PATENT DOCUMENT

Publication Number: US-10418763-B2
Application Number: US-201815954425-A
Country: US
Kind Code: B2

Title: Connector insert assembly

Abstract:
Connector inserts having retention features with good reliability and holding force. These connector inserts may include ground contacts that provide an insertion portion having a reduced length. These connector inserts may be reliable, have an attractive appearance, and be readily manufactured.

Claims:
What is claimed is: 
     
       1. A connector insert comprising:
 a housing having a front opening, a first side opening along a right side, a second side opening along a left side, a first plurality of slots along a top side, and a second plurality of slots along a bottom side; 
 a first plurality of contacts in the first plurality of slots in the housing; 
 a second plurality of contacts in the second plurality of slots in the housing; 
 a first retention spring in the first side opening in the housing, the first retention spring having a first length and including a contacting portion at a first end to engage a first notch on a tongue of a connector receptacle; 
 a second retention spring in the second side opening in the housing, the second retention spring having the first length and including a contacting portion at a first end to engage a second notch on the tongue of the connector receptacle; 
 a first ground contact between the front opening of the housing and the first plurality of contacts; 
 a second ground contact between the front opening of the housing and the second plurality of contacts; and 
 a shield over the housing, the first retention spring, and the second retention spring, the shield contacting the first retention spring and the second retention spring when the connector insert is inserted into the connector receptacle, 
 wherein the first ground contact and the second ground contact each include a plurality of contacting portions joined by a cross beam, the cross beam attached to a first lateral support structure and a second lateral support structure, wherein the first lateral support structure and the second lateral support structure wrap around approximately one-half of the circumference of the housing in the lateral direction. 
 
     
     
       2. The connector insert of  claim 1  wherein the shield contacts the first retention spring and the second retention spring before the connector insert is inserted into the connector receptacle. 
     
     
       3. The connector insert of  claim 1  wherein the first retention spring further comprises a dimple, and a portion of the first retention spring from the dimple to the contacting portion forms a deflection arm that deflects as the connector insert is inserted into the connector receptacle. 
     
     
       4. The connector insert of  claim 3  wherein the deflection arm has a length that is a majority of the first length. 
     
     
       5. The connector insert of  claim 3  wherein the deflection arm has a length that is greater than one-half of the first length. 
     
     
       6. The connector insert of  claim 1  further comprising a first insulating layer between the first plurality of contacts and the shield and a second insulating layer between the second plurality of contacts and the shield. 
     
     
       7. The connector insert of  claim 6  wherein the first insulating layer and the second insulating layer are pieces of tape. 
     
     
       8. The connector insert of  claim 1  wherein the connector insert has a front lip around the front opening, wherein an inside portion of the front lip is formed by the housing and the outside portion of the front lip is formed by the shield. 
     
     
       9. A connector insert comprising:
 a housing having a front opening, a first side opening along a right side, a second side opening along a left side, a first plurality of slots along a top side, and a second plurality of slots along a bottom side; 
 a first plurality of contacts in the first plurality of slots in the housing; 
 a second plurality of contacts in the second plurality of slots in the housing; 
 a first retention spring in the first side opening in the housing; 
 a second retention spring in the second side opening in the housing, wherein the first retention spring and the second retention spring are preloaded; 
 a first electromagnetic interference (EMI) spring between the front opening and the first plurality of contacts; 
 a second EMI spring between the front opening and the second plurality of contacts, wherein the first EMI spring and the second EMI spring each include a plurality of ground contacts joined by a plurality of consecutive crossbars; and 
 a shield over the housing, the first retention spring, and the second retention spring. 
 
     
     
       10. The connector insert of  claim 9  wherein the first EMI spring and the second EMI spring each wrap around approximately one-half of the circumference of the housing in the lateral direction. 
     
     
       11. The connector insert of  claim 9  further comprising a first insulating layer between the first plurality of contacts and the shield and a second insulating layer between the second plurality of contacts and the shield. 
     
     
       12. The connector insert of  claim 11  wherein the first insulating layer and the second insulating layer are pieces of tape. 
     
     
       13. The connector insert of  claim 9  wherein the first retention spring and the second retention spring each has a first length and includes a contacting portion at a first end to engage a notch on a tongue of a connector receptacle, where each retention spring further includes a dimple, the dimple contacting the shield when the connector insert is inserted into the connector receptacle. 
     
     
       14. The connector insert of  claim 13  wherein the shield contacts the dimple on the first retention spring and the dimple on the second retention spring before the connector insert is inserted into the connector receptacle. 
     
     
       15. The connector insert of  claim 9  wherein the connector insert has a front lip around the front opening, wherein an inside portion of the front lip is formed by the housing and the outside portion of the front lip is formed by the shield. 
     
     
       16. A connector insert comprising:
 a housing having a front opening, a first side opening along a right side, a second side opening along a left side, a first plurality of slots along a top side, and a second plurality of slots along a bottom side; 
 a first contact assembly comprising: 
 a first plurality of contacts in the first plurality of slots in the housing; and 
 an insert molded housing around portions of the first plurality of contacts; 
 a second contact assembly comprising: 
 a second plurality of contacts in the second plurality of slots in the housing; and 
 an insert molded housing around portions of the second plurality of contacts; 
 a central ground plane between the first contact assembly and the second contact assembly, the central ground plane comprising a first articulating arm and a second articulating arm, 
 a first retention spring attached to the first articulating arm and located in the first side opening in the housing; 
 a second retention spring attached to the second articulating arm and located in the second side opening in the housing; 
 a first electromagnetic interference (EMI) spring between the front opening and the first plurality of contacts; 
 a second EMI spring between the front opening and the second plurality of contacts, wherein the first and second EMI springs each include a plurality of ground contacts joined by a plurality of consecutive crossbars; and 
 a shield over the housing, the first retention spring, and the second retention spring. 
 
     
     
       17. The connector insert of  claim 16  wherein the first retention spring and the second retention spring are preloaded. 
     
     
       18. The connector insert of  claim 16  wherein the first and second EMI springs each comprise a shield contact contacting an inside surface of the shield. 
     
     
       19. The connector insert of  claim 16  wherein a tab on the insert molded housing of the first contact assembly passes through a first opening in the central ground plane and into a hole in the insert molded housing of the second contact assembly, and a tab on the insert molded housing of the second contact assembly passes through a second opening in the central ground plane and into a hole in the insert molded housing of the first contact assembly. 
     
     
       20. The connector insert of  claim 16  wherein the first EMI spring and the second EMI spring each wrap around approximately one-half of the circumference of the housing in the lateral direction.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 15/368,691, filed Dec. 5, 2016, which is a continuation of U.S. patent application Ser. No. 14/641,375, filed Mar. 7, 2015, which is a continuation-in-part of U.S. patent application Ser. No. 14/543,803, filed Nov. 17, 2014, which claims the benefit of U.S. provisional patent application No. 62/003,012, filed May 26, 2014, which are incorporated by reference. 
    
    
     BACKGROUND 
     The amount of data transferred between electronic devices has grown tremendously the last several years. Large amounts of audio, streaming video, text, and other types of data content are now regularly transferred among desktop and portable computers, media devices, handheld media devices, displays, storage devices, and other types of electronic devices. Power may be transferred with this data, or power may be transferred separately. 
     Power and data may be conveyed over cables that may include wire conductors, fiber optic cables, or some combination of these or other conductors. Cable assemblies may include a connector insert at each end of a cable, though other cable assemblies may be connected or tethered to an electronic device in a dedicated manner. The connector inserts may be inserted into receptacles in the communicating electronic devices to form pathways for power and data. 
     The data rates through these connector inserts may be quite high. To provide these high data rates, it may be desirable that these connector inserts have good matching, a high signal integrity, and low insertion loss. This may require the impedance of signal contacts in the connector insert to be matched and close to a target value. 
     These connector inserts may be inserted into a device receptacle once or more each day for multiple years. It may be desirable that these connector inserts have and maintain a pleasant physical appearance as a poor appearance may lead to user dissatisfaction with both the cable assembly and the electronic devices that it connects to. 
     Electronic devices may be sold in the millions, with an attendant number of cable assemblies and their connector inserts sold alongside. With such volumes, any difficulties in the manufacturing process may become significant. For such reasons, it may be desirable that these connector inserts may be reliably manufactured. 
     Thus, what is needed are connector inserts having signal contacts with a matched impedance near a target value for good signal integrity and low insertion loss, a pleasant physical appearance, and that may be reliably manufactured. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide connector inserts having contacts with a matched impedance near a target value for good signal integrity and low insertion loss, a pleasant physical appearance, and that may be reliably manufactured. 
     An illustrative embodiment of the present invention may provide connector inserts having signal contacts with a matched impedance near a target value to improve signal integrity and provide a low insertion loss in order to allow high data rates. This matching may be achieved in part by increasing an impedance of the signal contacts. For example, various embodiments of the present invention may include ground planes between rows of contacts in a connector in order to electrically isolate signals in the different rows from each other. Also, a grounded shield may surround these rows of contacts. The ground plane and shield may increase capacitance to the signal contacts, thereby lowering the impedance at the contacts below a target value and thereby degrading signal integrity. Accordingly, in order to improve signal integrity and facilitate matching, embodiments of the present invention may thin or reduce thicknesses of one or more of the shield, ground plane, or contacts in order to increase the distances between the structures. This increase in distance may increase the impedance at the contacts to near a target value, again improving matching among the signal contacts. 
     In other embodiments of the present invention, the shape of a signal contact when it is in a deflected or inserted state may be optimized. For example, a contact may be contoured to be at a maximum distance from the ground plane and shield over its length in order to increase impedance at the contact. In a specific embodiment of the present invention where the ground plane and shield are substantially flat, the signal contacts may be substantially flat as well, and where either or both the ground plane and shield are curved, the signal contacts may be substantially curved as well. 
     In this embodiment of the present invention, the signal contacts of a connector insert may be designed to be substantially flat when the connector insert is inserted into a connector receptacle. This design may also include a desired normal force to be applied to a contact on a connector receptacle by a connector insert signal contact. From this design, the shape of the connector insert signal contacts when the connector insert is not inserted in a connector receptacle may be determined. That is, from knowing the shape of a connector insert signal contact in a deflected state and the desired normal force to be made during a connection, the shape of a connector insert signal contact in a non-deflected state may be determined. The connector insert signal contacts may be manufactured using the determined non-deflected state information. This stands in contrast to typical design procedures that design a contact beginning with the non-deflected state. 
     These and other embodiments of the present invention may provide connector inserts having a pleasant appearance. In these embodiments, a leading edge of the connector insert may be a plastic tip. This plastic tip may be a front portion of a housing in the connector insert. Embodiments of the present invention may provide features to prevent light gaps from occurring between the plastic tip and shield. One illustrative embodiment of the present invention may provide a step or ledge on the plastic tip to block light from passing between the plastic tip and the shield. In other embodiments of the present invention, a force may be exerted on the shield acting to keep the shield adjacent to, or in proximity of, the plastic tip. This force may be applied at a rear of the shield by one or more arms having ramped surfaces, where the arms are biased in an outward direction and the ramps are arranged to apply a force to the shield. 
     After a connector insert portion has been manufactured, a cable may be attached to it. The cable may include a ground shield or braiding. During cable attachment, the braiding may be pulled back and a ground cap may be placed over the braiding. The cap may then be crimped to secure the cable in place. The crimping may be done with a multi-section die, where contacting surfaces of the die include various points or peaks along their surface. These points may effectively wrinkle or jog the perimeter of the cap, thereby reducing the dimensions of a cross-section of the cable. This reduction in cross section may improve the flow of plastic while a strain relief is formed around the cable. This may, in turn, increase the manufacturability of the connector insert. 
     Another illustrative embodiment of the present invention may include retention springs for a connector insert. These retention springs may engage notches on sides of the tongue of a connector receptacle when the connector insert is inserted into the connector receptacle. These retention springs may include a contacting portion for engaging the notches on the tongue. The retention springs may also include an optional dimple. The dimple, if present, may engage in inside of a shield of the connector insert while the connector insert is inserted into the connector receptacle, otherwise, the retention spring surface itself may engage the inside of the shield while the connector insert is being inserted. In other embodiments of the present invention, the dimple if present, may engage in inside of the shield before the connector insert is inserted, otherwise the retention spring surface itself may engage the inside of the shield before the connector insert is inserted. The retention spring may include a deflection arm extending from the dimple, if present, to the contacting portion. In other embodiments of the present invention, the deflection arm may extend from a location where the retention spring contacts the shield to the contacting portion. A majority of the length of the retention spring may be made up of this deflection arm. This deflection arm may deflect as the connector insert is inserted into a connector receptacle. In this way, stresses may be spread out over the retention spring during insertion. This may help to avoid a concentration of stress that could otherwise cause a cold working failure or cracking in the retention spring. Specifically, a surface or dimple (if present) may contact a surface, such as a shield, when the connector insert starts to be inserted into a connector receptacle. Force or stress may concentrate here, but the retention spring may be made thicker or wider in one or more directions here to support the stress. As the insert continues to be inserted, the deflection arm may deflect, absorbing stresses over a long portion of the retention spring. Particularly where no dimple is present, the contact area between the retention spring and shield or other surface may “rock” or move along the length of the retention spring (towards the contacting portion), again helping to distribute the points of high stress compensation. This configuration may provide a retention spring that is hard enough to provide a good retention force but not fail due to cold working. These retention springs may be formed in various ways. For example, the may be forged, stamped, metal-injection-molded, or formed in other ways. 
     Another illustrative embodiment of the present invention may include ground contacts near a front opening of the connector insert. These ground contacts may be connected by a cross piece. The cross piece may be supported by one or more spring structures, which may wrap laterally around a front portion of a housing for the connector insert. In a specific embodiment of the present invention, the support structures may wrap around approximately one-half of a circumference of the housing. 
     Another illustrative embodiment of the present invention may provide a connector insert having a front lip. An inside portion of the front lip may be formed of a nonconductive housing, while an outside portion may be formed of a conductive shield. This arrangement may help to prevent the conductive shield from contacting and shorting contacts on a tongue of a connector receptacle while the connector insert is inserted into the connector receptacle. To further protect against shorting receptacle contacts, the housing may be arranged to be either aligned with or extending beyond the shield. Also, having a portion of lip formed by the shield may help to strengthen a leading edge of the connector insert. 
     The signal contacts included in a connector insert according to an embodiment of the present invention may be pre-biased to provide a force against contacts on a top of a connector receptacle. This pre-bias may provide a force at a front opening of the connector insert in a direction such that the opening may tend to close up. Accordingly, embodiments of the present invention may provide an end cap having bowed outside edges. These outwardly bowed edges may provide a countervailing force during manufacturing to help the opening of the connector insert to remain open. 
     These and other embodiments of the present invention may provide retention springs for connector inserts, where the retention springs are preloaded. Specifically, the retention springs may be attached to articulating arms extending from a central ground plane. After attachment to the central ground plane, the retention springs may have a greater spacing between contacting portions than necessary. As the retention springs are inserted into a shield of the connector insert, a compressive force may be applied to sides of the retention springs such that the articulating arms are angled towards the central ground plane and the contacting portions are driven closer together. This compression may also provide a preloading on the retention springs. When a connector receptacle tongue is inserted into the connector insert, a user may have to overcome the preloading of the retention spring before the tongue may continue to be inserted. This preloading may provide the connector insert with a more consistent insertion profile, more stable normal forces, and a greater durability. It may simplify manufacturing of the retention springs, allowing the use of softer materials that may be stamped instead of being forged. These retention springs may have a more uniform thickness along their length, since the insertion profile of the connector is not being primarily determined by the shape of the retention springs. The retention springs may be laser welded to the articulating arms extending from the central ground plane at several locations. This may provide an attachment between the retention springs and the central ground plane that may withstand the application of force during assembly as well as the preloading force. The attached retention springs and the central ground plane may form a unit that is easily mated to a connector insert housing to simplify assembly. 
     These and other embodiments of the present invention may provide ground contacts near a front opening of the connector insert. These ground contacts may be included on electromagnetic interference (EMI) springs. (The term EMI springs may also refer more generally to ground contacts, as in the examples above.) These EMI springs may include continuous crossbars. These consecutive crossbars may be formed separately and joined or they may be formed as a single piece. Ground contacts may be located at junctions of the crossbars. Attaching the ground contacts to the crossbars themselves may reduce an amount of housing that may need to be removed to make space for the EMI springs. That is, with a reduced thickness to the EMI springs, a channel or guide holding the EMI springs may be shallower narrower, thereby allowing the housing to be thicker and more rigid. The more substantial housing may minimize warpage of the housing near the front of the connector insert. The ground contacts may be exposed at openings in a housing for the connector insert. The crossbars may be located in a channel or guide in the housing, where the channel or guide extends laterally across and near the front of the connector insert housing. These EMI springs may extend nearly 180 degrees around the opening of the connector insert. The outside crossbars may include feet that snap or otherwise fit in a right-angle portion of the channel or guide, where the right-angle portion extends in a direction orthogonal to the remainder of the channel or guide and away from the front of the connector insert. The ground contacts may extend from the crossbars into a central passage of the connector insert and may be folded back into the passage. The ground contacts may also include lateral extensions that extend roughly parallel to the central passage. During insertion of a tongue into the connector insert, these lateral extensions may prevent the ground contacts from being pushed back into the connector insert between the shield and the housing. Shield contacts may be located between the ground contacts, and may extend from the two center crossbars away from the central passage of the connector insert where they may contact the outside shield of the connector insert. These shield contacts may also push against the shield thereby helping to hold the EMI springs in place. The crossbars may have a torsion force applied during their assembly into the housing. This, along with the flexibility of the crossbars and the ground contacts themselves, may help to more evenly distribute forces when the ground contacts engage a connector receptacle tongue. By more evenly distributing forces, the amount of permanent deformation of the EMI springs may be reduced. Also, the force applied to a connector receptacle tongue by the ground contacts may be reduced, thereby reducing wear on the tongue. This force may further be refined by tapering one or more of the crossbars in one or more directions along their length. 
     In various embodiments of the present invention, contacts, shields, and other conductive portions of connector inserts and receptacles may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, forging, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), or other nonconductive material or combination of materials. The printed circuit boards used may be formed of FR-4, BT or other material. Printed circuit boards may be replaced by other substrates, such as flexible circuit boards, in many embodiments of the present invention. 
     Embodiments of the present invention may provide connector inserts and receptacles that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector inserts and receptacles may provide pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), 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 may provide connector inserts and receptacles that may 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 inserts and receptacles may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a connector insert according to an embodiment of the present invention that has been inserted into a connector receptacle according to an embodiment of the present invention; 
         FIG. 2  illustrates a portion of a connector system according to an embodiment of the present invention; 
         FIG. 3  illustrates signal contacts in a deflected or inserted state according to an embodiment of the present invention; 
         FIG. 4  illustrates signal contact in a non-deflected or extracted state according to an embodiment of the present invention; 
         FIG. 5  illustrates a front end of a connector insert according to an embodiment of the present invention; 
         FIG. 6  illustrates a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 7  illustrates a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 8  illustrates a cutaway view of a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 9  illustrates a structure for crimping a cap around an end of a cable according to an embodiment of the present invention; 
         FIG. 10  illustrates an exploded view of a connector insert according to an embodiment of the present invention; 
         FIG. 11  illustrates a retention spring that may be used in a connector insert according to an embodiment of the present invention; 
         FIG. 12  illustrates a top cut-away view of a connector insert according to an embodiment of the present invention; 
         FIG. 13  illustrates a front view of a connector insert according to an embodiment of the present invention; 
         FIG. 14  illustrates a connector insert portion and a ground contact according to an embodiment of the present invention; 
         FIG. 15  illustrates steps in the manufacturing of a connector insert according to an embodiment of the present invention; 
         FIG. 16  illustrates forces being exerted at a connector insert opening according to an embodiment of the present invention; 
         FIGS. 17A-17B  illustrate an end cap being inserted into an opening of a connector insert according to an embodiment of the present invention; 
         FIG. 18  illustrates the operation of an end cap that may be employed during manufacturing of a connector insert according to an embodiment of the present invention; 
         FIG. 19  illustrates another connector insert according to an embodiment of the present invention; 
         FIG. 20  illustrates a contact assembly for a connector insert according to an embodiment of the present invention; 
         FIG. 21  illustrates a central ground plane and retention springs for a connector insert according to an embodiment of the present invention; 
         FIG. 22  illustrates a portion of the assembly of a connector insert according to an embodiment of the present invention; 
         FIG. 23  illustrates a preloading of retention springs according to an embodiment of the present invention; 
         FIG. 24  illustrates views of retention springs according to an embodiment of the present invention; 
         FIGS. 25-26  illustrate further views of retention springs according to an embodiment of the present invention; 
         FIG. 27  illustrates a portion of an assembly of a connector insert according to an embodiment of the present invention; 
         FIG. 28  illustrates a housing for a connector insert according to an embodiment of the present invention; 
         FIG. 29  illustrates a side view of a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 30  illustrates a portion of a connector insert according to an embodiment of the present invention; and 
         FIGS. 31-32  illustrate EMI springs according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates a connector insert according to embodiments of the present invention that is been inserted into a connector receptacle according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     Specifically, connector insert  110  has been inserted into connector receptacle  120 . Connector receptacle  120  may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. Connector insert  110  and connector receptacle  120  may provide pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), 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. In other embodiments of the present invention, connector insert  110  and connector receptacle  120  may 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 connector insert  110  and connector receptacle  120  may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. More information about connector insert  110  and connector receptacle  120  may be found in U.S. patent application Ser. No. 14/543,711, filed Nov. 17, 2014, which is incorporated by reference. 
     Connector insert  110  may include a number of contacts for conveying signals. These signals may include high-speed differential signals, as well as other types of signals. To increase signal integrity and reduce insertion losses, it may be desirable to increase an impedance of the signal contacts. More specifically, it may be desirable to match the impedance across the various contacts in a connector plug or insert so that they all have a value near a target value. In some embodiments of the present invention, this matching is facilitated by decreasing capacitances between the signal contacts in the connector insert to other conductive structures in the connector insert  110  and connector receptacle  120 . This may be done by increasing the physical spacing between the signal contacts and these other structures. 
     Various connector receptacles may include ground structures, such as shields or center or central ground planes, or both. These shields and ground planes may have a particularly contour, which may be but is not necessarily flat. The signal contacts may then be designed to have a similar contour when they are deflected due to the connector insert being inserted into a connector receptacle. From this deflected shape, a non-deflected shape may be determined. From this non-deflected shape the contact may be formed. Variations between the shape of the contact and the shape of the ground structures may exist. These variations may be adjusted based at least in part on a desired contact force between the contact for the connector insert and a corresponding contact in a connector receptacle. This contact force may also at least partially account for differences between the deflected and non-deflected shapes of the contact for the connector insert. An example of this is shown in the following figures. 
       FIG. 2  illustrates a portion of a connector system according to an embodiment of the present invention. This figure includes a connector insert  110  having signal contacts  112  and  114 , shield  118 , and center ground plane  119 . This figure also includes a connector receptacle  120  including a tongue  122  having a center ground plane  129 , shield  128 , and contacts  124 . Contacts  124  may engage contacts  112  and  114  at locations  113  when connector insert  110  is inserted into connector receptacle  120 . Ground contacts, such as ground contacts  230 , may electrically connect to contacts  240  on receptacle tongue  122 . Ground contacts  240  may connect to shield  128  in the receptacle, which may electrically connect to shield  118  on the insert. Shield  118  may connect to ground contact  230 , thereby forming a ground shield around tongue  122  and contacts  114 . 
     Since contacts  112  and  114  are between shield  118  (and shield  128 ) and center ground planes  119  and  129 , contacts  112  and  114  may capacitively couple to shield  118  and center ground planes  119  and  129 . This capacitance may increase with decreasing distance. This increase in capacitance may reduce the impedance at signal contacts  112  and  114 , thereby reducing signal integrity. This reduction in capacitance may complicate the overall goal of matching the impedance near a target value at signal contacts  112  and  114 . 
     Accordingly, embodiments of the present invention may reduce a thickness of one or more of signal contacts  112  and  114 , shield  118 , shield  128 , and center ground planes  119  and  129 . These decreasing thicknesses may increase a distance or spacing between these structures, thereby increasing impedance. In other embodiments of the present invention, signal contacts  112  and  114  may be contoured to increase distances, such as distances  202  and  204  to center ground planes  119  and  129 , and distances  208  and  209  to shields  118  and their associated ground contacts. For example, where shield  128  and center ground plane  119  may be curved, contacts  112  and  114  may be curved as well in order to maximize these distances. In a special case as illustrated, center ground plane  119 , center ground plane  129  in the tongue of connector receptacle  120 , and shields  118  and  128  have substantially straight or flat surfaces. Accordingly, signal contact  112  and  114  may be arranged to be substantially flat in a deflected state when in the connector insert is inserted into the connector receptacle. 
     Signal contacts  112  and  114  may be designed using a method according to an embodiment of the present invention, where the design process begins with signal contacts  112  and  114  in this nearly flat or straight deflected state. That is, signal contacts may be designed to follow the contours of the center ground planes  119  and  129  and shields  118  and  128  in the state where connector insert  110  is inserted into connector receptacle  120 . A desired normal force at location  113  may be factored in as well. From this, a shape of signal contacts  112  and  114  in a non-deflected or extracted state may be determined. Signal contacts  112  and  114  may be manufactured in this state and used an embodiment of the present invention. This stands in contrast to conventional design techniques that begin by designing a signal contact in a non-deflected or non-inserted state. 
     Unfortunately, it may be problematic to form signal contacts  112  and  114  such that they are completely flat in a deflected state. For example, at least a slight amount of curvature at location  113  may be desirable such that contact is made between signal contact  112  in the connector insert and signal contact  124  in the connector receptacle. Specifically, without such curvature, a portion of connector insert signal contact  112  may rest on a front of the tongue  122 . This may cause contact  112  to lift at location  113  and disconnect from connector receptacle contact  124 . Also, to avoid tongue  122  from engaging an edge of signal contact  112  during insertion, a raised portion  115  having a sloped leading edge and a tip  116  may be included at an end of signal contact  112 . This raised portion  115  may cause a localized drop or dip in the impedance of signal contact  112 . To reduce this dip or reduction in impedance, raised portion  115  may have a substantially flat surface at tip  116  in an attempt to increase the distance between tip  116  and shield  118 . That is, tip  116  may have a top surface that is substantially parallel to shield  118 . 
       FIG. 3  illustrates signal contacts in a deflected or inserted state according to an embodiment of the present invention. As shown, contacts  112  may be substantially flat. Deviations from this at location  113  may be present, as described above. From this arrangement, as well as the desired force to be applied at location  113 , the shape of signal contacts  112  in a non-deflected state may be determined. An example is shown in the following figure. 
       FIG. 4  illustrates signal contact in a non-deflected or extracted state according to an embodiment of the present invention. As shown, contacts  112  and  114  may bend towards each other in the non-inserted state. Signal contacts  112  and  114  may be manufactured in the non-deflected state and used an embodiment of the present invention. Again, when the connector insert including contact  112  is inserted in a corresponding connector receptacle, contact  112  may defect to a substantially flat or straight position. 
     Various embodiments of the present invention may include a tip, formed of plastic or other material, on a front leading edge of a connector insert. In these embodiments of the present invention, it may be desirable to ensure that there are no gaps or spaces visible between the plastic tip and shield of a connector insert. Accordingly, embodiments of the present invention may provide features to reduce or limit these gaps. Examples are shown in the following figures. 
       FIG. 5  illustrates a front end of a connector insert according to an embodiment of the present invention. In this example, plastic tip  520  may be located on a front of the connector insert next to shield  510 . That is, shield  510  may meet the plastic tip  520  at a rear of the plastic tip  520  away from a front of the connector insert. While plastic tip  520  may be made of plastic, it may instead be formed of other non-conductive material. A plastic tip  520  may be used to avoid marring of the connector insert and corresponding connector receptacle and to preserve their appearance over time. Plastic tip  520  may also be durable as compared to metallic or other types of front ends. Plastic tip  520  may be a front end of a molded portion or housing  524  in the connector insert. 
     A gap  530  between plastic tip  520  and shield  510  may exist. This arrangement may allow light from opening  550  to pass through opening  522 , which may be present for ground contacts  560  to electrically connect to shield  510 , through gap  530  where it may be visible to a user. Accordingly, plastic tip  520  may include a ledge  540  to block light that may otherwise pass through gap  530 . Specifically, ledge  540  may be present between edges  544  and  542 . Ledge  540  may effectively cover an end of gap  530 , thereby preventing light leakage. Put another way, opening  522  may be formed such that it has a leading edge  542  that is behind gap  530  in the direction away from the front opening of the connector insert. 
     In other embodiments of the present invention, a force may be applied to the remote end of shield  510  to reduce the gap  530  between shield  510  and plastic tip  520 . An example is shown in the following figure. 
       FIG. 6  illustrates a portion of a connector insert according to an embodiment of the present invention. In this example, shield  510  may be adjacent to or in close proximity to plastic tip  520 . This close proximity may be caused by a force being applied to shield  510 . Specifically, during assembly, arms  620  may be compressed or folded in closer to each other such that shield  510  may be slid over plastic housing  610 . When shield  510  reaches plastic tip  520 , arms  620  may be released, whereupon they may push out and against an end of shield  510 . That is, arms  620  may be biased outward such that when they are released, they push out and against a rear portion of shield  510 . Specifically, a surface  630  of arms  620  may be ramped or sloped such that a force is applied to shield  510  moving it adjacent to or in close proximity to plastic tip  520 . A molded piece  650  may be inserted through a back end of shield  510  in order to force arms  620  outward, thereby holding shield  510  in place against plastic tip  520 . 
     In this example, tape piece  670  may be included. Tape piece  670  may help to prevent signal contacts in the connector insert from contacting shield  510 . Tape piece  670  may be sloped as shown so that it is not caught on the leading edge of shield  510  as shield  510  slides over plastic housing  610  during assembly. 
     Once this connector insertion portion is complete, a housing and cable may be attached to a rear portion of the assembly. This may be done in a way that avoids or reduces various problems in the manufacturing process An example is shown in the following figure. 
       FIG. 7  illustrates a portion of a connector insert according to an embodiment of the present invention. In this example, cable  780  may pass through cap  770 . Cap  770  may be covered or partially covered by strain relief  760 . Conductors  740  in cable  780  may terminate on printed circuit board  730  at contacts  750 . Traces (not shown) on printed circuit board  730  may connect contacts  750  to contacts in the connector insert. The printed circuit board  730  of a connector insert may be housed in housing  720 . 
       FIG. 8  illustrates a cutaway view of a portion of a connector insert according to an embodiment of the present invention. Again, conductors  740  may terminate at contacts  750  on printed circuit board  730 . Braiding  810  of cable  780  may be folded back onto itself and crimped by cap  770 . An example of how this crimping maybe done is shown in the following figure. 
       FIG. 9  illustrates a structure for crimping a cap around an end of a cable according to an embodiment of the present invention. In this example, four tool die pieces  900  may be used. These die pieces may be pushed inwards until gap  910  is reduced to a small or zero distance between each tool die piece  900 . This may crimp cap  770  around the braiding  6410  of cable  780 . The tool die piece  900  may include various points or peaks, such as  920  and  930 . These points may effectively wrinkle or jog the perimeter of the cap, thereby reducing the dimensions of a cross-section of cable  780 . This may improve the flow of plastic while forming strain relief  760  around cable  780 . 
     Embodiments of the present invention may provide connector inserts having improved ground contacts and retention spring features. An example is shown in the following figure. 
       FIG. 10  illustrates an exploded view of a connector insert according to an embodiment of the present invention. This connector insert may include a shield  1010  around housing  1020 . A number of contacts  1030  may be placed in housing  1020 . Specifically, contacts  1030  may be located in slots  1028  and top and bottom sides of housing  1020 . Secondary housing  1032  may secure contacts  1030  together as a unit. Side retention springs  1050  may be located in side openings  1022  in housing  1020 . Ground contacts  1040  may be located at a front of the connector insert between an opening of a connector insert and contacts  1030 . Ground contacts  1040  may be located in grooves  1024  in housing  1020 . Insulating layers  1060  may be used to prevent contacts  1030  from contacting shield  1010 . Insulating layers  1060  may be pieces of Kapton tape or other insulating material. Shield  1010  may include tabs  1012  which may engage notch  1026  when housing  1020  is inserted into shield  1010  during manufacturing. 
       FIG. 11  illustrates a retention spring that may be used in a connector insert according to an embodiment of the present invention. Retention springs  1050  may include a contacting portion  1110 . Contacting portion  1110  may engage a notch in a tongue in a connector receptacle when a connector insert is inserted into the connector receptacle. Retention spring  1050  may further include dimple  1120 , though in other embodiments of the present invention, dimple  1120  may be absent. Dimple  1120 , if present, or the surface of retention spring  1050  if not, may engage in inside of shield  1010  when the connector insert is inserted into a connector receptacle. In other embodiments of the present invention, dimple  1120 , if present, or the surface of retention spring  1050  if not, may contact and inside of shield  1010  before the connector insert is inserted into a connector receptacle. Retention spring  1050  may further include prongs  1130 . Prongs  1130  may secure retention spring  1050  to a housing of the connector insert. 
     Retention spring  1050  may have an overall first length  1150 . Retention spring  1050  may also include a deflection arm  1160 . The deflection arm  1160  may extend from dimple  1120 , if present, to contacting portion  1110 . In other embodiments of the present invention, the deflection arm  1160  may extend from a location where the retention spring  1050  contacts the shield  1010  to the contacting portion  1110 . The deflection arm  1160  may consume a majority of the length of retention spring  1050 . That is, the length of the deflection arm  1160  may be more than one half of the length  1150  of the total retention spring. In this way, stresses may be spread out over the retention spring  1050  during insertion. This may help to avoid a concentration of stress that could otherwise cause a cold working failure or cracking in the retention spring  1050 . Specifically, a surface or dimple  1120  (if present) of retention spring  1050  may contact a surface, such as an inside of shield  1010 , when the connector insert starts to be inserted into a connector receptacle. Force or stress may concentrate at this point, but the retention spring may be made thicker or wider in or more directions near dimple  1120  (if present) to support the stress. As the insert continues to be inserted, the deflection arm may deflect, absorbing further stresses over a long portion of the retention spring  1050 . Particularly where no dimple  1120  is present, the contact area between retention spring  1050  and shield  1010  or other surface may “rock” or move along the length of the retention spring  1050  (towards the contacting portion  1110 ), again helping to distribute the points of high stress compensation. This configuration may provide a retention spring that is hard enough to provide a good retention force but not fail due to cold working. These retention springs may be formed in various ways. For example, the may be forged, stamped, metal-injection-molded, or formed in other ways. Further details on these retention springs may be found in co-pending U.S. patent application Ser. No. 14/543,748, filed Nov. 17, 2014, which is incorporated by reference. 
       FIG. 12  illustrates a top cut-away view of a connector insert according to an embodiment of the present invention. This connector insert may include a number of contacts  1030 . Ground contacts  1040  may be located between contacts  1030  and a front opening and housing  1020 . Retention springs  1050  may be located along outside edges of the connector insert. Retention springs  1050  may include contacting portions  1110 . Contacting portion  1110  may engage and fit in a notch on sides of a tongue of a connector receptacle when the connector insert is inserted into the connector receptacle. Retention springs  1050  may further include dimple  1120 , though dimple  1120  may be absent in various embodiments of the present invention. Dimple  1120 , if present, may engage an inside of shield  1010  when the connector insert is inserted into a connector receptacle, or before and while the connector insert is inserted into a connector receptacle. If dimple  1120  is not present, the retention spring surface itself may engage an inside of shield  1010  when the connector insert is inserted into a connector receptacle, or before and while the connector insert is inserted into a connector receptacle. Retention springs  1050  may include prongs  1130  for securing retention springs  1050  to the insert housing. An outside housing  1210  may surround a rear portion of the connector insert. Housing  1210  may be grasped by a user during the insertion and extraction of the connector insert into and out of a connector receptacle. 
       FIG. 13  illustrates a front view of a connector insert according to an embodiment of the present invention. Again, the connector insert may have a shield  1010  around housing  1020 . Retention springs  1050  may be located in openings and sides of housing  1020 . Ground contacts  1040  may be located near a front opening of the connector insert. A housing  1210  may surround a rear portion of a connector insert. 
     The connector insert may include a front lip defining a front opening. This lip may have an inside portion formed of housing  1020  and an outside portion formed of shield  1010 . By providing an inside portion of the lip formed of a non-conductive material, shield  1010  is less likely to engage and short to contacts on a tongue of a connector receptacle while the connector insert is being inserted into the connector receptacle. To further protect against shorting receptacle contacts, the housing  1020  may be arranged to be either aligned with or extending beyond the shield  1010 . Having at least a portion of the lip formed of shield  1010  may help to improve the strength of the leading edge of the connector. 
     As shown in  FIG. 2  above, the connector insert may include front ground contacts for engaging ground contacts on a connector receptacle tongue when the connector insert is inserted into the connector receptacle. It may be desirable that these ground contacts do not increase an overall length of an insert portion of a connector insert dramatically. An example of such a ground contact is shown in the following figure. The operation of such a ground contact was shown above in reference to ground contact  230  in  FIG. 2 . Other examples and further information regarding the operation of these ground contacts may be found in co-pending U.S. patent application Ser. No. 14/543,717, filed Nov. 17, 2014, which is incorporated by reference. 
       FIG. 14  illustrates a connector insert portion and a ground contact according to an embodiment of the present invention. This connector insert may include a housing  1020  supporting retention springs  1050  and ground contacts  1040 . Ground contacts  440  may be located in groove  1024  near a front of housing  1020 . Ground contacts  1040  may reduce an overall length of an insert portion of a connector insert by wrapping laterally around approximately half the circumference of housing  1020 . By wrapping laterally in this way, the increase in the overall length of the insert portion caused by the inclusion of the ground contacts  1040  is limited. 
     Ground contacts  1040  may include contacting portions  1440 , which may be joined by crosspiece  1430 . Crosspiece  1430  may be held in place by supporting structures  1410 . Supporting structures  1410  may include tabs  1420  for holding ground contacts  1040  securely in place in groove  1024  in housing  1020 . Ground contacts  1040  may also connect to an inside of shield  1010 . 
     Again, a tape or other insulating layer  1060  may be placed between contacts  1030  and shield  1010  to prevent contacts  1030  from contacting shield  1010 . Insulating or tape layer  1060  may be attached to housing  1020 . When housing  1020  is inserted into shield  1010 , care should be taken to avoid having shield  1010  strip away insulating or tape layer  1060 . Accordingly, embodiments of the present invention may arrange housing  1020  to protect the tape or insulating layer  1060  during insertion of housing  1020  into shield  1010 . An example is shown in the following figure. 
       FIG. 15  illustrates steps in the manufacturing of a connector insert according to an embodiment of the present invention. In this figure, housing  1020  is shown being inserted into shield  1010 . Insulating or tape layer  1060  may be located on top and bottom surfaces of housing  1020 . Housing  1020  may include notch portion  1510 . Notch portion  1510  may provide a space for tape layer  1060  to be placed such that it is not peeled away by shield  1010  when housing  1020  is inserted into shield  1010 . 
     Again, the connector insert may include a front lip having outside portion formed by shield  1010  and an inside portion formed by housing  1020 . Accordingly, shield  1010  may include a surface  1018  to engage surface  1029  of housing  1080 . This connector insert may also include ground contact  1040 . 
     In various embodiments of the present invention, signal contacts  1030  may be pre-biased in a way that results in a force being exerted at the opening of a connector insert. This force may be in a direction that tends to close the connector insert opening. This may result in a connector receptacle tongue being damaged during the insertion of the connector insert into a connector receptacle. Accordingly, embodiments of the present invention may provide manufacturing steps to avoid or mitigate this problem. An example is shown in the following figures. 
       FIG. 16  illustrates forces being exerted at a connector insert opening according to an embodiment of the present invention. Contacts  1030  may be located in housing  1020 . Contacts  1030  may be pre-biased to exert a force on contacts on a tongue of a connector receptacle when the connector insert is inserted into the connector receptacle. This pre-bias may cause contacts  1030  to exert a force on housing  1020 . This force may act to close a front opening of the connector insert. Accordingly, embodiments of the present invention may provide an end cap that may be inserted into the front opening of a connector insert during manufacturing. An example is shown in the following figure. 
       FIGS. 17A-17B  illustrate an end cap being inserted into an opening of a connector insert according to an embodiment of the present invention. End cap  1720  may have a handle portion  1722  that may be grasped by an operator during assembly. The operation of end cap  1720  is shown in the following figure. 
       FIG. 18  illustrates the operation of an end cap that may be employed during manufacturing of a connector insert according to an embodiment of the present invention. State A illustrates an opening  1712  of a connector insert. Opening  1712  may have top and bottom sides biased outwardly to create compensate for forces that will be applied by contacts  1030  as shown above. Similarly, end cap  1720  may have top and bottom sides that are bowed or biased outwardly as well, as shown in stage B. End cap  1720  may be inserted into opening  1712  in stage C. At this time, the connector insert may be subjected to a high-temperature process, such as a reflow process. Ordinarily, this heating could cause the opening to droop and close. Instead, the outward shape may provide an arch of support to maintain the shape of the opening and keep it from closing. At stage D, end cap  1720  may be removed. After some time, stage E may be reached. At this stage, the top and bottom sides of opening  1712  may remain either straight or partially outwardly bowed. 
       FIG. 19  illustrates another connector insert according to an embodiment of the present invention. Connector insert  1900  may include two contact assemblies  1910 . Contact assemblies  1910  may each include a number of contacts  1920  supported by housing  1930 . Contacts  1920  may include contacting portions  1922 . Contacting portions  1922  may form electrical connections with contacts on a tongue of a corresponding connector receptacle when connector insert  1900  is mated with the corresponding connector receptacle. Contacts  1920  may further include tail portions  1924 . Tail portions  1924  may be soldered or otherwise connected to a board or conductors (not shown) in connector insert  1900 . Housing  1930  may include interlocking features including tabs  1932  and opening or holes  1934 . Specifically, tab  1932  on lower contact assembly  1910  may fit into an opening or hole  1934  in housing  1930  of an upper contact assembly  1910 . Similarly, tab  1932  on an upper contact assembly  1910  may fit into an opening or hole  1934  in housing  1930  of a lower contact assembly  1910 . Tabs  1932  may include crush ribs to securely engage opening or hole  1934 . 
     Connector insert  1900  may further include a central ground plane  1940 . Central ground plane  1940  may be plated with nickel to reduce stray and induced currents in central ground plane  1940 . Central ground plane  1940  may include openings  1942  to allow passage of tabs  1932 . Central ground plane  1940  may also include articulating arms  1944 . Articulating arms  1944  may be soldered or laser welded at points  1946  to retention springs  1950 . Retention springs  1950  may include contacting portions  1952 . Contacting portions  1952  may engage notches on sides of a tongue of a corresponding connector receptacle. Retention springs  1950  may further include dimples  1954 . Dimples  1954  may engage an inside surface of shield  1990 . Retention springs  1950  may further include clasp  1956 . Clasp  1956  may hold a printed circuit board or other appropriate substrate (not shown) located in connector insert  1900 . 
     Once assembled, the contact assemblies  1910 , central ground plane  1940 , and retention springs  1950  may be inserted into housing  1960 . Housing  1960  may include side slots  1962  for retention springs  1950 . Side slots  1962  may include openings  1964  for contacting portions  1952  of retention springs  1950 . An isolation layer  1970  may electrically isolate contacts  1920  from an inside surface of shield  1990 . A front portion of housing  1960  may include a central passage  1961  defining a front opening. Front portion of housing  1960  may further include a channel or guide  1966 . Channel or guide  1966  may include openings  1968 . Channel or guide  1966  may further include a right-angle portion  1967 . 
     Connector insert  1900  may further include electromagnetic or EMI springs  1980 . (The term EMI springs may also refer more generally to ground contacts, as in the examples above.) EMI springs  1980  may include crossbars  1981  arranged in a consecutive fashion. These consecutive crossbars  1981  may be formed separately and joined or they may be formed as a single piece. For example, four crossbars  1981  may be used to form EMI springs  1980 , though other numbers of crossbars may be used in other embodiments of the present invention. Ground contacts  1982  may be located at junctions of crossbars  1981  and may be accessible through openings  1968 . EMI springs  1980  may further include shield contacts  1984 , which may contact an inside of shield  1990 . Shield contacts  1984  may push on EMI springs  1980  thereby helping to keep EMI springs  1980  in place. EMI springs  1980  may include feet  1986 , which may fit in right-angle portions  1967  of channel or guide  1966 . 
     The housing assembly including housing  1960 , contact assemblies  1910 , central ground plane  1940 , and retention springs  1950 , may be inserted into shell or shield  1990 . Shield  1990  may be arranged to fit in a corresponding connector receptacle (not shown.) Shield  1990  may include a front opening  1992  to accept a tongue of a corresponding connector receptacle. Further details of this assembly process are shown below. 
       FIG. 20  illustrates a contact assembly for a connector insert according to an embodiment of the present invention. Housing  1930  may be inserted molded around portions of contacts  1920  to form contact assembly  1910 . Contacts  1920  may include contacting portions  1922 . Contacting portions  1922  may form electrical connections with corresponding contacts on a tongue of a connector receptacle (not shown.) Contacts  1920  may further include tail portions  1924 . Tail portions  1924  may be soldered or otherwise connected or attached to a board or other appropriate substrate (not shown) in connector insert  1900 . Housing  1930  may include tab  1932  and opening or hole  1934 . Tab  1932  may pass through an opening  1942  and central ground plane  1940  and into a corresponding opening or hole  1934  on a second contact assembly  1910  (as shown in  FIG. 19 .) Tab  1932  on that connector assembly may pass through a second opening  1942  in central ground plane  1940  and into opening or hole  1934 . 
     As shown in  FIG. 19 , these and other embodiments of the present invention may provide retention springs  1950  for connector insert  1900 , where retention springs  1950  are preloaded. Specifically, retention springs  1950  may be attached to articulating arms  1944  extending from central ground plane  1940 . After attachment, retention springs  1950  may have a greater spacing between contacting portions  1952  than necessary. As retention springs  1950  are inserted into shield  1990  of connector insert  1900 , a compressive force may be applied to sides of retention springs  1950  such that articulating arms  1944  are angled towards the central ground plane  1940  and contacting portions  1952  are driven closer together. This compression may also provide a preloading on retention springs  1950 . When a connector receptacle tongue is inserted into connector insert  1900 , a user may have to overcome the preloading of retention springs  1950  before the tongue may continue to be inserted. This preloading may provide connector insert  1900  with a more consistent insertion profile, more stable normal forces, and a greater durability. It may simplify manufacturing of retention springs  1950 , allowing the use of softer materials that may be stamped instead of being forged. These retention springs  1950  may have a more uniform thickness along their length, since the insertion profile of connector insert  1900  is not being primarily determined by the shape of the retention springs. Retention springs  1950  may be laser welded to articulating arms  1944  at several locations. This may provide an attachment between retention springs  1950  and central ground plane  1940  that may withstand the application of force during assembly as well as the preloading force. The attached retention springs  1950  and central ground plane  1940  may form a unit that is easily mated to connector insert housing  1960  to simplify assembly. Examples of these retention springs  1950  are shown in the following figures. 
       FIG. 21  illustrates a central ground plane and retention springs for a connector insert according to an embodiment of the present invention. Central ground plane  1940  may include openings  1942  to allow passage of tabs  1932 . Central ground plane  1940  may further include articulating arms  1944 . Articulating arms  1944  may be soldered or laser welded to retention springs  1950  at locations or points  1946 . Retention springs  1950  may include dimples  1954 . Dimples  1954  may provide a contacting point with an inside of shield  1990 , as shown in  FIG. 19 . Retention springs  1950  may further include contacting portions  1952 . Contacting portions  1952  may fit in openings  1964  of housing  1960  as shown in  FIG. 19 . Contacting portions  1952  may engage notches on a side of a connector receptacle tongue (not shown) when mated with connector insert  1900 . 
       FIG. 22  illustrates a portion of the assembly of a connector insert according to an embodiment of the present invention. In this example, retention springs  1950  may be attached to articulating arms  1944  of central ground plane  1940 . Again, retention springs  1950  may be splayed such that their contacting portions  1952  are spaced apart. This may allow space between retention springs  1950  to allow contact assemblies  1910  and central ground plane  1940  to be assembled together. Specifically, tabs  1932  may pass through openings  1942  in central ground plane  1940  to fit in opposing openings or holes  1934  in housing  1930  of contact assembly  1910 . Contact assemblies  1910  may include contacts  1920  partially housed by insert molded housings  1930 . Tabs  1932  may include crush ribs to secure housings  1930  to each other. 
       FIG. 23  illustrates a preloading of retention springs according to an embodiment of the present invention. After retention springs  1950  have been attached to articulating arms  1944  of central ground plane  1940 , contacting portions  1952  of retention springs  1950  may be separated by a distance A. This assembly may then be inserted into shield  1990 , as shown in  FIG. 19 . Dimples  1954  may engage an inside surface of shield  1990  and retention springs  1950  may be pushed, for example with a tool (not shown), into the shield  1990  such that that dimples  1954  may be pushed inwards towards each other. This may push articulating arms  1944  downward as shown toward the bulk portion of central ground plane  1940 . This compressive force may reduce a distance between contacting portions  1952  to a distance B, were B is less than A. This compressive force may provide a preload on retention springs  1950 . Specifically, as a tongue is inserted into connector insert  1900 , the preload force provided by the compression at dimples  1954  may need to be overcome by a user before contacting portions  1952  can separate to allow further insertion of the tongue. 
     This preload force may improve the consistency of the insertion profile of connector insert  1900 . This may simplify the design and manufacturing of retention springs  1950 , since the preload force and not the shape of retention springs  1950  is primarily responsible for determining the insertion profile. This may also lead to improved durability of connector insert  1900 . 
       FIG. 24  illustrates views of retention springs according to an embodiment of the present invention. Retention springs  1950  may include contacting portions  1952  and dimples  1954 . Retention springs  1950  may fit in side slots  1962  in housing  1960 . Retention spring  1950  may be laser or spot welded to central ground plane  1940  at points  1946 . 
       FIGS. 25-26  illustrate further views of retention springs according to an embodiment of the present invention. Retention springs  1950  may include contacting portions  1952 , dimples  1954 , openings  1953 , and clasp  1956 . Clasp  1956  may securely hold, and may be soldered to, a board or other substrate (not shown) in connector insert  1900 . Dimple  1954  may engage an inside surface of shield  1990 , as shown in  FIG. 19 . Opening  1953  may provide a passage for ends of articulating arms  1944  of central ground plane  1940 , as shown in  FIG. 23 . Contacting portions  1952  may engage notches on a side of a tongue of a corresponding connector receptacle (not shown.) 
     These and other embodiments of the present invention may provide ground contacts  1982  near a front opening of connector insert  1900 . These ground contacts  1982  may be included on electromagnetic interference (EMI) springs  1980 . These EMI springs  1980  may include four or other numbers of continuous crossbars  1981 . These consecutive crossbars  1981  may be formed separately and joined or they may be formed as a single piece. Ground contacts  1982  may be located at junctions of crossbars  1981 . Attaching ground contacts  1982  to crossbars  1981  themselves may reduce an amount of housing that may need to be removed to make space for the EMI springs. This may allow the housing to have a greater thickness, which may result in a reduced amount of warpage at a front opening of connector insert  1900 . The ground contacts may be exposed at openings  1968  in housing  1960  for connector insert  1900 . Crossbars  1981  may be located in channel or guide  1966  in housing  1960 , where channel or guide  1966  extends laterally across and near the front of connector insert housing  1960 . These EMI springs  1980  may extend nearly 180 degrees around the opening of the connector insert. The outside crossbars may include feet  1986  that snap or otherwise fit in a right-angle portion  1967  of channel or guide  1966 , where the right-angle portion  1967  extends in a direction orthogonal to the remainder of the channel or guide  1966  and away from the front of connector insert  1900 . Ground contacts  1982  may extend from the crossbars into a central passage  1961  of the connector insert  1900  and may be folded back into central passage  1961 . Ground contacts  1982  may also include lateral extensions  1983  that extend roughly parallel to central passage  1961 . During insertion of a tongue into connector insert  1900 , these lateral extensions  1983  may prevent ground contacts  1982  from being pushed back into connector insert  1900  between shield  1990  and housing  1960 . Shield contacts  1984  may be located between ground contacts  1982 , and may extend from the two center crossbars  1981  away from the central passage  1961  of the connector insert  1900  where they may contact an inside surface of shield  1990  of connector insert  1900 . These shield contacts  1984  may also push against the shield  1990  thereby helping to hold EMI springs  1980  in place. The crossbars  1981  may have a torsion force applied during their assembly into housing  1960 . This, along with the flexibility of the crossbars  1981  and ground contacts  1982 , may help to evenly distribute forces when the ground contacts engage a connector receptacle tongue. By more evenly distributing these forces, the amount of permanent deformation of EMI springs  1980  may be reduced. Also, the force applied to a connector receptacle tongue by ground contacts  1982  may be reduced, thereby reducing wear on the tongue. This force may further be refined by tapering one or more of crossbars  1981  in one or more directions along their length. 
       FIG. 27  illustrates a portion of an assembly of a connector insert according to an embodiment of the present invention. In this example, contacts  1920  and retention springs  1950  have been inserted into housing  1960 . EMI springs  1980  may be inserted into channel or guide  1966  in housing  1960 . That completed subassembly may then be inserted into shield  1990 . 
       FIG. 28  illustrates a housing for a connector insert according to an embodiment of the present invention. Housing  1960  may include side slots  1962  for retention springs  1950 , as shown in  FIG. 19 . Side slots  1962  may include openings  1964  for contacting portions  1952  of retention springs  1950 , as shown in  FIG. 19 . Housing  1960  may include slots  1969  for contacts  1920 , as shown in  FIG. 19 . A front of housing  1960  may support channel or guide  1966 . Openings  1968  from channel or guide  1966  may extend into central passage  1961 . Opening  1968  may provide a passage for ground contacts  1982 , as shown below in  FIG. 30 . Channel or guide  1966  may include a right-angle portion  1967 . Feet  1986  of EMI springs  1980  may be inserted into right-angle portions  1967 , as shown in  FIG. 19 . 
     In the example of  FIG. 19 , during the insertion of a connector receptacle tongue into connector insert  1900 , ground contacts  1982  may be pushed by the tongue towards a rear of connector insert  1900 . Without more, ground contacts  1982  may become wedged between housing  1960  and shield  1990 . Accordingly, embodiments of the present invention may include a lateral portion of ground contact  1982 , where the lateral portion may be blocked form rearward movement by an interior surface of housing  1960 . An example is shown in the following figure. 
       FIG. 29  illustrates a side view of a portion of a connector insert according to an embodiment of the present invention. In this example, a leading edge of shield  1990  may be around housing  1960 . An opening  1968  in housing  1960  may allow access to ground contact  1982 . Ground contact  1982  may further include a lateral extension  1983 . As ground contact  1982  encounters a tongue of a corresponding connector receptacle, ground contact  1982  may be forced upward and rotated into a position shown as  2982 . Ground contact  1982  may further include a lateral extension  1983 . Lateral extension  1983  may encounter a wall or surface  1963  of housing  1960 . Lateral extension  1983  may be prevented from traveling in a rearward direction by wall or surface  1963 . Accordingly, lateral extension  1983  may similarly rotate to a position shown here as  2983 . This may help to prevent ground contact  1982  or other portions of EMI springs  1980  from being pushed between housing  1960  and shield  1990 . 
       FIG. 30  illustrates a portion of a connector insert according to an embodiment of the present invention. In this example, EMI spring  1980  may be located in channel or guide  1966 . EMI spring  1980  may include a one or more crossbars  1981 . In this example, four crossbars  1981  may be arranged in a consecutive fashion. Ground contacts  1982  may be located at junctions of crossbars  1981 . Ground contacts  1982  may further include lateral extensions  1983 . The center crossbars  1981  may include shield contacts  1984 , while the outer crossbars  1981  may include feet  1986 . 
     Again, EMI springs  1980  may be located in channel or guide  1966 . Ground contacts  1982  may be located in openings  1968  in housing  1960 . Feet  1986  may be located in right-angle portions  1967  of channel or guide  1966 . Shield contacts  1984  may contact an inside surface of shield  1990 , as shown in  FIG. 19 . Shield contacts  1984  may push against shield  1990 , thereby helping maintain EMI springs  1980  in place. In this example, EMI springs  1980  may wrap around approximately one half of the circumference of housing  1960 . 
       FIGS. 31-32  illustrate EMI springs according to an embodiment of the present invention. EMI springs  1980  may include ground contacts  1982  at junctions of crossbars  1981 . These consecutive crossbars  1981  may be formed separately and joined or they may be formed as a single piece. EMI springs  1980  may include four crossbars  1981  arranged in a consecutive fashion, though other numbers of crossbars, such as two, three, five or other numbers may be used, and they may be formed separately and joined or they may be formed as a single piece. Center crossbars  1981  may include shield contacts  1984 . Outer crossbars  1981  may include feet  1986 . 
     A torsion or twisting force may be applied to EMI springs  1980 . This torsion force, along with the distribution of ground contacts  1982  along crossbars  1981 , may distribute forces applied to EMI springs  1980  during insertion of a connector receptacle tongue (not shown) into connector insert  1900 . Specifically, the torsion force may be applied in a direction to push ground contacts  1982  further into openings  1968  in housing  1960 . This may lead to a reduced force from ground contacts  1982  applied to the tongue during insertion, thereby reducing wear on the connector receptacle. Outer crossbars  1981  may include tapered portions  1989 . These tapered portions may further help to distribute force along the length of EMI springs  1980 . 
     In various embodiments of the present invention, contacts and other conductive portions of connector inserts and receptacles may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, forging, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), or other nonconductive material or combination of materials. The printed circuit boards used may be formed of FR-4, BT or other material. Printed circuit boards may be replaced by other substrates, such as flexible circuit boards, in many embodiments of the present invention. 
     Embodiments of the present invention may provide connector inserts and receptacles that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector inserts and receptacles may provide pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB-C, High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt, Lightning, Joint Test Action Group (JTAG), test-access-port (TAP), 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 may provide connector inserts and receptacles that may 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 inserts and receptacles may 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: 20180416
Publication Date: 20190917
Grant Date: 20190917
Priority Date: 20140526
Inventors: TZIVISKOS, GEORGE
HACK, PAUL J.
Yuen, Samuel W.
NG, Nathan N.
GAO, ZHENG
AMINI, MAHMOUD R.
KIM, MIN CHUL
ABRAHAM, COLIN J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R43/0221", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6582", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6275", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6585", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4921", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6597", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/0221", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/70", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6585", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4921", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/64", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6582", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6585", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/64", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6582", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6597", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/0221", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6275", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/70", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/4921", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/64", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 63104843