PATENT DOCUMENT

Publication Number: US-8480422-B2
Application Number: US-201113106468-A
Country: US
Kind Code: B2

Title: Connector assemblies with overmolds

Abstract:
This is directed to connector assemblies for electric cables, and methods of manufacturing the same, that may include a body molded about one or more connections made between one or more conductive leads of the electric cable and one or more electrical contacts of the connector assembly. The molded body may provide support to the connections and may maintain the relative positions of the traces for functionally aligning exposed portions of the traces with other connector assemblies.

Claims:
What is claimed is: 
     
       1. A method for constructing a connector assembly for a cable, comprising:
 electrically coupling a first conductive lead of the cable to a first conductive trace of the connector assembly; 
 electrically coupling the first conductive trace of the connector assembly to a first portion of a second conductive trace of the connector assembly; 
 injecting a first material into a mold cavity for forming a molded body about at least a portion of the first conductive lead and about at least a portion of the first and second conductive traces without covering a second portion of the second conductive trace, the second portion extending outwardly from the molded body and configured to be electrically coupled to one or more contacts of a second connector; and 
 wherein the molded body is configured to: expose at least a first portion of the first conductive trace; and expose at least the first portion of the second conductive trace. 
 
     
     
       2. The method of  claim 1 , further comprising placing the at least a portion of the first conductive lead and the at least a portion of the first conductive trace into the mold cavity before the electrically coupling. 
     
     
       3. The method of  claim 1 , further comprising placing the at least a portion of the first conductive lead and the at least a portion of the first conductive trace into the mold cavity after the electrically coupling. 
     
     
       4. The method of  claim 1 , further comprising electrically coupling the first conductive trace to the first portion of the second conductive trace of the connector assembly after the injecting. 
     
     
       5. The method of  claim 1 , further comprising electrically coupling the first conductive trace to the first portion of the second conductive trace of the connector assembly before the injecting. 
     
     
       6. The method of  claim 1 , further comprising electrically coupling a conductive electronic component to the first conductive trace and to the first portion of the second conductive trace of the connector assembly. 
     
     
       7. The method of  claim 6 , wherein the conductive electronic component comprises at least one of a thermal fuse, a thermal cut off (“TCO”), a resistor, and a capacitor. 
     
     
       8. The method of  claim 6 , wherein the conductive electronic component is configured to break an electrical connection between the first conductive trace and the second conductive trace when a temperature of the conductive electronic component rises above a certain threshold. 
     
     
       9. The method of  claim 1 , further comprising forming a recess in the molded body. 
     
     
       10. The method of  claim 9 , further comprising positioning a conductive electronic component within the recess. 
     
     
       11. The method of  claim 10 , wherein the positioning comprises electrically coupling the conductive electronic component to the first portion of the first conductive trace and to the first portion of the second conductive trace of the connector assembly. 
     
     
       12. The method of  claim 10 , further comprising injecting a second material into a second mold cavity for forming a second molded body about at least a portion of the conductive electronic component. 
     
     
       13. The method of  claim 1 , wherein the molded body supports an electrical connection between the first conductive lead and the first conductive trace. 
     
     
       14. The method of  claim 1 , further comprising inserting the molded body into a cavity of a connector subassembly. 
     
     
       15. The method of  claim 14 , wherein the inserting comprises electrically coupling the first conductive trace to a first electrical contact of the connector subassembly. 
     
     
       16. A system comprising:
 a cable comprising a first conductive lead; and 
 a first connector subassembly comprising:
 a first conductive trace electrically coupled to the first conductive lead and electrically coupled to a first portion of a second conductive trace of the first connector subassembly; 
 an overmold about at least a first portion of the first conductive lead, about at least a portion of the first conductive trace and about at least a portion of the second conductive trace without covering a second portion of the second conductive trace, the second portion extending outwardly from the overmold and configured to be electrically coupled to one or more contacts of a second connector subassembly; and 
 
 wherein the overmold is configured to expose at least a first portion of the first conductive trace and expose at least a first portion of the second conductive trace. 
 
     
     
       17. The system of  claim 16 , wherein the overmold supports the electrical coupling between the first conductive lead and the first conductive trace. 
     
     
       18. The system of  claim 16 , wherein the overmold is a strain relief for the electrical coupling between the first conductive lead and the first conductive trace. 
     
     
       19. The system of  claim 16 , wherein the overmold is configured to distribute a load applied to at least one of the cable and the first connector subassembly. 
     
     
       20. The system of  claim 16 , wherein a second portion of the first conductive trace extends out of the overmold. 
     
     
       21. The system of  claim 16 , wherein the second connector subassembly comprises: a first electrical contact; and a body defining a cavity. 
     
     
       22. The system of  claim 21 , wherein the overmold is positioned within the cavity. 
     
     
       23. The system of  claim 21 , wherein the first conductive trace is coupled to the first electrical contact within the cavity. 
     
     
       24. The system of  claim 21 , wherein, when the overmold is positioned within the cavity, the body restricts the movement of the overmold in at least one direction of freedom. 
     
     
       25. A system comprising:
 a first conductive lead; 
 a first conductive trace electrically coupled to the first conductive lead; 
 a second conductive trace having a first portion electrically coupled to the first trace; 
 an overmold configured to maintain a relative position between the first conductive trace and the second conductive trace without covering a second portion of the second conductive trace, the second portion extending outwardly from the overmold and configured to be electrically coupled to one or more contacts of a second connector; and 
 wherein the overmold is further configured to: expose at least a first portion of the first conductive trace; and expose at least the first portion of the second conductive trace. 
 
     
     
       26. The system of  claim 25  further comprising a connector subassembly comprising:
 a first electrical contact; and 
 a body defining a cavity, wherein the second portion of the second conductive trace is coupled to the first electrical contact within the cavity. 
 
     
     
       27. A system comprising:
 a first conductive lead; 
 a first conductive trace electrically coupled to the first conductive lead; 
 a second conductive trace having a first portion electrically coupled to the first trace; and 
 an overmold configured to maintain a relative position between the first conductive trace and the second conductive trace without covering a second portion of the second conductive trace, the second portion extending outwardly from the overmold and configured to be electrically coupled to one or more contacts of a second connector; 
 wherein the overmold is further configured to: expose at least a first portion of the first conductive trace; and expose at least the first portion of the second conductive trace; and 
 wherein a conductive element is electrically coupled to the first portion of the first conductive trace and to the first portion of the second conductive trace. 
 
     
     
       28. A system comprising:
 a first conductive trace; 
 a second conductive trace; 
 an overmold configured to maintain a relative position between the first conductive trace and the second conductive trace; 
 a conductive electronic component electrically coupled to the first conductive trace and the second conductive trace, wherein the conductive electronic component comprises at least one of a thermal fuse, a thermal cut off (“TCO”), a resistor, and a capacitor; and 
 wherein the overmold is further configured to: expose at least a first portion of the first conductive trace; and expose at least a first portion of the second conductive trace.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 61/355,961, filed Jun. 17, 2010, which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This is directed to electric cable connector assemblies and, more particularly, to such connector assemblies constructed by overmolding a body about connections made between conductive leads of an electric cable and electrical contacts of the connector assembly. 
     BACKGROUND OF THE DISCLOSURE 
     An electric cable may include one or more conductive lines or leads (e.g., wires) extending between a first connector assembly and a second connector assembly. Each connector assembly may be configured to electrically couple the conductive leads of the cable to a number of electrical contacts of the connector assembly. The electrical contacts of a connector assembly may be relatively positioned in a particular manner for electrically coupling the conductive leads of a cable to various types of electronic device input/output (“I/O”) components that can mate with the connector assembly (e.g., Universal Serial Bus (“USB”) connectors, 30-pin connectors, etc.). Known connector assemblies often include a generally planar printed circuit board with conductive traces provided therealong that extend from the electrical contacts, and the conductive leads of the cable are often soldered or otherwise fixed to portions of these traces of the circuit board. However, such an arrangement often provides little to no support for the connections between the conductive leads and the traces of the circuit board. 
     SUMMARY OF THE DISCLOSURE 
     Therefore, there are provided connector assemblies, and methods of manufacturing the same, that may include a body or shell overmolded about one or more connections between conductive leads of an electric cable and electrical contacts of the connector assembly. 
     For example, according to some embodiments, there is provided a method for constructing a connector assembly for a cable. The method may include electrically coupling a first conductive lead of the cable to a first conductive trace of the connector assembly. The method may also include injecting a first material into a mold cavity for forming a molded body about at least a portion of the first conductive lead and about at least a portion of the first conductive trace. In some embodiments, the method may also include electrically coupling a conductive electronic component to the first conductive trace and to a second conductive trace of the connector assembly. The conductive electronic component may include at least one of a thermal fuse, a thermal cut off (“TCO”), a resistor, and a capacitor. Additionally or alternatively, the method may also include inserting the molded body into a cavity of a connector subassembly. Such inserting may include electrically coupling the first conductive trace to a first electrical contact of the connector subassembly. 
     In other embodiments, there is provided a system that may include a cable having a first conductive lead. The system may also include a first connector subassembly having a first conductive trace electrically coupled to the first conductive lead. The first connector subassembly may also have an overmold about at least a first portion of the first conductive lead and about at least a first portion of the first conductive trace. The overmold may support the electrical coupling between the first conductive lead and the first conductive trace. The overmold may be a strain relief for the electrical coupling between the first conductive lead and the first conductive trace. The overmold may be configured to distribute a load applied to at least one of the cable and the first connector subassembly. The system may also include a first electrical contact and a body defining a cavity. The overmold may be positioned in the cavity and the first conductive trace may be coupled to the first electrical contact within the cavity. 
     In yet other embodiments, there is provided a system that may include a first conductive lead, a first conductive trace electrically coupled to the first conductive lead, a second conductive trace, and an overmold that may be configured to maintain a relative position between the first conductive trace and the second conductive trace. The system may also include a connector subassembly that may have a first electrical contact and a body defining a cavity. A portion of the second conductive trace may extend out of the overmold and may be coupled to the first electrical contact within the cavity. 
     In yet still other embodiments, there is provided a system that may include a first conductive trace, a second conductive trace, and an overmold that may be configured to maintain a relative position between the first conductive trace and the second conductive trace. The system may also include a conductive electronic component that may be electrically coupled to the first conductive trace and the second conductive trace. The conductive electronic component may include at least one of a thermal fuse, a thermal cut off (“TCO”), a resistor, and a capacitor. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the invention, its nature, and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a top, front, right perspective view of an electric cable system constructed in accordance with some embodiments of the invention; 
         FIG. 2  is a top, front, right perspective exploded view of a first connector assembly of the cable system of  FIG. 1 , in accordance with some embodiments of the invention; 
         FIG. 3  is a top, front, right perspective non-exploded view of the first connector assembly of  FIGS. 1 and 2 , in accordance with some embodiments of the invention; 
         FIG. 4  is a partial cross-sectional view of the first connector assembly of  FIGS. 1-3 , taken from line IV-IV of  FIG. 3 , in accordance with some embodiments of the invention; 
         FIG. 5  is a top, front, right perspective view of a first connector subassembly of the first connector assembly of  FIGS. 1-4 , in accordance with some embodiments of the invention; 
         FIG. 6  is a top, back, left perspective view of the first connector subassembly of  FIG. 5 , in accordance with some embodiments of the invention; 
         FIG. 7  is a top elevational view of the first connector subassembly of  FIGS. 5 and 6 , taken from line VII-VII of  FIG. 5 , in accordance with some embodiments of the invention; 
         FIG. 8  is a top elevational view, similar to  FIG. 7 , of the first connector subassembly of  FIGS. 5-7 , but with an additional component, in accordance with some embodiments of the invention; 
         FIG. 9  is a cross-sectional view of the first connector subassembly of  FIGS. 5-8 , taken from line IX-IX of  FIG. 8 , in accordance with some embodiments of the invention; and 
         FIG. 10  is a flowchart of an illustrative process for manufacturing a connector assembly, in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Connector assemblies, and methods of manufacturing the same, that may include a body or shell overmolded about one or more electrical connections made between conductive leads of an electric cable and electrical contacts of the connector assembly are provided and described with reference to  FIGS. 1-10 . 
     As shown in  FIG. 1 , for example, an electric cable system  7  may include an electric cable  10  and at least a first connector assembly  100 . Cable  10  may include one or more conductive lines or leads (e.g., wires), each of which may extend from first connector assembly  100 . In some embodiments, as shown in  FIG. 1 , electric cable system  7  may include first connector assembly  100  and a second connector assembly  200 , and at least one of the conductive leads of cable  10  may extend between first connector assembly  100  and second connector assembly  200  for transferring data, power, and/or other electrical signal-types between electronic device input/output (“I/O”) components coupled to the connector assemblies. 
     For example, cable  10  may include at least four conductive leads, such as a first conductive lead  1 , a second conductive lead  2 , a third conductive lead  3 , and a fourth conductive lead  4 , each of which may extend between first connector assembly  100  and second connector assembly  200 . Cable  10  may also include a cable jacket  5  that may extend between connector assemblies  100  and  200  and that may surround and/or protect one or more of conductive leads  1 - 4 . A portion of cable jacket  5  has been removed from  FIG. 1  so that portions of conductive leads  1 - 4  of cable  10  may be shown in  FIG. 1 . 
     Connector assemblies  100  and  200  may each be configured to electrically couple one or more of conductive leads  1 - 4  to a number of electrical contacts of the connector assembly. The quantity, size, and relative positioning of these electrical contacts may vary between connector assemblies of cable system  7  and may determine the types of electronic device I/O components that can mate with the connector assemblies of cable system  7 . For example, as shown in  FIG. 1 , first connector assembly  100  may include six (6) electrical contacts  198 , while second connector assembly  200  may only include four (4) electrical contacts  298 . Each one of connector assemblies  100  and  200  may be any suitable connector assembly type (e.g., a Universal Serial Bus (“USB”) connector assembly, a 30-pin connector assembly, such as those provided by Apple Inc. of Cupertino, Calif., and the like) for mating and electrically communicating with any suitable electronic device I/O component (not shown). Therefore, in some embodiments, first connector assembly  100  may be a 30-pin connector assembly and second connector assembly  200  may be a USB connector assembly, such that conductive leads  1 - 4  of cable  10  may electrically couple two different types of electronic device I/O components to one another (e.g., a first electronic device I/O component configured to receive and communicate with a 30-pin connector assembly, and a second electronic device I/O component configured to receive and communicate with a USB connector assembly). 
     As shown in  FIGS. 2-4 , for example, first connector assembly  100  of cable system  7  may include a first connector subassembly  110  and a second connector subassembly  190 . First connector subassembly  110  may include one or more conductive contacts or traces, each of which may be electrically coupled to one of conductive leads  1 - 4  of cable  10 . For example, as shown in  FIG. 2 , first connector subassembly  110  may include a first conductive trace  111  electrically coupled to first conductive lead  1 , a second conductive trace  112  electrically coupled to second conductive lead  2 , a third conductive trace  113  electrically coupled to third conductive lead  3 , and a fourth conductive trace  114  electrically coupled to fourth conductive lead  4 . The various ways in which conductive traces  111 - 114  may be electrically coupled to conductive leads  1 - 4  are described below with respect to  FIGS. 5-9 . Each one of conductive traces  111 - 114  may be metal or any other suitable conductive material for electrically coupling with a respective one of conductive leads  1 - 4 . First connector subassembly  110  may also include a body  120 , which may support the connections between conductive leads  1 - 4  and conductive traces  111 - 114 . Moreover, first connector subassembly  110  may also include a cable crimp  145 , which may help guide cable jacket  5  and conductive leads  1 - 4  into and/or hold cable jacket  5  and conductive leads  1 - 4  against body  120  of subassembly  110 . 
     Second connector subassembly  190  may include one or more electrical contacts  198 . For example, as shown in  FIGS. 2-4 , second connector subassembly  190  may include six (6) electrical contacts  198  (i.e., first electrical contact  198   a , second electrical contact  198   b , third electrical contact  198   c , fourth electrical contact  198   d , fifth electrical contact  198   e , and sixth electrical contact  198   f ), although it is to be understood that second connector subassembly  190  may include any other suitable number of electrical contacts  198  depending on the type of electronic device I/O component to which connector assembly  100  is to be electrically coupled. Second connector subassembly  190  may also include a body  180  defining a cavity  185 . Body  180  may be made of any suitable material, such as plastic or any other suitable non-conductive or insulative material, that may maintain electrical contacts  198  in their relative positions and expose at least a portion of each electrical contact  198  within cavity  185  for electrical coupling with first connector subassembly  110 . 
     For example, as shown in  FIGS. 2-4 , a portion of each one of electrical contacts  198  may be exposed in cavity  185 , such that when first connector subassembly  110  is inserted into cavity  185  of second connector subassembly  190  (e.g., inserted downwardly in the direction of arrow D of  FIG. 2 ), each one of conductive traces  111 - 114  of first connector subassembly  110  may be electrically coupled with one or more electrical contacts  198  of second connector subassembly  190 . In some embodiments, the number of conductive traces of first connector subassembly  110  may equal the number of electrical contacts  198  of second connector subassembly  190 , such that each conductive trace may be electrically coupled to a respective electrical contact  198 . However, in other embodiments, and as shown in  FIGS. 2-4 , the number of conductive traces of first connector subassembly  110  may be less than the number of electrical contacts  198  of second connector subassembly  190 . In such embodiments, two or more electrical contacts  198  of second connector subassembly  190  may be electrically coupled to the same conductive trace of first connector subassembly  110 . 
     For example, as shown in  FIGS. 2-4 , first conductive trace  111  of first connector subassembly  110  may be aligned with and electrically coupled to each one of electrical contacts  198   a ,  198   b , and  198   c  of second connector subassembly  190 , while second conductive trace  112  of first connector subassembly  110  may be aligned with and electrically coupled to electrical contact  198   e  of second connector subassembly  190 , while third conductive trace  113  of first connector subassembly  110  may be aligned with and electrically coupled to electrical contact  198   f  of second connector subassembly  190 , and while fourth conductive trace  114  of first connector subassembly  110  may be aligned with and electrically coupled to electrical contact  198   d  of second connector subassembly  190 . Each electrical contact  198  of second connector subassembly  190  may be electrically coupled to a conductive trace of first connector subassembly  110  in any suitable manner including, but not limited to, laser welding, fusing, soldering, and the like. 
     The shape of cavity  185  of second connector subassembly  190  may be configured to substantially match the shape of body  120  of first connector subassembly  110 . In some embodiments, body  120  may be positioned within cavity  185 , such that first subassembly  110  and second subassembly  190  may interlock with one another and/or restrict the other&#39;s movement in one or more degrees or directions of freedom. For example, as shown in  FIGS. 3 and 4 , once body  120  is positioned within cavity  185 , first subassembly  110  and second subassembly  190  may restrict the other&#39;s movement in at least one direction perpendicular to arrow D of  FIG. 2 . Moreover, when body  120  is positioned within cavity  185 , one or more electrical contacts  198  of second connector subassembly  190  may be electrically coupled to one or more conductive traces  111 - 114  of first connector subassembly  110  (e.g., within cavity  185 ). 
     In addition to or instead of the shapes of cavity  185  and body  120  interlocking to hold subassemblies  110  and  190  in functional alignment, a cover or any other suitable component (not shown) may be positioned about at least portions of first connector subassembly  110  and second connector subassembly  190  to hold the subassemblies together to form first connector assembly  100 . For example, a thermoplastic cover or overmold or adhesive wrap may be provided to hold subassemblies  110  and  190  together such that the electrical connections between electrical contacts  198  and conductive traces  111 - 114  may be maintained. 
     As mentioned above, and as shown in greater detail in  FIGS. 5-9 , for example, first connector subassembly  110  may include first conductive trace  111  electrically coupled to first conductive lead  1 , second conductive trace  112  electrically coupled to second conductive lead  2 , third conductive trace  113  electrically coupled to third conductive lead  3 , and fourth conductive trace  114  electrically coupled to fourth conductive lead  4 . For example, as shown in  FIG. 4 , an exposed end of first conductive lead  1  of cable  10  may be electrically coupled to a first portion of first conductive trace  111  of first connector subassembly  110  in any suitable manner including, but not limited to, crimping, fusing, welding, and the like. A second portion of first conductive trace  111  may be electrically coupled to one or more electrical contacts  198  of second connector subassembly  190  (e.g., electrical contacts  198   a - 198   c , as shown in  FIGS. 2-4 ). Similarly, an exposed end of second conductive lead  2  may be electrically coupled to a first portion of second conductive trace  112 , while a second portion of second conductive trace  112  may be electrically coupled to one or more electrical contacts  198  of second connector subassembly  190  (e.g., electrical contact  198   e , as shown in  FIGS. 2-4 ). Similarly, an exposed end of third conductive lead  3  may be electrically coupled to a first portion of third conductive trace  113 , while a second portion of third conductive trace  113  may be electrically coupled to one or more electrical contacts  198  of second connector subassembly  190  (e.g., electrical contact  198   f , as shown in  FIGS. 2-4 ). 
     Furthermore, in some embodiments, an exposed end of fourth conductive lead  4  may be electrically coupled to a first portion of fourth conductive trace  114 , while a second portion of fourth conductive trace  114  may be electrically coupled to one or more electrical contacts  198  of second connector subassembly  190  (e.g., electrical contact  198   d , as shown in  FIGS. 2-4 ). However, in some embodiments, fourth conductive lead  4  of cable  10  may not be electrically coupled directly to fourth conductive trace  114  of first connector subassembly  110 . Instead, fourth conductive lead  4  may be electrically coupled to fourth conductive trace  114  via one or more intermediary conductive components. For example, as shown in  FIGS. 5-9 , fourth conductive lead  4  may be electrically coupled (e.g., directly coupled) to an intermediate conductive trace  116  of first connector subassembly  110 , and intermediate conductive trace  116  may be electrically coupled to fourth conductive trace  114  in various suitable ways. In some embodiments, intermediate conductive trace  116  may be electrically coupled to fourth conductive trace  114  through a conductive electronic component  118 . As shown in  FIGS. 5-9 , for example, fourth conductive lead  4  of cable  10  may be electrically coupled directly to a first portion  116   a  of intermediate conductive trace  116 , while conductive electronic component  118  may be electrically coupled to both a second portion  116   b  of intermediate conductive trace  116  and a first portion  114   a  of fourth conductive trace  114 . A second portion  114   b  of fourth conductive trace  114  may be electrically coupled to one or more electrical contacts  198  of second connector subassembly  190  (e.g., electrical contact  198   d , as shown in  FIGS. 2-4 ). 
     Like conductive traces  111 ,  112 , and  113 , each one of fourth conductive trace  114  and intermediate conductive trace  116  may be metal or any other suitable conductive material for electrically coupling with a respective one of conductive leads  1 - 4  and/or electrical contacts  198 . In some embodiments, conductive electronic component  118  may also be metal or any other suitable conductive material. However, in other embodiments, conductive electronic component  118  may be a more sophisticated conductive element including, but not limited to, a thermal fuse, a thermal cut off (“TCO”), a resistor, a capacitor, or the like. For example, conductive electronic component  118  may be a thermal fuse that may be configured to break the connection between intermediate conductive trace  116  and fourth conductive trace  114  if the temperature of conductive electronic component  118  rises above a certain threshold. 
     Fourth conductive lead  4  may be electrically coupled to first portion  116   a  of intermediate conductive trace  116  in any suitable manner including, but not limited to, crimping, fusing, welding, and the like. Conductive electronic component  118  may be electrically coupled to each one of intermediate conductive trace  116  and fourth conductive trace  114  in any suitable way. However, thermal fusing and/or welding of conductive electronic component  118  to intermediate conductive trace  116  and/or fourth conductive trace  114  may be better than soldering, as soldering may raise the temperature of conductive component  118  above a threshold of component  118 . For example, as shown in  FIGS. 8 and 9 , a first portion  118   a  of conductive component  118  may be electrically coupled to second portion  116   b  of intermediate conductive trace  116  and a second portion  118   b  of conductive component  118  may be electrically coupled to first portion  114   a  of fourth conductive trace  114 . In some embodiments, the electrical coupling of portions  118   a  and  118   b  of conductive component  118  may each be achieved using thermal fusing or welding, followed by applying a non-conductive glue to the connection points. 
     Rather than providing one or more of conductive traces  111 - 114  or  116  as traces on a printed circuit board, traces  111 - 114  and  116  may be at least partially supported by body  120  of first connector subassembly  110 . For example, shell or body  120  may be molded about and around the connections formed between conductive leads  1 - 4  and conductive traces  111 - 114  and  116 . In some embodiments, a fixture assembly  901  may include one or more fixtures that may be used to temporarily hold conductive leads  1 - 4  and conductive traces  111 - 114  and  116  in their electrically coupled positions of  FIGS. 5-9  while a material may be injected into a mold cavity  951  for forming overmolded shell or body  120  about and around the electrically coupled elements, as shown in  FIGS. 5-9 , for example. Body  120  may also be formed about or around at least a portion of cable jacket  5  and/or at least a portion of cable crimp  145 , as shown in  FIGS. 5-9 . 
     In some embodiments, one or more fixtures may be used to temporarily hold any portion of cable  10  and/or any portion of first connector subassembly  110 . For example, as shown in  FIG. 8 , a first fixture  901   a  of fixture assembly  901  may hold a portion of jacket  5  and/or a portion of crimp  145  and a second fixture  901   b  of fixture assembly  901  may hold a portion of one or more of conductive traces  111 - 114  (e.g., second portion  114   b  of fourth conductive trace  114 ). Such first and second fixtures of fixture assembly  901  may be held relative to one another to maintain each conductive lead of cable  10  (e.g., leads  1 - 4 ) and each conductive trace of first connector assembly  100  (e.g., traces  111 - 114  and  116 ) in their electrically coupled positions of  FIGS. 5-9 . In other embodiments, fixture assembly  901  may include only a single fixture. Alternatively, fixture assembly  901  may include more than two fixtures. 
     As also shown in  FIG. 8 , a mold cavity  951  may be positioned relative to each fixture of fixture assembly  901  and about and/or around at least a portion of one or more of the conductive traces of first connector assembly  100  and about and/or around at least a portion of one or more of the conductive leads of cable  10 , while a material may be injected into mold cavity  951  for forming overmolded shell or body  120  about and around at least a portion of each of the electrically coupled elements, as shown in  FIGS. 5-9 , for example. In some embodiments, mold cavity  951  may include multiple distinct mold cavities that may be injected independently or at the same time in order to form body  120 . In some embodiments, at least a portion of mold cavity  951  and at least one fixture of fixture assembly  901  may be incorporated into a single element. For example, first fixture  901   a , second fixture  901   b , and cavity  951  may all be provided as a single manufacturing element  991 , as shown in  FIG. 8 . Body  120  may be configured to maintain the relative positions held by fixture assembly  901  of one or more portions of cable  10  and/or one or more portions of first connector subassembly  110 . 
     Body  120  may be molded from any suitable material including, but not limited to, soft elastomers, thermoplastics, thermosetting plastic materials, and the like. When the mold material for body  120  is injected into a mold cavity for forming body  120  of first connector subassembly  110 , the material can fill the mold cavity and flow around conductive leads  1 - 4  and/or conductive traces  111 - 114  and  116 . Body  120  may be formed using different injection molding materials for different portions of body  120 . For example, a softer material may be used for inner portions of body  120  and a harder material may be used to mold an outer portion of body  120 . Different portions of mold cavity  951  may be filled with different injection molding materials or molding materials with different properties. It is to be appreciated that molded body  120  may be formed to have any suitable shape simply by designing a cavity mold with desired dimensions. Unlike printed circuit boards that are often difficult to customize to a particular shape, molded body  120  may be formed to have a unique shape that may correspond to and interlock with another component, such as cavity  185  of second connector subassembly  190 . By enabling a close fit between body  120  of connector subassembly  110  and cavity  185  of connector subassembly  190 , the two subassemblies may better maintain the functional alignment and electrical connections between conductive traces  111 - 114  of first connector subassembly  110  and electrical contacts  198  of second connector subassembly  190 . 
     Overmolded body  120  may support the electrical connections made between leads  1 - 4  and traces  111 - 114  and  116 , such that body  120  may act as a strain relief for the termination of leads  1 - 4  at first connector subassembly  110 . Unlike printed circuit boards, molded body  120  may be at least partially formed of a material that is soft or malleable enough to flex or otherwise distribute a load or pressure applied to cable  10  and/or first connector assembly  100  of system  7  that might otherwise threaten the integrity of the connections between the leads and traces. Overmolded body  120  may also be formed about leads  1 - 4  and traces  111 - 114  and  116  to appropriately manage and route those elements through body  120 , such that their electrical connections are properly supported and such that the positioning of the portions of traces  111 - 114  extending outwardly from body  120  (e.g., portion  114   b ) may be properly maintained for functional alignment with other components (e.g., contacts  198  of second connector subassembly  190 ). 
     Body  120  may be molded about leads  1 - 4  and traces  111 - 114  and  116  before conductive component  118  may be electrically coupled to traces  114  and  116 . For example, as shown in  FIGS. 5-9 , a body cavity or recess  125  may be formed in body  120  that may expose at least second portion  116   b  of trace  116  and first portion  114   a  of trace  114 . Body recess  125  may be dish shaped or any other suitable shape that may allow conductive component  118  to be electrically coupled to traces  114  and  116  after body  120  has been formed. Recess  125  may be formed after at least a first portion of body  120  has been formed. In some embodiments, a second portion of body  120  (not shown) may be molded on top of conductive component  118  after or concurrently with the other portions of body  120  shown in  FIGS. 5-9 . Body  120  may be a mold for managing and/or routing wires or electrical traces from one location to another (e.g., for electrical coupling or termination). Body  120  may be a mold that can act as a strain relief for electrically coupled paths. 
       FIG. 10  is a flowchart of an illustrative process  1000  for manufacturing a connector assembly (e.g., first connector subassembly  110  of  FIGS. 5-9 ). At step  1002 , at least one conductive lead of a cable is electrically coupled to a respective conductive trace of the assembly. For example, each conductive lead of cable  10  may be crimped, fused, welded, soldered, or otherwise electrically coupled to a conductive trace of first connector subassembly  110 . Next, at step  1004 , at least one electrically coupled lead and trace may be positioned within a mold cavity. For example, one or more fixtures may be used to hold the electrically coupled lead and trace in a predetermined configuration within a mold cavity. Next, at step  1006 , a material may be injected into the mold cavity for forming a molded body about at least a portion of each electrically coupled lead and about at least a portion of each electrically coupled trace. 
     For example, a connector assembly body may be molded about at least a portion of each lead and each trace for holding each electrically coupled lead and trace in a particular configuration. A material may be injected into a mold cavity and may harden for maintaining the leads and traces in such a particular configuration. In some embodiments, the connector assembly body molded at step  1006  may include a recess, or such a recess may be formed into the body after step  1006 , for exposing at least a portion of not only a first trace that is electrically coupled to a first lead but also at least a portion of a second trace. In such embodiments, a conductive component may then be positioned within the recess and coupled to those two at least partially exposed traces. For example, a thermal fuse may be electrically coupled to two such traces while enabling the electrical connection to be broken when the temperature of the thermal fuse exceeds a certain temperature. 
     It is understood that the steps shown in process  1000  of  FIG. 10  are merely illustrative and that existing steps may be modified or omitted, additional steps may be added, and the order of certain steps may be altered. For example, in some embodiments, the electrical coupling of a trace and lead at step  1002  may be performed after the trace and lead are positioned within a mold cavity at step  1004 , but before the mold cavity is injected at step  1006 . 
     The previously described embodiments are presented for purposes of illustration and not of limitation. It is understood that one or more features of an embodiment can be combined with one or more features of another embodiment to provide systems and/or methods without deviating from the spirit and scope of the invention. 
     Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. 
     The above-described embodiments of the invention are presented for purposes of illustration and not of limitation.

Metadata:
Filing Date: 20110512
Publication Date: 20130709
Grant Date: 20130709
Priority Date: 20100617
Inventors: SIAHAAN EDWARD
FRAZIER CAMERON
ARDISANA JOHN
GOLKO AL
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/504", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 45329072