam positioned away from the lower beam in a first direction, each beam terminating in a contacting surface at a first end, the upper beam and the lower beam joined together at a second end of the upper beam and a second end of the lower beam; and 
 a joining portion extending from the anchor to the second end of the upper beam and the second end of the lower beam, wherein the joining portion is narrower than the forked portion in the first direction; and 
 
 a shell around the board. 
 
     
     
       2. The connector insert of  claim 1  wherein the joining portion allows the forked portion to move relative to the anchor. 
     
     
       3. The connector insert of  claim 1  wherein the joining portion allows the forked portion to move in the first direction relative to the anchor. 
     
     
       4. The connector insert of  claim 3  wherein each contact in the plurality of contacts further comprises a barb, the barb inserted into the housing to secure the contact to the housing. 
     
     
       5. The connector insert of  claim 3  wherein each contact in the plurality of contacts further comprises a first barb and a second barb, the first barb extending from the anchor towards the first end and above the joining portion, the second barb extending from the anchor towards the first end and below the joining portion, wherein the first barb and the second barb are inserted into the housing to secure the contact to the housing. 
     
     
       6. The connector insert of  claim 3  wherein the shell and the attraction plate enclose the housing, the plurality of contacts, and the board. 
     
     
       7. The connector insert of  claim 3  wherein the housing is nonconductive. 
     
     
       8. The connector insert of  claim 3  further comprising a plurality of circuits on the board. 
     
     
       9. The connector insert of  claim 1  wherein the joining portion is narrower than the anchor in the first direction. 
     
     
       10. The connector insert of  claim 1  wherein each contacting surface is formed as a protrusion extending towards the opposing beam. 
     
     
       11. A connector receptacle comprising:
 a contact housing having a mesa, the mesa formed as a tapered front end of the contact housing; 
 a first plurality of contacts supported by the contact housing, each of the first plurality of contacts having a contacting surface on the mesa; 
 a second plurality of contacts supported by the contact housing, each of the second plurality of contacts having a plurality of contacting surfaces on the mesa; and 
 a plurality of magnets and a plurality of magnetic elements positioned around the contact housing, 
 wherein each of the plurality of magnetic elements has a first magnet adjacent to a first side of the magnetic element and a second magnet adjacent to a second side of the magnetic element. 
 
     
     
       12. The connector receptacle of  claim 11  further comprising a top housing around the top, back, and side of the plurality of magnets and the plurality of magnetic elements. 
     
     
       13. The connector receptacle of  claim 12  further comprising shielding around the top housing, the plurality of magnets, and the plurality of magnetic elements. 
     
     
       14. The connector receptacle of  claim 13  wherein the shielding comprises a face plate, the face plate having an opening such that the mesa extends through the opening. 
     
     
       15. The connector receptacle of  claim 14  wherein the shielding further comprises:
 a top shell over the top, sides, and back of the top housing, the top shell attached to the face plate; and 
 a bottom shell under the bottom and over the sides of the top housing, the bottom shell attached to the top shell. 
 
     
     
       16. The connector receptacle of  claim 15  further comprising a lock portion, wherein the contact housing is located between the top housing and the lock portion. 
     
     
       17. The connector receptacle of  claim 16  wherein the lock portion fits with the top housing to secure the contact housing in place. 
     
     
       18. A connector receptacle comprising:
 a plurality of contacts; 
 a first magnetic element having a first magnet at a first surface and a second magnet at a second surface, the first surface adjacent to the second surface; and 
 a second magnetic element having a third magnet at a first surface and a fourth magnet at a second surface, the first surface opposite the second surface. 
 
     
     
       19. The connector receptacle of  claim 18  wherein the plurality of contacts are arranged as a line of contacts, the first magnet element is at a first end of the line of contacts, and the second magnetic element is below the line of contacts. 
     
     
       20. The connector receptacle of  claim 19  further comprising:
 a third magnetic element having a fifth magnet at a first surface and a sixth magnet at a second surface, the first surface adjacent to the second surface, 
 wherein the third magnetic element is at a second end of the line of contacts. 
 
     
     
       21. The connector receptacle of  claim 20  further comprising:
 a fourth magnetic element having a seventh magnet at a first surface and the fourth magnet at a second surface, the first surface opposite to the second surface, 
 wherein the fourth magnetic element is below the line of contacts. 
 
     
     
       22. The connector receptacle of  claim 21  further comprising:
 a fifth magnetic element having an eighth magnet at a first surface and a ninth magnet at a second surface, the first surface opposite to the second surface; and 
 a sixth magnetic element having the ninth magnet at a first surface and a tenth magnet at a second surface, the first surface opposite to the second surface, 
 wherein the fifth magnetic element and the sixth magnetic element are above the line of contacts. 
 
     
     
       23. A connector insert comprising:
 an attraction plate having a passage forming a front opening; 
 a housing located in the passage; 
 a board comprising a plurality of pads; 
 a plurality of contacts located in the housing, each contact in the plurality of contacts comprising:
 an anchor at a first end, the anchor soldered to a corresponding pad on the board; 
 a forked portion, the forked portion including an upper beam and a lower beam, each beam terminating in a contacting surface at a first end, wherein each contacting surface is formed as a protrusion extending towards the opposing beam, the upper beam and the lower beam joined together at a second end of the upper beam and a second end of the lower beam; and 
 a joining portion between the anchor, the second end of the upper beam, and the second end of the lower beam; and 
 
 a shell around the board. 
 
     
     
       24. The connector insert of  claim 23  wherein each contact in the plurality of contacts further comprises a barb, wherein the barb is inserted into the housing to secure the contact to the housing. 
     
     
       25. The connector insert of  claim 23  wherein each contact in the plurality of contacts further comprises a first barb and a second barb, the first barb extending from the anchor towards the first end and above the joining portion, the second barb extending from the anchor towards the first end and below the joining portion, wherein the first barb and the second barb are inserted into the housing to secure the contact to the housing. 
     
     
       26. The connector insert of  claim 23  wherein the upper beam is positioned away from the lower beam in a first direction, and the joining portion extends from the anchor to the second end of the upper beam and the second end of the lower beam. 
     
     
       27. The connector insert of  claim 23  wherein the upper beam is positioned away from the lower beam in a first direction and the joining portion is narrower than the forked portion in the first direction. 
     
     
       28. The connector insert of  claim 27  wherein the joining portion is narrower than the anchor in the first direction.

Description:
BACKGROUND 
     Electronic devices can share power and data over cables that can include one or more wires, fiber optic cables, or other conductors. Connector inserts can be located at each end of these cables and can be inserted into connector receptacles in the communicating electronic devices to form power and data pathways. 
     Unfortunately, these connector receptacles can consume a large amount of space on a surface of these electronic devices. At the same time, these electronic devices have become smaller and thinner over the past several years. This can make it difficult for designers to find appropriate locations for connector receptacles on new electronic devices. Accordingly, it can be desirable to have connector receptacles that can have a low profile and can be utilized with these new smaller and thinner devices. 
     An electronic device can house a connector receptacle that can receive power and data through a connector insert attached to a first end of a cable. The cable can be subject to forces that can work to dislodge the connector insert from the connector receptacle, thereby interrupting the flow of power and data. Accordingly, it can be desirable to provide connector systems that can form a strong attachment between the connector insert and the connector receptacle. 
     A connector receptacle can be located on an electronic device in a position where it will be out of the way when the electronic device is being used. This can mean that a user might not have a direct view of the connector receptacle as the connector insert is plugged in. Accordingly, it can be desirable that a connection can be made despite the connector insert being misaligned with the connector receptacle. 
     Also, some of these electronic devices become tremendously popular. As a result, connector receptacles on the electronic devices and connector inserts on cables can be sold in very large quantities. Therefore, it can be desirable that these connectors be readily manufactured such that customer demand for them can be met. 
     Thus, what is needed are connectors that have a low profile, can form strong and reliable connections despite connection alignment errors, and can be readily manufactured. 
     SUMMARY 
     Accordingly, embodiments of the present invention can provide connectors that have a low profile, can form strong and reliable connections despite connection alignment errors, and can be readily manufactured. An illustrative embodiment of the present invention can provide a connector receptacle having a magnetic array arranged to provide a strong attachment that allows the use of a low profile connector receptacle and connector insert. The magnetic array can include magnets and magnetic elements, where the magnetic elements can be magnetically conductive pole-pieces. Each pole piece can have magnets at two of its sides. The magnets can be arranged in an alternating manner such that the field lines of the pole pieces provide a strong magnetic attachment to a magnetically conductive attraction plate of a connector insert. 
     These and other embodiments of the present invention can provide connectors that can form reliable connections by providing connector insert contacts that can have more than one contacting surface to connect to corresponding connector receptacle contacts. A connector insert contact can include a forked portion, where the forked portion includes an upper beam and a lower beam. Each beam can terminate in a contacting surface at a first end. The upper beam and the lower beam can connect at a second end. Contacts in the connector receptacle can have a conical cross-section such that the contacting surface of the upper beam can physically and electrically connect to a top surface of a connector receptacle contact and the contacting surface of the lower beam can physically and electrically connect to a bottom surface of the connector receptacle contact. Using more than one contacting surface can provide redundancy that can increase the reliability of a connection between the connector insert and the connector receptacle, as well as reduce the impedance of the connection between contacts. 
     These and other embodiments of the present invention can further improve the reliability of a connection between a connector insert and a connector receptacle by providing a shallow slope to the conical cross section of contacts in the receptacle. This slope can limit a parasitic force on the connector insert that would otherwise act to expel the connector insert from the connector receptacle. Instead, the expulsion force provided by the conical shape of the connector receptacle contacts can readily be overcome by the magnetic attraction between the connector insert and the connector receptacle. 
     These and other embodiments of the present invention can further improve the reliability of a connection by providing a connector insert that can rotate through a first arc relative to a connector receptacle. Various forces can act on the connector insert when it is plugged into a connector receptacle. One such force can be caused by a cable attached to the connector insert. The weight of this cable can pull down on the connector insert relative to the connector receptacle. Embodiments of the present invention can include a magnetic array to prevent a disconnection. Embodiments of the present invention can also provide an attraction plate and contacts for a connector insert that can rotate downward relative to the connector receptacle to further avoid an inadvertent disconnection. 
     These and other embodiments of the present invention can further improve the reliability of a connection between a connector insert and a connector receptacle by providing a contacts for a connector insert that wipe across surfaces of corresponding contacts in a connector receptacle. This wiping action can help to remove dust, corrosion buildup, and other particulate matter than could otherwise hamper a physical and electrical connection between contacts. 
     These and other embodiments of the present invention can provide a reliable connection despite alignment errors between a connector insert and a connector receptacle by providing contacts for the connector insert that can self-align to corresponding contacts of a connector receptacle. The contacts of the connector insert can include a joining portion that joins an anchor fixed to a board or other structure in the connector insert to a forked portion having one or more beams. The joining portion can allow the beams to move relative to the anchor, thereby allowing the contacts of the connector insert to properly mate with corresponding contacts of the connector receptacle despite misalignments of the connector insert and connector receptacle. 
     These and other embodiments of the present invention can provide connector inserts and connector receptacles that can avoid power sequencing problems. Specifically, power and data contacts in the connector receptacle can have a conical shape where the tip of the cone is absent and replaced by nonconductive material. Conversely, ground contacts can have a conical shape complete with the tip of the cone. As a result, ground connections can be formed before power and data connections as a connector insert is plugged into a connector receptacle, and ground connections can be broken after power and data connections when a connector insert is extracted from the connector receptacle. This make-first break-last arrangement can help to prevent power supply sequencing problems between a connector insert and a connector receptacle. 
     These and other embodiments of the present invention can provide connector inserts and connector receptacles that can be readily manufactured. Contacts of the connector receptacle can be formed by stamping, thereby simplifying manufacturing. 
     While embodiments of the present invention can provide useful connector inserts and connector receptacles for delivering power, these and other embodiments of the present invention can be used as connector receptacles in other types of connector systems, such as connector systems that can be used to convey power, data, or both. 
     In various embodiments of the present invention, contacts, shields, and other conductive portions of a connector receptacle or connector insert can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. The nonconductive portions, such as, housings, locking portions, and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The printed circuit boards or other boards used can be formed of FR-4 or other material. 
     Embodiments of the present invention can provide connector receptacles and connector inserts that can be located in, and can connect to, various types of devices such as portable computing devices, tablet computers, desktop computers, laptop computers, all-in-one computers, wearable computing devices, smart phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. These connector receptacles and connector inserts can provide interconnect pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Peripheral Component Interconnect express, Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention can provide connector receptacles and connector inserts that can be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles and connector inserts can be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Various embodiments of the present invention can incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention can be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system that can be improved by the incorporation of embodiments of the present invention; 
         FIG. 2  illustrates a connector receptacle according to an embodiment of the present invention; 
         FIG. 3  is a front view of the connector receptacle of  FIG. 2  positioned in the electronic device  FIG. 1 ; 
         FIG. 4  is an exploded view of the connector receptacle in  FIG. 2 ; 
         FIG. 5  illustrates a connector insert according to an embodiment of the present invention; 
         FIG. 6  illustrates a front view of the connector insert of  FIG. 5 ; 
         FIG. 7  illustrates a top view of the connector insert of  FIG. 5 ; 
         FIG. 8  is an exploded view of the connector insert of  FIG. 5 ; 
         FIG. 9  illustrates a cutaway side view of a connector insert and a connector receptacle according to an embodiment of the present invention; 
         FIG. 10  illustrates a cutaway side view of a connector insert mated with a connector receptacle according to embodiments of the present invention; 
         FIG. 11  is a close-up cross-section view of a connector insert mated with a connector receptacle according to an embodiment of the present invention; 
         FIGS. 12-15  illustrates a contact of a connector insert mating with and then disconnecting from a contact of a connector receptacle according to an embodiment of the present invention; and 
         FIG. 16  illustrates a magnetic array according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates an electronic system that can be improved by the incorporation of an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     This figure illustrates an electronic device  300  including connector receptacle  100 . Electronic device  300  may include bottom housing  301  encasing connector receptacle  100 . Electronic device  300  can further include top housing  302  over bottom housing  301 . Top housing  302  can house a screen or monitor, or other electronic components (not shown.) Bottom housing  301  can house a keyboard, processor, battery, or other electronic components (not shown.) The electronic components in top housing  302  and bottom housing  301  can receive and provide power data or power using connector receptacle  100 . In one example, the electronic components in top housing  302  and bottom housing  301  can receive power via connector receptacle  100  and can provide data regarding a charging status of a battery of electronic device  300 . 
     Connector receptacle  100  can include top shield  110  having tabs  114 . Tabs  114  can be inserted into and soldered to openings (not shown) in a printed circuit board (not shown) in bottom housing  301  of electronic device  300 . Connector insert  200  can be plugged into or mated with connector receptacle  100 . Connector insert  200  can include passage  202  for a cable (not shown.) 
     In this example, electronic device  300  can be a laptop or portable computer. In these and other embodiments of the present invention, electronic device  300  can instead be another portable computing device, tablet computer, desktop computer, all-in-one computer, wearable computing device, smart phone, storage device, portable media player, navigation system, monitor, power supply, video delivery system, adapter, remote control device, charger, or other device. 
     Power supplies, ground, and data signals can be conveyed by connector insert  200  and connector receptacle  100 . These power supplies, ground, and signals can be compliant with and form pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™ Joint Test Action Group (JTAG), test-access-port (TAP), Peripheral Component Interconnect express, Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention can provide connector receptacles and connector inserts that can be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles and connector inserts can be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Examples of connector receptacles  100  and connector inserts  200  are shown in the following figures. 
       FIG. 2  illustrates a connector receptacle according to an embodiment of the present invention. Connector receptacle  100  can include mesa  120 . Mesa  120  can support contacting surfaces for contacts  130  (shown in  FIG. 4 .) Mesa  120  can support contacting surfaces  134 , contacting surfaces  136 , and contacting surfaces  138 . Contacting surfaces  134 , contacting surfaces  136 , and contacting surfaces  138  can each convey one or more of power, ground, or a signal. In one example, the two outside contacting surfaces  134  can convey ground, while the two adjacent contacting surfaces  136  can convey power. Central contacting surfaces  138  can convey a signal. The signal can be indicative of a charging status of a battery in electronic device  300  (shown in  FIG. 1 ), though other signals can be conveyed by central contacting surface  138 . 
     In this particular example, contacting surfaces  134  may wrap around a front edge  139  of mesa  120 . Conversely, contacting surfaces  136  and contacting surfaces  138  can stop short of front edge  139  of mesa  120 . This can allow corresponding contacts in connector insert  200  (shown in  FIG. 5 ) to connect to ground contacting surfaces  134  before they connect to power contacting surfaces  136  when connector insert  200  is connected to connector receptacle  100 . This can also allow corresponding contacts in connector insert  200  to disconnect from ground contacting surfaces  134  after they disconnect from power contacting surfaces  136  as connector insert  200  is disconnected from connector receptacle  100 . 
     Mesa  120  can extend through an opening  142  in faceplate  140 . Faceplate  140  and top shield  110  may shield top housing  150 . Tab  152  of top housing  150  may fit in slot  112  in top shield  110  to secure top shield  110  to top housing  150 . Top shield  110  can include tab  114 . Tab  114  can fit in and be soldered to an opening in a printed circuit board (not shown) or other appropriate substrate. Connector receptacle  100  may be further stabilized by posts  154 , which may emerge from a bottom of top housing  150 . 
       FIG. 3  is a front view of the connector receptacle of  FIG. 2  positioned in the electronic device  FIG. 1 . In this example, connector receptacle  100  can be positioned in electronic device  300 . Faceplate  140  and mesa  120  of connector receptacle  100  can be located in opening  310  of bottom housing  301  of electronic device  300 . Mesa  120  can support contacting surfaces  134 , contacting surfaces  136 , and contacting surfaces  138 . Contacting surfaces  134  can wrap around front edge  139  of mesa  120 . Conversely, portions of contacting surfaces  136  and contacting surfaces  138  can stop short and be isolated each other at front edge  139 . 
       FIG. 4  is an exploded view of the connector receptacle in  FIG. 2 . Contacts  130  can be supported by contact housing  122 . Contact housing  122  can terminate at a front edge in mesa  120 . Mesa  120  can support contacting surfaces  134 , contacting surfaces  136 , and contacting surfaces  138  of contacts  130 . Contacts  130  can terminate in surface-mount contacting portions  137 , though in other embodiments of the present invention, contacts  130  can terminate in through-hole contacting portions (not shown.) 
     Mesa  120  can extend through opening  142  in faceplate  140 . Contact housing  122  can include rear portion  124  that can be placed under shelf  156  of top housing  150 . Locking portion  160  can fit under shelf  156  such that contact housing  122  is between shelf  156  and locking portion  160 , thereby securing contact housing  122  in place. Top shield  110  can fit over top housing  150  such that tab  152  fits in slot  112 , thereby securing top shield  110  to top housing  150 . Top shield  110  can include tab  114 . Tab  114  can be inserted into and soldered to an opening (not shown) in a printed circuit board (not shown) or other appropriate substrate. Bottom shield  170  can fit under top housing  150  and be spot or laser welded to top shield  110  along sides  174 . Bottom tab  162  of locking portion  160  can fit in opening  172  in bottom shield  170 , thereby providing mechanical support, along with posts  154  for connector receptacle  100 . 
     Connector receptacle  100  can further include a magnetic array  180 . Magnetic array  180  can be formed of magnets  182  and magnetic elements or pole pieces  184 . Magnets  182  and pole pieces  184  can be positioned around contact housing  122 . Further details of magnetic array  180  are shown in  FIG. 16  below. Magnetic array  180  can provide a strong attachment between connector receptacle  100  and connector insert  200  (shown in  FIG. 5 .) Each pole piece  184  can have magnets at more one or more than one of its sides. The magnets can be arranged an alternating manner such that field lines between the pole pieces provide a strong magnetic attraction to a magnetically conductive attraction plate  210  (shown in  FIG. 5 ) of connector insert  200 . Strong magnetic attraction can allow the use of a low profile connector receptacle  100  and connector insert  200 , thereby allowing connector receptacle  100  to be used in a thin or low-profile electronic device  300  (shown in  FIG. 1 .) 
       FIG. 5  illustrates a connector insert according to an embodiment of the present invention. Connector insert  200  can be housed by shell  240 . Front extension  212  of attraction plate  210  can be arranged to fit in opening  310  of bottom housing  301  of electronic device  300  as shown in  FIG. 3 . Front extension  212  can support contact housing  220 . Contact housing  220  can support contacts  230  (shown in  FIG. 8 ) having contacting portions  232 . Contacting portions  232  can be exposed in recess  214  in front extension  212  of attraction plate  210 . 
       FIG. 6  illustrates a front view of the connector insert of  FIG. 5 . In this example, connector insert  200  can be housed in shell  240 . Front extension  212  of attraction plate  210  can support housing  220 . Housing  220  can support contacts  230  (shown in  FIG. 8 ) having contacting portions  232 . Contacting portions  232  can be exposed in recess  214  of front extension  212 . 
       FIG. 7  illustrates a top view of the connector insert of  FIG. 5 . Connector insert  200  can be housed by shell  240 . Front extension  212  can extend from attraction plate  210  and can support housing  220 . 
       FIG. 8  is an exploded view of the connector insert of  FIG. 5 . Connector insert  200  can include shell  240  and attraction plate  210 . Shell  240  and attraction plate  210  can enclose housing  220 , contacts  230 , and board  250 . Housing  220  can fit in passage  215  of attraction plate  210 . Recess  214  can be formed in front extension  212  of attraction plate  210 . Slots  222  can be formed in housing  220 . Contacts  230  can be located in slots  222  in housing  220 . Housing  220  can be formed around contacts  230 , or contacts  230  can be inserted into housing  220 . 
     Contacting portions  232  of contacts  230  can be available at a front of housing  220  in recess  214  of attraction plate  210 . Contacts  230  can further include anchors  238 . Anchors  238  can be soldered to pads (not shown) along front edge  254  of board  250 . Board  250  can support electronics  252 . Electronics  252  can include one or more light emitting diodes to indicate that a connection has been made between connector insert  200  and connector receptacle  100 , as shown in  FIG. 1 . These light emitting diodes can be color coded to indicate a charging status of a battery in electronic device  300  (shown in  FIG. 1 .) For example, the light emitting diodes can indicate that a battery is being charged, is fully charged, or other status information. This status information can be conveyed from connector receptacle  100  to connector insert  200  over center contacting portion  318  and a corresponding contact  230 . 
       FIG. 9  illustrates a cutaway side view of a connector insert and a connector receptacle according to an embodiment of the present invention. Connector receptacle  100  can include contacts  130  supported by contact housing  122 . Contacts  130  can terminate in contacting surface  132 A and contacting surface  132 B on mesa  120  (shown in  FIG. 4 .) Contacting surface  132 A and contacting surface  132 B can be separated from each other at front edge  139  of mesa  120 . Contacting surface  132 A and contacting surface  132 B of contact  130  can be located in opening  310  in bottom housing  301  of electronic device  300  (shown in  FIG. 1 .) Contacts  130  can terminate in surface-mount contacting portions  137 , though in these and other embodiments of the present invention, contacts  130  can terminate in through-hole contacting portions (not shown.) Surface-mount contacting portions  137  can be soldered to pads (not shown) on a printed circuit board (not shown) or other appropriate substrate, while through-hole contacting portions can be inserted into and soldered to holes in a printed circuit board or other appropriate substrate. 
     Connector receptacle  100  can further include magnet array  180 , top housing  150 , and locking portion  160 . Contact housing  122  can be held in place between top housing  150  and locking portion  160  and can pass through opening  187  (shown in  FIG. 16 ) in magnetic array  180 . Top shield  110 , along with faceplate  140  and bottom shield  170 , can electrically shield connector receptacle  100 . 
     Connector insert  200  can include contacts  230  supported by housing  220 . Housing  220  can be supported by front extension  212  of attraction plate  210 . Contact  230  can include upper beam  233  terminating in contacting surface  232 A, and lower beam  234  terminating in contacting surface  232 B. Contacting surface  232 B can physically and electrically connect to contacting surface  132 B of contacts  130 , and contacting surface  232 B can physically and electrically connect to contacting surface  132 B of contact  130  when connector insert  200  is inserted into connector receptacle  100 . 
     In this particular example, contact  130  can terminate in a conical contacting portion were a tip has been removed and replaced by nonconductive front edge  139 , thereby leaving contacting surfaces  132 A and contacting surface  132 B exposed. Contacting surface  132 A and contacting surface  132 B can be used as contacting surfaces  136  or contacting surfaces  138 , or other contacting surfaces. Other contacts  130  can terminate in a conical contacting portion were a tip is not been removed. For example, contacting surface  134  (shown in  FIG. 4 ) can be formed as a conical contacting portion were a tip is not been removed. 
       FIG. 10  illustrates a cutaway side view of a connector insert mated with a connector receptacle according to embodiments of the present invention. In this example, connector insert  200  has been mated with connector receptacle  100 . Specifically, front extension  212  of attraction plate  210  has been inserted into opening  310  in bottom housing  301  of electronic device  300  (shown in  FIG. 1 .) Contact  130  in connector receptacle  100  can include contacting surface  132 A and contacting surface  132 B which can physically and electrically connect to contacting surface  232 A and contacting surface  232 B of contact  230  in connector insert  200 . 
     In this example, contact  230  in connector insert  200  can include two contacting surfaces, specifically, contacting surface  232 A and contacting surface  232 B. Each of these contacting surfaces can physically and electrically connect to corresponding contacting surfaces of contact  130  in connector receptacle  100 , specifically contacting surface  132 A and contacting surface  132 B. Providing two contacting surfaces in this way can provide redundancy, thereby improving the reliability of a connection between connector insert  200  and connector receptacle  100 . The use of two such contacting surfaces can also reduce the impedance of the connection between contact  230  in connector insert  200  and contact  130  in connector receptacle  100 . 
     Contact  130  in connector receptacle  100  can terminate in in a conical contact portion that forms contacting surface  132 A and contacting surface  132 B. The slope on this conical contact portion can be relatively shallow. This can in turn provide a self-wiping feature as connector insert  200  is inserted into and extracted from connector receptacle  100 . Specifically, contacting surface  232 A and contacting surface  232 B can wipe across contacting surface  132 A and contacting surface  132 B during the insertion and extraction of connector insert  200  from connector receptacle  100 . This can act to remove corrosion, debris, or other particulate matter from these surfaces, thereby improving reliability and reducing the impedance of a connection between contact  230  in connector insert  200  and connector receptacle  100 . 
     When connector insert  200  is inserted in connector receptacle  100 , various forces may act on connector insert  200 . One such force may be that of a cable (not shown) pulling down on a back end of connector insert  200 . This can tend to rotate connector insert  200  out of connector receptacle  100 , thereby causing an inadvertent disconnection. Accordingly, connector insert  200  may be arranged such that connector insert  200  may rotate through an angle without disconnecting from connector receptacle  100 . For example, front extension  212  may have a curved surface  213  leading into the remainder of attraction plate  210 . This curvature, along with shape of contacting surface  232 A and contacting surface  232 B, can allow connector insert  200  to rotate through an angle without disconnecting from connector receptacle  100 . 
     Another force that can act to create an inadvertent disconnection is the force generated by contacting surface  232 A and contacting surface  232 B on contacting surface  132 A and contacting surface  132 B. These forces can act to expel connector insert  200  from connector receptacle. Accordingly, in these and other embodiments of the present invention, a slope of contacting surface  132 A and contacting surface  132 B can be made shallow to reduce the expulsion force. Also, a magnetic attraction between magnetic array  180  and attraction plate  210  can be high such that the expulsion force is readily overcome. 
       FIG. 11  is a close-up cross-section view of a connector insert mated with a connector receptacle according to an embodiment of the present invention. In this example, connector receptacle  100  can be located in opening  310  in bottom housing  301  of electronic device  300  (shown in  FIG. 1 .) Connector receptacle  100  can include contact  130 . Contact  130  can terminate in contacting surface  132 A and contacting surface  132 B. Contacting surface  132 A can physically and electrically connect to contacting surface  232 A of contact  230  in connector insert  200 . Contacting surface  132 B can physically and electrically connect to contacting surface  232 B of contact  230 . Again, contacting surface  132 A and contacting surface  132 B can be used as contacting surfaces  136  or contacting surfaces  138 . 
     Contact  230  can include upper beam  233  that can terminate in contacting surface  232 A, and lower beam  234  that can terminate in contacting surface  232 B. Contact  230  can further include anchor  238 , which may be soldered or otherwise fixed to a board or other stable structure. Anchor  238  can be connected to a forked portion comprising upper beam  233  and lower beam  234  through joining portion  236 . Contact  230  can be supported by housing  220  in attraction plate  210 . Shell  240  can house contact  230  and housing  220 . 
     In these and other embodiments of the present invention, it can be desirable for a connector insert and a connector receptacle to mate properly despite the presence of a lateral or rotational misalignment. Accordingly, embodiments of the present invention can provide contacts that can accommodate such a misalignment. Examples are shown in the following figures. 
       FIGS. 12-15  illustrates a contact of a connector insert mating with and then disconnecting from a contact of a connector receptacle according to an embodiment of the present invention. In  FIG. 12 , contact  230  is about to be mated with contacts  130 . Contact  230  is shown as being misaligned with contact  130  by an amount  1210 . 
     In  FIG. 13 , contacting surface  132 A of contact  130 A has begun to engage contacting surface  232 A of contact  230 . Similarly, contacting surface  132 B of contact  130  has begun to engage contacting surface  232 B of contact  230 . Anchor  238  can be fixed in place by being soldered to board  250  (shown in  FIG. 9 ) or other structure. Barbs  237  can be inserted into housing  220  (shown in  FIG. 9 ) in order to secure contacts  230  to housing  220 . Anchor  238  can be attached to upper beam  233  and lower beam  234  by joining portion  236 . Joining portion  236  can flex downward, thereby allowing contacting surface  232 A and contacting surface  232 B to engage contacting surface  132 A and contacting surface  132 B of contact  130 . The downward deflection provided by joining portion  236  can allow contacting surface  232 A to engage contacting surface  132 A earlier than might otherwise be possible. This can reduce the stress on contacting surface  232 B and lower beam  234 . This reduction in stress can reduce the permanent deformation of contact  230  thereby resulting in as more fatigue resistant design. 
     In  FIG. 14 , joining portion  236  of contact  230  can flex downward while upper beam  233  and lower beam  234  can separate as contacting surface  232 A rides up the sloped surface of contacting surface  132 A and contacting surface  232 B rides down the slope surface of contacting surface  132 B. Again, the movement between the contact positions shown in  FIG. 13  and  FIG. 14  can provide a wiping action across the various contacting surfaces, thereby helping to keep them clear of debris, corrosion, and other particulate matter or contaminates in order to improve reliability of connection and reduce impedance. 
     In  FIG. 15 , contact  130  has been extracted from contact  230 , contact  230  can return to its normal position. 
       FIG. 16  illustrates a magnetic array according to an embodiment of the present invention. Magnetic array  180  can include magnets  182  and pole pieces  184 . Each pole piece  184  can convey field lines with either a North or a South polarity as shown. Each pole piece  184  can have magnets at two or more surfaces. Each North pole piece  184  can have magnets  182  oriented with their North pole at a surface of the pole piece  184  and a South pole away from the surface of the pole piece  184 . Each South pole piece  184  can have magnets  182  oriented with their South pole at a surface of the pole piece  184  and a North pole away from the surface of the pole piece  184 . These surfaces can be adjacent surfaces or opposite surfaces. For example, pole piece  184 A can have magnet  182 A a magnet at first surface  1610  and magnet  182 B at second surface  1620 , where first surface  1610  and second surface  1620  are adjacent surfaces. Pole piece  184 A can further have magnet  182 C at third surface  1630 , where third surface  1630  is opposite first surface  1610  and adjacent to second surface  1620 . Pole piece  184 B can have magnet  182 C at fourth surface  1640  and magnet  182 D at fifth surface  1650 , where fourth surface  1640  and fifth surface  1650  are opposite surfaces. The remaining pole pieces may be configured in a similar manner. 
     While embodiments of the present invention can provide useful connector inserts and connector receptacles for delivering power, these and other embodiments of the present invention can be used as connector receptacles in other types of connector systems, such as connector systems that can be used to convey power, data, or both. 
     In various embodiments of the present invention, contacts, shields, and other conductive portions of a connector receptacle or connector insert can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. The nonconductive portions, such as, housings, locking portions, and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The printed circuit boards or other boards used can be formed of FR-4 or other material. 
     Embodiments of the present invention can provide connector receptacles and connector inserts that can be located in, and can connect to, various types of devices such as portable computing devices, tablet computers, desktop computers, laptop computers, all-in-one computers, wearable computing devices, smart phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. These connector receptacles and connector inserts can provide interconnect pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Peripheral Component Interconnect express, Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention can provide connector receptacles and connector inserts that can be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles and connector inserts can be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     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: 20200924
Publication Date: 20220823
Grant Date: 20220823
Priority Date: 20200924
Inventors: AMINI, MAHMOUD R.
YARI BOROUJENI, AYOUB
DIFONZO, JOHN C.
HAMEL, BRADLEY J.
TZIVISKOS, GEORGE
ZHU, HAO
HACK, PAUL
Gery, Jean-March
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/6581", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/41", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/112", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/112", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/112", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 80740940