PATENT DOCUMENT

Publication Number: US-9350125-B2
Application Number: US-201414183254-A
Country: US
Kind Code: B2

Title: Reversible USB connector with compliant member to spread stress and increase contact normal force

Abstract:
Embodiments can provide reversible or dual orientation USB plug connectors for mating with standard USB receptacle connectors, e.g., a standard Type A USB receptacle connector. Accordingly, the present invention may be compatible with any current or future electronic device that includes a standard USB receptacle connector. USB plug connectors according to the present invention can have a 180 degree symmetrical, double orientation design, which enables the plug connector to be inserted into a corresponding receptacle connector in either of two intuitive orientations. Thus, embodiments of the present invention may reduce the potential for USB connector damage and user frustration during the incorrect insertion of a USB plug connector into a corresponding USB receptacle connector of an electronic device. Reversible USB plug connectors according to the present invention may include a compliant member or structural support for distributing stress and increasing contact normal force at the tongue of the reversible USB plug connector.

Claims:
What is claimed is: 
     
       1. A reversible plug connector comprising:
 a body; 
 a dielectric base; 
 a shell extending from the body and having an opening at a first end that communicates with a cavity defined by inner surfaces of the shell and the dielectric base; 
 a deflectable tongue disposed within the cavity and extending from the dielectric base towards the opening, the tongue having a tip proximal the opening and first and second opposing surfaces that extend from the tip towards the base, the tongue including a first plurality of contacts exposed at the first opposing surface of the tongue proximal the tip and a second plurality of contacts exposed at the second opposing surface of the tongue proximal the tip; and 
 a support structure that includes first and second support members disposed adjacent to the base and located on opposite sides of the tongue, the first support member having a first major surface that faces the first opposing surface of the tongue, the second support member having a second major surface that faces the second opposing surface of the tongue, the second support member defining a curved recess. 
 
     
     
       2. The plug connector set forth in  claim 1  wherein the curved recess defined by the second support member faces one of the inner surfaces of the shell. 
     
     
       3. The plug connector set forth in  claim 1  wherein the curved recess is defined by the second major surface. 
     
     
       4. The plug connector set forth in  claim 1  wherein the first and second support members are symmetric about a length direction of the tongue. 
     
     
       5. The plug connector set forth in  claim 1  wherein the first and second support members both define curved recesses. 
     
     
       6. The plug connector set forth in  claim 1 , wherein the first and second major surfaces are oriented in first and second planes, respectively, the first plane extending parallel to the second plane. 
     
     
       7. The plug connector set forth in  claim 1  wherein the tongue includes a plurality of contact frames. 
     
     
       8. A reversible plug connector comprising:
 a body; 
 a dielectric base; 
 a shell extending from the body and having an opening at a first end that communicates with a cavity defined by inner surfaces of the shell and the dielectric base; 
 a deflectable tongue disposed within the cavity and extending from the dielectric base towards the opening, the tongue having a tip proximal the opening and first and second opposing surfaces that extend from the tip towards the base, the tongue including a plurality of contacts exposed at the first and second surfaces of the tongue proximal the tip, the tongue including a first insulating material disposed between the plurality of contacts proximate the tip and a second insulating material substantially surrounding the first insulating material, the second insulating material formed of a different material than the first insulating material; and 
 a support structure that includes first and second support members disposed adjacent to the base and located on opposite sides of the tongue, the first support member having a first major surface that faces the first surface of the tongue, the second support member located having a second major surface that faces the second surface of the tongue. 
 
     
     
       9. The plug connector set forth in  claim 8  wherein the first and second support members form a tapered opening through which the tongue extends. 
     
     
       10. The plug connector set forth in  claim 8  wherein at least one of the first and second major surfaces includes a series of hills and valleys. 
     
     
       11. The plug connector set forth in  claim 8  wherein at least one of the first and second major surfaces defines a curved recess that distributes stress across a bending portion of the tongue when the tongue is deflected. 
     
     
       12. The plug connector set forth in  claim 8  wherein the first support member extends farther from the base than that of the second support member. 
     
     
       13. The plug connector set forth in  claim 8  wherein the tongue includes a printed circuit board proximate the tip of the tongue. 
     
     
       14. The plug connector set forth in  claim 8  wherein the first and second support members are assembled with the base. 
     
     
       15. A reversible Universal Serial Bus plug connector comprising:
 a body; 
 a dielectric base; 
 a support structure being disposed adjacent to the base; 
 a shell extending from the body and having an opening at a first end that communicates with a cavity defined by four inner surfaces of the shell and the support structure; 
 a deflectable tongue disposed within the cavity and extending from a surface of the slot towards the opening, the tongue having a tip proximal the opening and first and second opposing surfaces that extend from the tip towards the surface of the slot, the tongue including a printed circuit board integrally formed with the tongue that includes a first plurality of contacts exposed at the first surface of the tongue proximal the tip and a second plurality of contacts exposed at the second surface of the tongue proximal the tip, 
 wherein a first portion of the support structure faces the first surface of the tongue and a second portion of the support structure faces the second surface of the tongue, wherein the first and second portions of the support structure are configured to distribute stress across the tongue when the tongue is deflected. 
 
     
     
       16. The plug connector set forth in  claim 15  wherein a portion of the printed circuit board is positioned proximate the tip of the deflectable tongue. 
     
     
       17. The plug connector set forth in  claim 15  wherein the first and second portions are oriented in first and second planes, respectively, the first plane extending parallel to the second plane. 
     
     
       18. The plug connector set forth in  claim 15  wherein the support structure has a varying durometer. 
     
     
       19. The plug connector set forth in  claim 15  wherein a cable is coupled to the body and includes a plurality of insulated wires that are electrically coupled to the printed circuit board. 
     
     
       20. The plug connector set forth in  claim 15  wherein the plurality of contacts are made from a metal alloy.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of commonly owned U.S. Provisional Patent Application No. 61/765,602 filed Feb. 15, 2013. Additionally, commonly owned U.S. Provisional Patent Application No. 61/765,602 filed Feb. 15, 2013 and U.S. Provisional Patent Application No. 61/756,413, filed Jan. 24, 2013 are hereby incorporated by reference herein in their entirety for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to input/output electrical connectors. More particularly, the present embodiments relate to data connectors 
     BACKGROUND OF THE INVENTION 
     Many electronic devices include data connectors, such as Universal Serial Bus (USB) connectors, that receive and provide power and data. These electrical connectors are typically female receptacle connectors and are designed to receive a male plug connector. The plug connector may be on the end of a cable and plug into an electronic device, thereby forming one or more conductive paths for signals and power. 
     USB connectors, like many other standard data connectors, require that male plug connectors be mated with corresponding female receptacle connectors in a single, specific orientation in order for the USB connection to function properly. Such connectors can be referred to as polarized connectors. Accordingly, USB receptacle connectors include an insertion opening with features that prevents USB plug connectors from being inserted into the USB receptacle connector in the wrong way. That is, it can only be inserted one way because it is a polarized connector. Many other commonly used data connectors, including mini USB connectors, FireWire connectors, as well as many other proprietary connectors are also polarized connectors. 
     It is sometimes difficult for users to determine when a polarized plug connector, such as a USB plug connector, is oriented in the correct orientation for insertion into a corresponding receptacle connector. Some USB plug and/or receptacle connectors may include markings to indicate their orientation such that users know how to properly insert a plug connector into corresponding receptacle connectors. However, these marking are not always utilized by users and/or can be confusing to some users. In some cases, these markings are not helpful because the markings cannot be easily viewed due to the location of the receptacle connector, lighting conditions, or other reasons. Even when visible, these markings may still be unhelpful because not all manufacturers apply these markings in a consistent fashion. Consequently, users may incorrectly insert a plug connector into a corresponding receptacle connector, which may potentially result in damage to the connectors and/or user frustration. 
     Accordingly, it is desirable to provide connectors, e.g., USB connectors, that do not suffer from all or some of these deficiencies. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
         FIGS. 1A and 1B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 2A and 2B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to one embodiment of the present invention; 
         FIGS. 3A and 3B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to another embodiment of the present invention; 
         FIGS. 4A and 4B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to yet another embodiment of the present invention; 
         FIGS. 5A and 5B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 6A and 6B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 7A and 7B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 8A and 8B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 9A and 9B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 10A and 10B  are simplified perspective and cross sectional views, respectively, of a USB plug connector in various stages of manufacture according to still another embodiment of the present invention; 
         FIGS. 11A and 11B  are simplified perspective and cross sectional views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 12A and 12B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 13A and 13B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 14A and 14B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 15A and 15B  are partially transparent simplified perspective and partially transparent front views, respectively, of a USB plug connector according to one particular embodiment of the connector of  FIGS. 11A-11B ; 
         FIGS. 15C-15F  are top views of contact frames, in their positions with respect to each other when embedded in a tab; 
         FIGS. 16A and 16B  are partial cross sectional perspective and cross sectional side views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIGS. 16C and 16D  are partial cross sectional, exploded perspective views of embodiments of structural support for assembling with and overmolding on tongue of plug connector, respectively, according to manufacturing methods of the present invention; 
         FIGS. 17A and 17B  are partial cross sectional perspective and cross sectional side views, respectively, of a USB plug connector according to one embodiment of the present invention; 
         FIG. 17C  is an exploded view of contact frames of the plug connector of  FIGS. 17A and 17B ; 
         FIGS. 18A and 18B  are exploded and cross sectional side views, respectively, of a USB plug connector according to an embodiment of the present invention; and 
         FIGS. 18C-18H  illustrate contact frames of the connector of  FIGS. 18A and 18B  in various stages of assembly according to an embodiment of the present invention; 
         FIGS. 19A and 19A-1  are cross sectional side and partially exploded, partially cross sectional perspective views, respectively, of a USB plug connector with its support structure removed according to one embodiment of the present invention; 
         FIGS. 19B and 19B-1  are cross sectional side and partially exploded, partial cross sectional perspective views, respectively, of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to one embodiment of the present invention; 
         FIGS. 19C-19F  are cross sectional side views of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to embodiments of the present invention; 
         FIGS. 19G-19J  are cross sectional side views of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to embodiments of the present invention; 
         FIG. 19K  is a cross sectional side vies of the USB plug connector of  FIGS. 19A and 19A-1  with a one-piece support structure according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to certain embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known details have not been described in detail in order not to unnecessarily obscure the present invention. 
     Embodiments can provide reversible or dual orientation USB plug connectors for mating with standard USB receptacle connectors, e.g., a standard Type A USB receptacle connector. Accordingly, the present invention may be compatible with any current or future electronic device that includes a standard USB receptacle connector. USB plug connectors according to the present invention can have a 180 degree symmetrical, dual or double orientation design which enables the plug connector to be inserted into a corresponding receptacle connector in either of two intuitive orientations. To allow for the orientation agnostic feature of such a plug connector, the portion of the plug connector having contacts may not be polarized. Instead, in some embodiments, the portion of the plug connector having contacts may be movable such that its contacts can mate with corresponding contacts of the receptacle connector in either of two intuitive orientations. Thus, embodiments of the present invention may reduce the potential for USB connector damage and user frustration during the insertion of the USB plug connector into a corresponding USB receptacle connector of an electronic device. 
     Methods for manufacturing plug connectors according to the present invention are also described below in relation to a specific plug connector embodiment. However, these methods of manufacture may apply to other plug connector embodiments described herein. 
     In order to better appreciate and understand the present invention, reference is first made to  FIGS. 1A and 1B , which are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector  10  according to one embodiment of the present invention. Connector  10  includes a body  15  and a shell  20  extending longitudinally away from body  15  in a direction parallel to the length of connector  10 . Shell  20  includes an opening  25  that communicates with a cavity defined by first, second, left and right inner surfaces  20   a - 20   d  of shell  20 , a tongue  30 , and first and second surfaces  35   a ,  35   b  of support structure  35 . As shown in  FIGS. 1A and 1B , tongue  30  may be centrally located between first and second inner surfaces  20   a ,  20   b  and extend parallel to the length of connector  10 . Contacts  40   a - 40   d  are disposed on a first major surface  30   a  and four additional contacts (only contact  40   e  is shown in  FIG. 1B ) are disposed on second major surface  30   b . As also shown in  FIGS. 1A and 1B , tongue  30  may include a bullnose tip  30   c  for reasons that will be explained below. 
     As shown in  FIGS. 1A and 1B , connector  10  can have a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a corresponding receptacle connector in both a first orientation where surface  30   a  is facing up or a second orientation where surface  30   a  is rotated 180 degrees and facing down. To allow for the orientation agnostic feature of connector  10 , tongue  30  is not polarized. That is, tongue  30  does not include a physical key that is configured to mate with a matching key in a corresponding receptacle connector designed to ensure that mating between the two connectors occurs only in a single orientation. Instead, if tongue  30  is divided into top and bottom halves along a horizontal plane that bisects the center of tongue  30  along its width, the physical shape of the upper half of tongue  30  is substantially the same as the physical shape of the lower half. Similarly, if tongue  30  is divided into left and right halves along a vertical plane that bisects the center of tab along its length, the physical shape of the left half of tongue  30  is substantially the same as the shape of the right half. Additionally, contacts  40   a - 40   d  and four additional contacts disposed on second major surface  30   b  can be positioned so that the contacts on first and second major surfaces  30   a ,  30   b  are arranged in a symmetric manner. Accordingly, the contacts disposed on first surface  30   a  (contacts  40   a - 40   d ) mate with contacts of the corresponding receptacle connector in one orientation and contacts disposed on second surface  30   b  mate with contacts of the corresponding receptacle connector in the other orientation. 
     Tongue  30  may be a printed circuit board (PCB) or may be made from one or more of a variety of dielectric materials including flexible, wear resistant materials such as liquid crystal polymers (LCP), polyoxymethylene (POM), Nylon and others. Structural support  35  may also be made from a variety of dielectric materials, including flexible polymers. The materials used to form tongue  30  and/or structural support  35  may be chosen such that tongue  30  deflects either toward first or second inner surfaces  20   a ,  20   b  of shell  20  when connector  10  is inserted into a corresponding receptacle connector. This deflection may occur as bullnose tip  30   c  comes into contact with internal features of a corresponding receptacle connector and leads tongue  30  to the appropriate region within a corresponding receptacle connector, allowing contacts disposed on either surface  30   a  or  30   b  of the plug connector  10  to mate with contacts on the corresponding receptacle connector. 
     As mentioned earlier, tongue  30  may be centrally located within opening  25  of shell  20 . For example, tongue  30  may be positioned within opening  25  such that its distance from first and second inner surfaces  20   a ,  20   b  causes connector  10  to always deflect, with the assistance of bullnose tip  30   c , toward the appropriate region within a corresponding receptacle connector regardless of whether plug connector  10  is in the first or second orientation, as described above. Portions of tongue  30  may deform and deflect in different manners in order to put its contact in position to mate with the contacts of the corresponding receptacle connector. The thickness of tongue  30  may be varied depending on the material of tongue  30  such that tongue  30  may elastically deform as necessary for mating events. 
     Body  15  is generally the portion of connector  10  that a user will hold onto when inserting or removing connector  10  from a corresponding receptacle connector. Body  15  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. While not shown in  FIG. 1A or 1B , a cable and a portion of shell  20  may extend within and be enclosed by body  15 . Also, electrical contact to the contacts of surfaces  30   a ,  30   b  can be made with individual wires in a cable within body  15 . In one embodiment, a cable includes a plurality of individual insulated wires for connecting to contacts of surfaces  30   a ,  30   b  that are soldered to bonding pads on a PCB housed within body  15  or on tongue  30  when tongue  30  is a PCB. The bonding pads on the PCB may be electrically coupled to corresponding individual contacts of surfaces  30   a  and  30   b . In some embodiments, contacts of one of surfaces  30   a  and  30   b  may be shorted through tongue  30  or a PCB to corresponding contacts on the other of surfaces  30   a  and  30   b  and then appropriately routed to the individual wires of a cable within body  15 . 
     The contacts of tongue  30  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material. In some embodiments, contacts can be printed on surfaces  30   a  and  30   b  using techniques similar to those used to print contacts on printed circuit boards. As with standard USB plug connectors, plug connector  10  may include contacts for power, ground and a pair of differential data signals (e.g., data transmit). For example, contact  40   a  may be a ground pin, contact  40   b  may be a Data+pin, contact  40   c  may be a Data−pin and contact  40   d  may be a power pin (VBUS). As mentioned earlier, the four additional contacts disposed on second major surface  30   b  can be positioned so that the contacts on first and second major surfaces  30   a ,  30   b  are arranged in a symmetric manner. Accordingly, pins may be designated for the contacts on the first and second major surfaces  30   a ,  30   b  such that the pinout may be the same for both surfaces  30   a ,  30   b . For example, a contact  40   e  on surface  30   b  corresponding to (aligned with in the length and width directions of connector  10 ) contact  40   a , may also be a power pin (VBUS), a contact on surface  30   b  corresponding to contact  40   b  may be a Data−pin, a contact on surface  30   b  corresponding to contact  40   c  may be a Data+pin and a contact on surface  30   b  corresponding to contact  40   d  may be a ground pin. In this manner, regardless of the orientation of plug connector  10 , the same pinout may be mated with a corresponding receptacle connector during a mating event. 
     In some embodiments, a sensing circuit in the connector  10  can detect which of surfaces  30   a  and  30   b  of tongue  30  will mate with the contacts of the corresponding receptacle connector and switch internal connections to the contacts in connector  10  as appropriate. For example, a software switch can be used to switch the contacts of connector  10  for the pair of differential data signals depending on the insertion orientation while a hardware switch can be used to switch the ground and power contacts. In other embodiments, both switches can be implemented in software or both switches can be implemented in hardware. In another example, the orientation of the connector can instead be detected by circuitry of connector  10  based on signals received over the contacts. As one example, upon inserting connector  10  within a receptacle connector of a host device, connector  10  may send an Acknowledgment signal to the serial control chip over one of the contacts of connector  10  designated for the specific contact and waits for a Response signal from the host device. If a Response signal is received, the contacts are aligned properly and data and power can be transferred between the connectors. If no response is received, connector  10  flips the signals to correspond to the second possible orientation (i.e., flips the signals 180 degrees) and repeats the Acknowledgement/Response signal routine. As another example, the host device may send the Acknowledgement signal and connector  10  may send the Response signal. 
     It may be desirable to provide an effective manufacturing process for plug connectors discussed above as well variations thereof. Accordingly, embodiments of the present invention provide for methods of manufacture of reversible or dual orientation USB plug connectors. For example, inserting molding, assembling, and other methods may be used to manufacture plug connectors according to the present invention. Examples of these methods are illustrated in the following figures. 
       FIGS. 2A and 2B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  110  in various stages of manufacture according to one embodiment of the present invention. Plug connector  110  includes a base  115  (only shown in  FIG. 2B ) that may be attached over metallic shield  117  and cable  119 . A shell  120  (only shown in  FIG. 2B ) may be assembled with base  115  and extend longitudinally away from body  15  in a direction parallel to the length of connector  110 . Shell  120  includes an opening  125  that communicates with a cavity defined in part by tongue  130  and support structure  135  from which tongue  130  extends. As shown in  FIGS. 2A and 2B , tongue  130  may be assembled with support structure  135  within shell  120  such that tongue  130  extends parallel to the length of connector  110 . Contacts  140   a - 140   d  may be soldered on a first major surface  130   a  and four additional contacts (only contact  140   e  is shown in  FIG. 2B ) may be soldered on a second major surface  130   b . Support structure  135  may also be overmolded in position to support and possibly provide increased deflection flexibility to tongue  130 . In this embodiment, tongue  130  may be a PCB that deflects when connector  110  is mated with a corresponding plug connector. 
     In some embodiments, tongue  130  may be overmolded with a resilient polymer, e.g., LCP or POM, before or after it is assembled with support structure  135 . In this embodiment, the contacts of plug connector  110  may be copper contacts that are thick enough to remain flush with the exterior surface of tongue  130  after tongue  130  has been overmolded with a resilient polymer. 
     The methods and structure described above in relation to  FIGS. 2A and 2B  may be varied in other embodiments. Examples of these variations are included in the following figures. 
       FIGS. 3A and 3B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  210  in various stages of manufacture according to another embodiment of the present invention. USB connector  210  is similar to USB connector  110  described above, except that an additional step of routing has been performed on tip  230   c  of tongue  230  such that tip  230  is bullnose shaped for reasons already discussed above. 
       FIGS. 4A and 4B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  310  in various stages of manufacture according to yet another embodiment of the present invention. Connector  310  is similar to embodiments discussed above, e.g., plug connectors  110  and  210 . However, although tongue  330  includes a PCB  332  like the other embodiments described above, tongue  330  also includes a sleeve  334  that may be assembled over PCB  332 . As show in  FIG. 4A , sleeve  334  may include openings  334   a - 334   d  and additional openings not shown such that all contacts of connector  310  (e.g., contacts  340   a - 340   d ) remain exposed and accessible by contacts of a corresponding USB receptacle connector. 
       FIGS. 5A and 5B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  410  in various stages of manufacture according to still another embodiment of the present invention. Connector  410  is also similar to embodiments discussed above, e.g., plug connectors  110  and  210 . However, although tongue  430  includes a PCB  432  like the other embodiments described above, tongue  430  also includes a sticker or label  450  that is adhered to PCB  432 . As shown in  FIG. 5A , label  450  may include openings  450   a - 450   d  and additional openings not shown such that all contacts of connector  410  (e.g., contacts  440   a - 440   d ) remain exposed and accessible by contacts of a corresponding USB receptacle connector. Label  450  may provide cosmetic benefits in addition to insulating the contacts of plug connector  410 . 
       FIGS. 6A and 6B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  510  in various stages of manufacture according to still another embodiment of the present invention. Connector  510  is also similar to embodiments discussed above, e.g., plug connectors  110  and  210 . However, although tongue  530  may include a PCB  532  like the other embodiments described above, PCB  532  may be inserted molded to form an overmold  555  surrounding PCB  532 . As shown in  FIG. 6A , overmold  555  may include openings  555   a - 555   d  and additional openings (not shown) corresponding to all the contacts of connector  510  (e.g., contacts  540   a - 540   d  as well as the contacts not shown in  FIG. 6A ). Accordingly, the contacts of connector  510  may remain exposed and accessible by contacts of a corresponding USB receptacle connector. Overmold  555  may provide a cosmetic benefit to tongue  530 . 
     An example of an embodiment that may be similar to plug connector  510  is shown in the following figures. 
       FIGS. 16A and 16B  are partial cross sectional perspective and cross sectional side views, respectively, of a USB plug connector  1610  according to one embodiment of the present invention. Again, connector  1610  may be similar to embodiments discussed above, e.g., plug connector  510 . However, further details are shown and discussed in relation to plug connector  1610 .  FIGS. 16A and 16B  show that connector  1610  may include a body  1615  and a shell  1620  extending longitudinally away from body  1615  in a direction parallel to the length of connector  1610 . Shell  1620  includes an opening  1625  that communicates with a cavity defined by inner surfaces, e.g., first and second inner surfaces  1620   a ,  1620   b  of shell  1620 , a tongue  1630 , and surfaces of support structure  1635 . 
     As shown in  FIGS. 16A and 16B , tongue  1630  may be centrally located between first and second inner surfaces  1620   a ,  1620   b  and extend in a direction parallel to length of connector  1610 . Contacts  1640   a - 1640   d  are disposed on a first major surface  1630   a  and four additional contacts (not shown) are disposed on second major surface  1630   b . Tongue  1630  may include a PCB  1632  that is inserted molded to form an overmold  1655  surrounding PCB  1632 . As shown in  FIG. 16A , overmold  1655  may include openings  1655   a - 1655   d  as well as additional openings (not shown) such that overmold  1655  includes openings corresponding to all the contacts of connector  1610  (e.g., contacts  1640   a - 1640   d  as well as the four additional contacts not shown). Accordingly, the contacts of connector  1610  may remain exposed and accessible by contacts of a corresponding USB receptacle connector. 
     In addition to the cosmetic benefits of overmolds discussed herein concerning other embodiments of the present invention, overmolds, e.g., overmolds  1655 , may also provide rigidity and wear resistance to a PCB, e.g., PCB  1632 . For example, overmold  1655  encloses PCB  1632  and may protect it from wear that occurs during insertion/extraction events, misuse and/or other events where tongue  1630  comes into contact with objects. Thus, overmold  1655  may help to extend the lifetime of connector  1610  as the dielectric materials typically used to make a PCB are not chosen based on their strong wear resistance characteristics. A PCB does not typically have strong rigidity characteristics either. Overmold  1655  may also increase the rigidity of PCB  1632  and tongue  1630  by providing an extra layer of material around tongue  1630 . 
     As mentioned previously, some plug connectors of the present invention may include structural support elements made from materials chosen to allow plug connector tongues to deflect. Connector  1610  may also include a structural support element, e.g., a structural support  1635 . Structural support  1635  may provide flexure to PCB  1632  to reduce stress and fatigue on PCB  1632  and allow tongue  1630 , along with PCB  1632 , to deflect toward and away from first or second inner surfaces  1620   a ,  1620   b  during insertion/extraction events. In order to provide this flexure, structural support  1635  may be made from an elastomer that deforms in response to stress, e.g., a mating event, but holds tongue  1630  centrally located between first and second inner surfaces  1620   a ,  1620   b  otherwise. 
       FIGS. 16A and 16B  also illustrate individual wires, wires  1636   a - 1636   d , that extend from the interior of cable  1619 . Wires  1636   a - 1636   d  may directly terminate on PCB  1632 , e.g., wires  1636   a - 1636   d  may be soldered to PCB  1632 . Cable  1619  may include insulated wires corresponding to each unique contact of plug connector  1610  and may be connected to the contacts of plug connector  1610  via PCB  1632 . For example, wire  1636   d  may be a grounding wire, wire  1636   c  may be a Data+wire, wire  1636   b  may be a Data−wire, and wires  1636   a  may be power wires. 
     Embodiments of the present invention also provide for effective methods of manufacturing plug connector  1610 . Examples of these methods are illustrated in the following figures. 
       FIGS. 16C and 16D  are partial cross sectional, exploded perspective views of embodiments of structural support  1635  for assembling with and overmolding on tongue  1630  of plug connector  1610 , respectively, according to manufacturing methods of the present invention. As shown in  FIG. 16C , tongue  1630  may include one or more interlock recesses, e.g., interlock recesses  1637   a - 1637   c . And although not shown in  FIG. 16C , support structure  1635   a  may include protruding interlock features corresponding to interlock recesses  1637   a - 1637   c . These interlock features—protrusions and corresponding recesses  1637   a - 1637   c —may be configured to align and/or interlock tongue  1630  and support structure  1635   a  when assembled together. A clearance fit, an interference fit or a snap-fit may hold tongue  1630  and support structure  1635   a  in their assembled positions. Other embodiments may use different interlock features, e.g., pins and holes, latch features or adhesives. 
     In another embodiment, a support structure may be overmolded over a portion of tongue  1630 . For example, tongue  1630  may be overmolded with a resilient polymer, e.g., LCP or POM, to form a support structure  1635   b , as shown in  FIG. 16D . In order to increase the bonding strength between tongue  1630  and support structure  1635   b , the same materials, compatible materials (i.e., materials of similar chemistry) or blends of compatible materials may be used to form both tongue  1630  and support structure  1635   b  such that a chemical bond may be created between the elements. Interlock features may also be used to strengthen the bond between tongue  1630  and support structure  1635   b . For example, during the overmolding of support structure  1635   b , molten plastic may flow into recesses  1637   a - 1637   c  and serve as an interlock between support structure  1635   b  and tongue  1630 . 
     In other embodiments, a support structure may also be integrally formed with tongue  1630 , similar to embodiments of plug connectors shown in other FIGS. of the present application. 
     The structures and methods shown in  FIGS. 16A-16D  and discussed in relation thereto may also be implemented in various ways in other embodiments of the present invention. 
     As mentioned above, the methods and structures described above in relation to  FIGS. 2A and 2B  may be varied in other embodiments. Additional examples of these variations are included in the following figures. 
       FIGS. 7A and 7B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  610  in various stages of manufacture according to still another embodiment of the present invention. Connector  610  is also similar to embodiments discussed above, e.g., plug connectors  110  and  210 . However, although tongue  630  may include a PCB  632  like the other embodiments described above, tongue  630  also includes a frame  660  that may be assembled over PCB  632 . In addition, a sticker or label  665  may be adhered to frame  660 . As shown in  FIG. 5A , label  665  may include openings  665   a - 665   d  and additional openings corresponding to all the contacts of connector  610  (e.g., contacts  640   a - 640   d  as well as the contacts not shown in  FIG. 6A ). Accordingly, the contacts of connector  610  may remain exposed and accessible by contacts of a corresponding USB receptacle connector. Label  665  may provide cosmetic benefits in addition to insulating the contacts of plug connector  510 . Frame  660  may also include openings (not shown) corresponding to the openings of label  665 . 
       FIGS. 8A and 8B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  710  in various stages of manufacture according to still another embodiment of the present invention. Connector  710  is also similar to embodiments discussed above, e.g., plug connectors  110  and  210 . However, in contrast with the connector discussed above, connector  710  does not include a PCB. Instead, tongue  730  can be produced via a single shot molding process. For example, contacts of connector  710  (e.g.,  740   a - 740   d ) may be inserted molded to form a tongue  730  having exposed contacts as shown in  FIG. 8A . Tongue  730  may then be assembled with structural support  735 , or structural support  735  may be overmolded around a portion of tongue  730 . 
       FIGS. 9A and 9B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  810  in various stages of manufacture according to still another embodiment of the present invention. Connector  810  is similar to embodiments discussed above, particularly connector  710 . Connector  810  does not include a PCB but rather a tongue  830  can be formed via a two shot molding process, as opposed to the one shot molding process of connector  710 . The first insert mold shot may be used to form a first portion  870  using a suitable dielectric material, e.g., LCP. As shown in  FIG. 9B , first portion  870  may be located between the opposing sets of contacts of connector  810 . The second insert mold shot may be used to form a second portion  875  using another dielectric material, e.g., LCP, POM or Nylon. Second portion  875  also forms a tip  830   c  of tongue  830 . Subsequently, an overmolding process may use nylon or another suitable dielectric to form the remaining portion of tongue  830  as well as structural support  835 . In this embodiment, the contacts of plug connector  810 , e.g., contacts  840   a  and  840   e , are soldered to PCB  832 . Contacts of plug connector  810  may be shorted through PCB  832  or otherwise routed to insulated wires of cable connected to connector  810 . 
       FIGS. 10A and 10B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  910  in various stages of manufacture according to still another embodiment of the present invention. Connector  910  is similar to embodiments discussed above, particularly connector  810 . Connector  910  includes a frame  980  that includes a clamshell style opening. A flex circuit  985  may be assembled in the clamshell opening of frame  980  in order to form a tongue  930  that includes contacts (e.g., contacts  940   a - 940   d ). 
     The methods of manufacturing discussed above may also be suitable in whole or in part for additional embodiments of plug connectors of the present invention. Examples of these additional embodiments of plug connectors of the present invention are illustrated in the following figures. 
       FIGS. 11A and 11B  are simplified perspective and cross sectional views, respectively, of a USB plug connector  1100  according to one embodiment of the present invention. Plug connector  1110  includes a body  1115  and a tab  1117  extending longitudinally away from body  1115  in a direction parallel to the length of connector  1110 . In contrast with connector  10  and similar variations, connector  1110  does not include a shell. Contacts  1140   a - 1140   d  are disposed on a first major surface  1130   a  and four additional contacts (only contact  1140   e  is shown in  FIG. 11B ) are disposed on a second major surface  1130   b . As also shown in  FIGS. 11A and 11B , tab  1117  may include a bullnose tip  1130   c  for at least the same reasons discussed above. 
     Connector  1100  can have a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a corresponding receptacle connector in both a first orientation where surface  1130   a  is facing up and a second orientation where surface  1130   a  is rotated 180 degrees and facing down. Specifics of general double or dual orientation designs are discussed in greater detail above. Simply stated, the dual orientation design of connector  1100  allows contacts disposed on first surface  1130   a  (contacts  1140   a - 1140   d ) to mate with contacts of the corresponding receptacle connector in one orientation and contacts disposed on second surface  1130   b  to mate with contacts of the corresponding receptacle connector in the other orientation. Despite connector  1110  being a dual orientation connector, this embodiment of the present invention may only be received by receptacle connectors specially designed for receiving connector  1100 . 
     Tab  1130  may be made from one or more of a variety of dielectric materials including wear resistant materials such as LCP, POM, Nylon and others. In contrast with connector  10 , connector  1110  may not be designed to deflect upon insertion into a corresponding receptacle connector. Instead, connector  1100  may remain rigid during insertion and extraction events. Materials used for making tab  1130  may be chosen accordingly. 
     Body  1115  is generally the portion of connector  1110  that a user will hold onto when inserting or removing connector  1110  from a corresponding receptacle connector. Body  1115  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. Also, electrical contact to the contacts of surfaces  1130   a ,  1130   b  can be made with individual wires in a cable within body  1115 . In one embodiment, a cable includes a plurality of individual insulated wires for connecting to contacts of surfaces  1130   a ,  1130   b  that are soldered to bonding pads on a PCB housed within body  1115 . The bonding pads on the PCB may be electrically coupled to corresponding individual contacts of surfaces  1130   a  and  1130   b . In some embodiments, contacts of one of surfaces  1130   a  and  1130   b  to be shorted through tab  1130  or a PCB to corresponding contacts on the other of surfaces  1130   a  and  1130   b  and then appropriately routed to the individual wires of a cable within body  1115 . 
     The contacts of tab  1130  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material. Plug connector  1110  may include standard USB contacts for power, ground and a pair of differential data signals (e.g., data transmit). For example, contact  1140   a  may be a ground pin, contact  1140   b  may be a Data+pin, contact  1140   c  may be a Data−pin, and contact  1140   d  may be a power pin (VBUS). As mentioned earlier, the four additional contacts disposed on second major surface  1130   b  can be positioned so that the contacts on first and second major surfaces  1130   a ,  1130   b  are arranged in a symmetric manner and have the same pinout. In this manner, either of two intuitive orientations may be used to mate the contacts of plug connector  1110  with contacts of a corresponding receptacle connector during a mating event. 
     A sensing circuit as described above may be included with connector  1110  and/or a corresponding receptacle connector. 
     An example of a particular embodiment of plug connector  1110  is shown in the following figures. 
       FIGS. 15A and 15B  are partially transparent simplified perspective and partially transparent front views, respectively, of a USB plug connector  1510  according to one particular embodiment of connector  1110 . Connector  1510  may provide the same pinout on both first and second major surfaces  1530   a ,  1530   b  of a tab  1530  using crossover contact frames  1596   a - 1596   d  that each include a contact for each of the major surfaces of tab  1530 . For example, as shown in  FIGS. 15A and 15B , tab  1530  extends in a longitudinal direction and includes contacts  1540   a - 1540   d  disposed on first major surface  1530   a  and contacts  1540   e - 1540   g  disposed on second major surface  1530   b . Contacts  1540   a - 1540   g  may be exposed portions of contact frames  1596   a - 1596   d . Crossover contact frames  1596   a - 1596   d  may serve to connect contacts  1540   a - 1540   d  to contacts  1540   h - 1540   e , respectively, and contacts  1540   a - 1540   h  to PCB  1532 , which may be assembled with tab  1530 . The configuration of crossover contact frames  1596   a - 1596   d  is further illustrated in the following figures. 
       FIGS. 15C-15F  are top views of contact frames  1596   a ;  1596   a  and  1596   b ;  1596   a ,  1596   b  and  1596   c ; and  1596   a ,  1596   b ,  1596   c  and  1596   d ; respectively, in their positions with respect to each other when embedded in tab  1530 . As shown in  FIG. 15C-F  as well as  FIGS. 15A and 15B , a crossover region exists between contacts  1540   a - 1540   d  and contacts  1540   e - 1540   h  where portions of contact frames  1596   a - 1596   d  overlap and cross. The overlapping and crossing of portions of contact frames  1596   a - 1596   d  in the crossover region may provide shielding to minimize electromagnetic interference (EMI) from degrading signals transferred through contacts  1540   a - 1540   h.    
     As with connector  1100 , connector  1510  can have a 180 degree symmetrical, double or dual orientation design. Similarly, connector  1510  may include a body having a cable attached thereto like body  1115  or any of the other body embodiments described herein. In one embodiment, a body (not shown in  FIGS. 15A-15F ) may be assembled with tab  1530 , house PCB  1532  and have a cable (not shown in  FIGS. 15A-15F ) attached thereto. The cable may include a plurality of individual insulated wires for connecting to contacts  1540   e - 1540   h  via PCB  1532  that includes solder connections between crossover contact frames  1596   a - 1596   d  and its bonding pads. 
     The contacts of connector  1510  may include contacts for power, ground and a pair of differential data signals (e.g., data transmit). For example, crossover contact frames  1596   a - 1596   d  may provide lines for ground, Data+, Data− and power (VBUS), respectively. Accordingly, contacts  1540   a  and  1540   h  may be a ground pins, contacts  1540   b  and  1540   g  may be a Data+pins, contacts  1540   c  and  1540   f  may be a Data−pins, and contacts  1540   d  and  1540   e  may power pins (VBUS). In this manner, regardless of the orientation of plug connector  1510 , the same pinout may be mated with a corresponding receptacle connector during a mating event. 
     An added benefit of this embodiment may be that sensing circuitry as discussed in relation to other embodiments contained herein may not be necessary for connector  1510  or a corresponding receptacle connector. This is possible because crossover contact frames  1596   a - 1596   d  may provide the same pinout on each of the first and second orientations and handle the routing of power and data received at contacts  1540   a - 1540   h  to PCB  1532 . In some embodiments, contact frames  1596   a - 1596   d  may even directly route power and data to individual wires of a cable connected to connector  1510 . Accordingly, features of connector  1510  may be useful for other embodiments described herein. 
     Contact frames  1596   a - 1596   d  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material using a metal stamping operation or other machining operations. Alternatively, contact frames  1596   a - 1596   d  may be molded. 
     The contact arrangements shown in  FIGS. 15A-15F  and discussed in relation thereto may be implemented in various ways in other embodiments, e.g., those embodiments that do not include a PCB disposed between the contacts of the plug connector. Additional embodiments of contact arrangements that may be implemented with plug connector embodiments that may not include PCB anywhere within the plug connector are shown in the following figures. 
       FIGS. 17A and 17B  are partial cross sectional perspective and cross sectional side views, respectively, of a USB plug connector  1710  according to one embodiment of the present invention. Plug connector  1710  may be similar to embodiments discussed above, e.g., plug connector  1610 . However, plug connector  1710  may not include a PCB.  FIGS. 17A and 17B  show that connector  1710  may include a body  1715  and a shell  1720  extending longitudinally away from body  1715  in a direction parallel to the length of connector  1710 . Shell  1720  includes an opening  1725  that communicates with a cavity. Tongue  1730  may be centrally located within shell  1720  and extend in a direction parallel to the length of plug connector  1710 . Contacts  1740   a - 1740   d  are exposed on a first major surface  1730   a  and contacts  1740   e - 1740   h  are exposed on a second major surface  1730   b . Contacts  1740   a - 1740   h  may be exposed portions of contact frames  1798   a - 1798   d.    
     Crossover contact frames  1798   a - 1798   d  may serve to connect contacts  1740   a - 1740   d  to contacts  1740   h - 1740   e , respectively, and contacts  1740   a - 1740   h  to wires of cable  1719 .  FIGS. 17A and 17B  illustrate insulated wires, wires  1736   a - 1736   d , that extend from the interior of cable  1719 . Wires  1736   a - 1736   d  may directly terminate on contact frames  1798   a - 1798   d , e.g., wires  1736   a - 1736   d  may be soldered to contact frames  1798   a - 1798   d . The Cable  1719  may include wires corresponding to each unique contact of plug connector  1710 . For example, wire  1736   d  may be a grounding wire that connects to contact frame  1798   a  (contacts  1740   a  and  1740   h ), wire  1736   c  may be a Data+wire that connects to contact frame  1798   b  (contacts  1740   b  and  1740   g ), wire  1736   b  may be a Data−wire that connects to contact frame  1798   d  (contacts  1740   c  and  1740   f ), and wires  1736   a  may be power wires that connect to contact frame  1798   c  (contacts  1740   d  and  1740   e ). In this manner, regardless of the orientation of plug connector  1710 , the same pinout may be mated with a corresponding receptacle connector during a mating event. 
     The configuration of crossover contact frames  1798   a - 1798   d  is further illustrated in the following figure. 
       FIG. 17C  is an exploded view of contact frames  1798   a - 1798   d  of plug connector  1710 . As can be understood from  FIG. 17C , a crossover region exists between contacts  1740   a - 1740   d  and contacts  1740   e - 1740   h  where portions of contact frames  1798   a - 1798   d  overlap and cross. Insulative spacers may be placed in this crossover region. For example, strips of electrical insulation materials, e.g., elastomers or other polymers with good electrical insulation properties, may be placed and/or adhered to the surfaces of contact frames  1798   a - 1798   d  adjacent to other surfaces of contact frames  1798   a - 1798   d  in plug connector  1710 , as shown in  FIG. 17C . For example, spacers  1746   a  and  1746   b  may shield portions of contact frame  1798   c  from portions of contact frame  1798   a . Spacers  1747  and  1748  may shield portions of contact frame  1798   b  from portions of contact frame  1798   d . Spacer  1749  may shield portions of contact frame  1798   c  from portions of contact frame  1798   a.    
     Depending the amount of EMI that is occurring between the contacts of plug connector  1710 , more or less and/or thicker or thinner insulative spacers may be implemented. For example, if additional shielding is required more and/or thicker insulative spacers may be placed in the crossover region between contact frames  1798   a - 1798   d . The overlapping and crossing of portions of contact frames  1798   a - 1798   d  in the crossover region in addition to the insulative spacers may provide shielding from EMI caused by signals passing through  1740   a - 1740   h , which EMI may degrade the signals transferred through contacts  1740   a - 1740   h.    
     Overmold  1755  may be formed around spacers  1746 - 1749  and contact frames  1798   a - 1798   d  to form tongue  1730 . As discussion herein, tongue overmolds may provide cosmetic, rigidity and wear resistance benefits. Materials used for other tongue overmold embodiments discussed herein may also be used for overmold  1755 . 
     The design of plug connector  1710 , as with plug connector  1510 , may be a 180 degree symmetrical, double or dual orientation design. An added benefit of contact frames  1798   a - 1798   d  may be that sensing circuitry as discussed in relation to other embodiments contained herein may not be necessary for connector  1710  or a corresponding receptacle connector for reasons similar to those mentioned concerning plug connector  1510 . 
     As shown in  FIG. 17B , plug connector  1710  may also include a structural support  1735  integrally formed with overmold  1755 . Structural support  1735  may provide flexure to tongue  1730  to reduce stress and fatigue on tongue  1730  and allow tongue  1730  to deflect during insertion/extraction events. In other embodiments, structural support  1735  may be separately overmolded over overmold  1755  or separately formed and then assembled with tongue  1730  using a clearance fit, an interference fit or a snap-fit or the like. 
     Contact frames  1798   a - 1798   d  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material using a metal stamping operation or other machining operations. Alternatively, contact frames  1798   a - 1798   d  may be molded. 
     An example of another plug connector embodiment that may not include PCB is shown in the following figures. 
       FIGS. 18A and 18B  are exploded and cross sectional side views, respectively, of a USB plug connector  1810  according to an embodiment of the present invention. Plug connector  1810  may be similar to embodiments discussed above which does not include a PCB, e.g., plug connector  1710 . As shown in  FIGS. 18A and 18B , connector  1810  includes a body  1815  and a shell  1820  extending longitudinally away from body  1815  in a direction parallel to the length of connector  1810 . Shell  1820  includes an opening  1825  that communicates with a cavity defined by first, second, left and right inner surfaces  1820   a - 1820   d  of shell  1820 , a tongue  1830 , and first and second support elements  1835   a ,  1835   b  assembled with a base  1837 . Tongue  1830  may be centrally located between first and second inner surfaces  1820   a ,  1820   b  and extend parallel to the length of connector  1810 . Tongue  1830  includes contacts  1840   a - 1840   d  exposed at a first major surface  1839   a  of a tip  1839  and four additional contacts (e.g., contacts  1840   e - 1840   h , as shown in  FIG. 18F ) exposed on a second major surface  1839   b . Contacts  1840   a - 1840   h  can be made from copper, nickel, brass, a metal alloy such as a copper-titanium alloy or any other appropriate conductive material. As shown in  FIGS. 18A and 18B , tongue  1830  may also include a bullnose tip  1839   c  for reasons that will be explained below. 
     Connector  1810  can have a 180-degree symmetrical, double orientation design that enables the connector to be inserted into a corresponding receptacle connector in either a first orientation where surface  1839   a  is facing up or a second orientation where surface  1839   a  is rotated 180 degrees and facing down. To allow for the orientation agnostic feature of connector  1810 , tongue  1830  is not polarized. That is, tongue  1830  does not include a physical key that is configured to mate with a matching key in a corresponding receptacle connector designed to ensure that mating between the two connectors only occurs in a single orientation. Instead, if tongue  1830  is divided into top and bottom halves along a horizontal plane that bisects the center of tongue  1830  along its width, the physical shape of the upper half of tongue  1830  is substantially the same as the physical shape of the lower half. Similarly, if tongue  1830  is divided into left and right halves along a vertical plane that bisects the center of tab along its length, the physical shape of the left half of tongue  1830  is substantially the same as the shape of the right half. Additionally, contacts  1840   a - 1840   d  and contacts  1840   e - 1840   g  can be positioned so that they are arranged in a symmetric manner. Accordingly, contacts  1840   a - 1840   d  can mate with contacts of the corresponding receptacle connector in one orientation and contacts  1840   e - 1840   h  (shown in  FIG. 18F ) can mate with contacts of the corresponding receptacle connector in the other orientation. 
     Tongue  1830  may be coupled to base  1837 , which can be made from a variety of dielectric materials, including flexible polymers and polyamides. The materials used to form tongue  1830  and/or base  1837  may be chosen such that tongue  1830  deflects either toward first or second inner surfaces  1820   a ,  1820   b  of shell  1820  when connector  1810  is inserted into a corresponding receptacle connector, e.g., a female USB connector. This deflection may occur as bullnose tip  1839   c  comes into contact with internal features of a corresponding receptacle connector, causing tongue  1830  to deflect toward an appropriate region within a corresponding receptacle connector and allowing contacts  1830   a - 1830   d  or  1830   e - 1830   h  of plug connector  1810  to mate with contacts on the corresponding receptacle connector. 
     As discussed above, tongue  1830  may be centrally located within opening  1825  of shell  1820 . For example, tongue  1830  may be positioned within opening  1825  such that its distance from first and second inner surfaces  1820   a ,  1820   b  always causes connector  1810  to deflect toward the appropriate region within a corresponding receptacle connector regardless of whether plug connector  1810  is in the first or second orientation, as described above. Portions of tongue  1830  may deform and deflect in different manners in order to put its contacts in position to mate with the contacts of the corresponding receptacle connector. Depending on the materials of the individual components of tongue  1830 , the size of tongue  1830  may be varied such that tongue  1830  elastically deforms as necessary during mating events. 
     Body  1815  is generally the portion of connector  1810  that a user will hold onto during mating events. Body  1815  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. A portion of a cable  1819  and shell  1820  may extend within and be enclosed by body  1815 . To prevent cable  1819  from being damaged when flexed during normal use (e.g., mating events), a strain relief element  1865  (e.g., a structure made from elastomers) may be formed over or assembled with the portion of cable  1819  closest to body  1815 , as shown in  FIG. 18A . 
     In one embodiment, cable  1819  includes a plurality of individual insulated wires  1836   a - 1836   d  for connecting to contacts  1840   a - 1840   h . The electrical connection between insulated wires  1836   a - 1836   d  and contacts  1840   a - 1840   h  can be formed by soldering wires  1836   a - 1836   d  to ends of contact frames  1898   a - 1898   d  (as shown in  FIGS. 18C, 18D and 18H ). As further discussed below, contacts  1840   a - 1840   h  may be exposed portions of contact frames  1898   a - 1898   h . Accordingly, contact frames  1898   a - 1898   h  can route electrical signals between wires  1836   a - 1836   d  and contacts  1840   a - 1840   h . A polymer innermold  1855  may be formed around the connection between wires  1836   a - 1836   d  and the ends of contact frames  1898   a - 1898   d . A metallic shield cap  1860  may be assembled over innermold  1855  and with shell  1820  to increase electromagnetic interference and electromagnetic compatibility performance (“EMI/EMC performance”) of connector  1810 . The configuration of contact frames  1898   a - 1898   h  is further illustrated in the following figures. 
       FIGS. 18C-18H  illustrate contact frames  1898   a - 1898   h  in various stages of assembly according to an embodiment of the present invention.  FIG. 18C  show a first set of contact frames  1898   a - 1898   d  shaped to extend through base  1837  and form a portion of tongue  1830  with raised protuberances that function as contacts  1840   a - 1840   d .  FIG. 18D  shows a second set of contact frames  1898   e - 1898   h  having raised protuberances that function as contacts  1840   e - 1840   h . Contact frames  1898   e - 1898   h  may be shaped to be coupled with the first set of contact frames  1898   a - 1898   d  such that contacts  1840   a - 1840   d  are electrically connected to contacts  1840   h - 1840   e , respectively. Contact frames  1898   a - 1898   e  and  1898   h  may also extend into base  1837 , while contact frames  1898   f  and  1898   g  do not extend into base  1837 . As shown in  FIG. 18D , contact frames  1898   f  and  1898   g  may be connected via an arm  1897 . The shape of contact frames  1898   f ,  1898   g  and arm  1987  can minimize or reduce electrical stub and thereby minimize insertion loss, allowing for improved signal integrity for contacts  1840   b ,  1840   d ,  1840   g  and  1840   f , which may be differential data contacts, as discussed below. 
     As shown in  FIG. 18E , a insulative spacer  1846  may be insert molded over and between portions of contacts  1898   a - 1898   d  to electrically shield and isolate contacts  1840   a - 1840   h , even when assembled as shown in  FIG. 18F . As such, portions of contact frames  1898   a - 1898   d  can overlap and cross contact frames  1898   e - 1898   h  while maintaining acceptable levels of EMI/EMC performance. Spacer  1846  can be made from dielectric materials, e.g., elastomers or other polymers with good electrical insulation properties. A larger or smaller, thicker or thinner and/or otherwise shaped insulative spacer  1846  may be implemented depending on the amount of EMI that is occurring between the contacts and/or contact frames of plug connector  1810 . For example, if additional shielding is required, insulative spacer  1846  may be thickened where any one of contact frames  1898   a - 1898   d  overlap any one of contact frames  1898   e - 1898   h , thereby shielding EMI that could potentially degrade the signals passing to or from contacts  1840   a - 1840   h  via contact frames  1898   a - 1898   h.    
     In order to achieve the 180-degree symmetrical, double or dual orientation design of connector  1810 , contact frames  1898   e - 1898   h  may be electrically connected to contact frames  1836   a - 1836   d  such that the same pinout or arrangement of contact types (e.g., data, power, ground) is provided at first and second surfaces  1839   a ,  1839   b . Accordingly, as shown in  FIG. 18F , contacts  1840   a - 1840   d  are electrically connected with contacts  1840   h - 1840   e , respectively, via the coupling (e.g., welding or otherwise electrically connecting) to the first and second set of contact frames. More specifically, a weld  1899   a  (e.g., a laser weld) may electrically couple contact frame  1898   a  to contact frame  1898   h , thereby coupling contacts  1840   a  and  1840   h ; a weld  1899   b  may electrically couple contact frame  1898   b  to contact frame  1898   g , thereby electrically coupling contacts  1840   b  and  1840   g ; a weld  1899   c  may electrically couple contact frame  1898   c  to contact frame  1898   f , thereby electrically coupling contacts  1840   c  and  1840   f ; and a weld  1899   e  may electrically couple contact frame  1898   e  to contact frame  1898   d , thereby electrically coupling contacts  1840   d  and  1840   e.    
     As with standard USB plug connectors, plug connector  1810  may include contacts for power, ground and a pair of differential data signals (e.g., data transmit). Cable  1819  may include wires corresponding to each of these unique contacts. As discussed above, wires  1836   a - 1836   d  may directly terminate on contact frames  1836   a - 1836   d  in order to couple with contacts  1840   a - 1840   h . For example, wire  1836   d  may be a grounding wire that connects to contacts  1840   d  and  1840   e  via contact frames  1898   d  and  1898   e , wire  1836   c  may be a Data+wire that connects to contacts  1840   c  and  1840   f  via contact frames  1898   c  and  1898   f , wire  1836   b  may be a Data−wire that connects contacts  1840   b  and  1840   g  via contact frames  1898   b  and  1898   g , and wires  1836   a  may be power wires that connect to contacts  1840   a  and  1840   h  via contact frames  1898   a  and  1898   h . In this manner, regardless of the orientation of plug connector  1810 , the same pinout may be mated with a corresponding receptacle connector during a mating event. 
     The design of plug connector  1810 , as with plug connector  1510 , may be a 180-degree symmetrical, double or dual orientation design. An added benefit of using contact frames, e.g., frames  1898   a - 1898   h  may be that sensing circuitry as discussed in relation to other embodiments contained herein may not be necessary for connector  1810  or a corresponding receptacle connector for reasons similar to those mentioned concerning plug connector  1510 . 
     As mentioned earlier, plug connector  1810  may also include a base  1837  and first and second support elements  1835   a ,  1835   b  assembled with a base  1837 . The combination of support elements  1835   a ,  1835   b  and base  1837  may support tongue  1830  as it flexes during insertion/extraction events in order to reduce stress and fatigue experienced by, e.g., contact frames  1898   a - 1898   h  of tongue  1830 . Base  1837  may be overmolded over contact frames  1898   a - 1898   e  and  1898   h  or separately formed and then assembled with the rest of tongue  1830  using a clearance fit, an interference fit, a snap-fit or the like. In another embodiment, support elements  1835   a ,  1835   b  may be overmolded separately or integrally with base  1837 . Support elements  1835   a ,  1835   b  may be made from a resilient polymer, e.g., LCP or POM. Overmolding may also be used to form tip  1839  over spacer  1846  and around the contacts of contact frames  1898   a - 1898   h , as shown in  FIG. 18H . Tip  1839  may provide cosmetic, rigidity and wear resistance benefits. Materials used for other tongue overmold embodiments discussed herein may also be used for tip  1839 . Alternatively, tip  1839  may be assembled on contact frames  1898   a - 1898   h.    
     Contact frames  1898   a - 1898   h  can be made from copper, nickel, brass, a metal alloy such as a copper-titanium alloy or any other appropriate conductive material using a metal stamping operation or other machining operations. Alternatively, contact frames  1898   a - 1898   h  may be molded. Contacts  1840   a - 1840   h  may be made from the same material as contact frames  1898   a - 1898   h . In addition, contacts  1840   a - 1840   h  may be plated with nickel and/or gold. 
     The structures and methods shown in  FIGS. 18A-18H  and discussed in relation thereto may also be implemented in various ways in other embodiments of the present invention. 
     It will be appreciated that connector  1810  is illustrative and that variations and modifications are possible. The shapes and number of contact frames of connector  1810  can be varied in ways not specifically described here. Further, while contact frames are described above as being coupled, i.e., via welding, at particular locations, it is to be understood that these weld points can vary for contact frames having different shapes and configurations. Further, the contact frames of connector  1810  may be replaced with a tongue-shaped element made from a metallic material or a polymer and not configured to carry signals. In this embodiment, a flex circuit having contacts may simply be wrapped around the tongue-shaped element to provide a dual orientation connector such as a USB connector. Embodiments of the present invention can be realized in a variety of apparatus including cable assemblies, docking stations and flash drives. Support elements or members  1835   a ,  1835   b , which collectively may be referred to as a support structure, of connector  1810  can be varied in ways not specifically described above. The following figures illustrate examples of variations of this support structure, which may be implemented in various embodiments described herein. 
     In order to discuss the utility of a support structure, such as support members  1835   a ,  1835   b , reference is first made to a reversible connector with its support structure removed:  FIGS. 19A and 19A-1  are cross sectional side and partially exploded, partially cross sectional perspective views, respectively, of a USB plug connector  1910  with its support structure removed according to one embodiment of the present invention. Plug connector  1910  may be similar to embodiments discussed above, e.g., plug connector  1810 . Again, for the purpose of discussion, the support structure (as shown in  FIGS. 19B and 19B-1 ) of plug connector  1910  is not shown in  FIGS. 19A and 19A-1 . As with connector  1810 , plug connector  1910  includes a body  1915  and a shell  1920  extending longitudinally away from body  1915  in a direction parallel to the length of connector  1910 . Shell  1920  includes an opening  1925  that communicates with a cavity defined by inner surfaces (e.g., surfaces  1820   a - 1820   d  as shown in  FIG. 18A ) of shell  1920  and a base  1937 . 
     Tongue  1930  may be centrally located between inner surfaces of shell  1920  and extend parallel to the length of connector  1910 . Tongue  1930  can include contacts (only contact  1940   a  is shown in  FIG. 19A-1 , but see, e.g., contacts  1840   a - 1840   d  in  FIG. 18A ) exposed at a first major surface  1939   a  of a contact region  1939  and additional contacts (e.g., contacts  1840   e - 1840   h , as shown in  FIG. 18F ) exposed on a second major surface of contact region  1939 . The contacts of connector  1910  may be exposed portions of contact frames  1998  (only contact frames  1998   a - 1998   c  are shown in  FIG. 19A-1 , but see, e.g., contact frames  1898   a - 1898   h  in  FIG. 18F ), at least some of which are spaced apart along a width of the tongue, as shown in  FIG. 19A-1 . Tongue  1930  may also include a bullnose tip  1939   c  (e.g., tip  1839   c , as shown in  FIG. 18B ). A cable  1919  can be coupled to base  1915  and include a plurality of individual insulated wires (e.g., wires  1836   a - 1836   d , as shown in  FIG. 18A ) for coupling with contacts of connector  1910 . 
     Like connector  1810  above, connector  1910  can also have a 180-degree symmetrical, double orientation design that enables the connector to be inserted into a corresponding receptacle connector in either a first orientation where surface  1939   a  is facing up or a second orientation where surface  1939   a  is rotated 180 degrees and facing down. For example, tongue  1930  may be positioned within opening  1925  such that tongue  1930  deflects toward the an inner surface of shell  1920  and is positioned in an appropriate region within a corresponding receptacle connector, regardless of whether plug connector  1910  is in the first or second orientation. Bending portions of tongue  1930  (e.g., portions of contact frames  1998 ) may bend or deform and deflect in different manners in order to put the contacts of connector  1910  in position to mate with the contacts of the corresponding receptacle connector. 
     The discussion of elements and variations thereof concerning connector  1810  may apply to corresponding elements of connector  1910 . Additional elements and variations thereof discussed with reference to connector  1810  above may also be implemented in connector  1910 . 
     The absence of a support structure in connector  1910  may result in a number of issues. As mentioned concerning other embodiments, a support structure (support members  1835   a ,  1835   b ), as well as a base (e.g., base  1837 ), can support a tongue as it flexes during insertion/extraction events in order to reduce stress experienced at any given point of the tongue.  FIG. 19A  can be used to identify where stress might be concentrated in the absence of a support structure. For example, the point at which tongue  1930  protrudes through base  1937  and into the cavity of shell  1920  may be the pivot point for tongue  1930 . As such, the majority of the stress experienced by tongue  1930  during a mating event may be concentrated at and/or around that pivot point, which would be the bending portion of tongue  1930 . Even if the stress experienced at this bending portion of tongue  1930  is less than the yield stress of the material at this bending portion of tongue  1930 , permanent deformation may occur over time if connector  1910  is left in the mated position for a period (e.g., if connector  1910  is left in receptacle for months, weeks or possibly even days). 
     To resolve these potential issues, the length of the bending portion of tongue  1930  could be increased such that the angle of deflection of tongue  1930  is decreased, resulting in less stress occurring at the bending portion. However, this could also decrease the contact normal force or contact mating force provided by tongue  1930  to press its contacts against the contacts of a corresponding receptacle connector during a mating event such that data and/or power can be transferred therebetween. That is, the stress occurring at the bending portion of tongue  1930  may correlate to the contact normal force provided by tongue  1930 . Alternatively, if the size of the bending portion of tongue  1930  could be increased such that the stress could be distributed over a larger portion of tongue  1930 , damage to and/or permanent deformation of tongue  1930  could potentially be avoided. For example, a structural support could be used to spread or distribute stress (e.g., uniformly spread stress) over a larger bending portion of a tongue, while maintaining or even increasing contact normal force by spreading stress instead of decreasing the overall stress. 
       FIGS. 19B and 19B-1  are cross sectional side and partially exploded, partial cross sectional perspective views, respectively, of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to one embodiment of the present invention. Structural support  1935  can include first and second support members  1935   a ,  1935   b  that are overmolded adjacent to, integrally formed with base  1937  (e.g., using a single or a multiple shot process) or separately formed and then assembled with base  1937  or other elements of connector  1910  (e.g., shell  1920 ) using a clearance fit, an interference fit, a snap-fit or the like. First and second support members  1935   a ,  1935   b  of structural support  1935  may be made from a compliant material such as a thermoplastic elastomer (e.g., silicone santoprene) or other materials suitable for distributing stress while maintaining or providing sufficient contact normal force. 
     As shown in  FIGS. 19B and 19B-1 , first and second support members  1935   a ,  1935   b  can be positioned on opposite sides of tongue  1930  with first support member  1935   a  including a surface  1936   a  that faces a surface of tongue  1930  and second support member  1935   b  including a surface  1936   b  that faces another surface of tongue  1930 .  FIGS. 19B and 19B-1  also show that the distance between surfaces  1936   a ,  1936   b  varies along the portion of the length of tongue  1930  that is positioned between these surfaces  1936   a ,  1936   b . For example, the distance between surfaces  1936   a ,  1936   b  may increase in the direction that tongue  1930  extends from base  1937 . Thus, the opening formed by the first and second support members  1935   a ,  1935   b  may be tapered. As such, when tongue  1930  deflects during a mating event, the stress experienced by tongue  1930  may be distributed across the bending portion of tongue  1930  (e.g., the portion of tongue  1930  that is deflected towards and makes contact with surface  1936   a  or surface  1936   b ). In some embodiments, this may cause tongue  1930  to experience a low, constant stress across the bending portion of tongue  1930  during mating events, as opposed to experiencing a high stress at the pivot point, as discussed with reference to  FIGS. 19A and 19A-1 . 
     First and second support members  1935   a ,  1935   b  may also include a recess (e.g., recesses  1938   a ,  1938   b ) at surfaces opposite surfaces  1936   a ,  1936   b , respectively, such that the height of first and second support members  1935   a ,  1935   b  also varies along the portion of the length of tongue  1930  that is positioned between surfaces  1936   a ,  1936   b . These recesses may be shaped and sized based on the height of first and second support members  1935   a ,  1935   b  in order to distribute stress and provide contact normal force for tongue  1930 . 
     Alternatively or additionally, the durometer of structural support  1935  may vary along a portion of the length of tongue  1930 . For example, the durometer of portions of first and second support elements  1935   a ,  1935   b  nearest to base  1937  may be higher than other portions of first and second support elements  1935   a ,  1935   b  that are closer to opening  1925 . In some embodiments, the durometer of first and second support elements  1935   a ,  1935   b  may not vary in the same manner along the length of tongue  1930 . The durometer of first and second support elements  1935   a ,  1935   b  may be adjusted based on the shape of first and second support elements  1935   a ,  1935   b , the material properties of the bending portions of tongue  1930 , the dimensions of tongue  1930  such that tongue  1930  is prevented from breaking due to stress while allowing the contacts of tongue  1930  to properly couple with the contacts of a corresponding receptacle connector during mating events. 
       FIGS. 19C-19F  are cross sectional side views of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to embodiments of the present invention. The support structures shown in  FIGS. 19C-19F  may be similar to support structure  1935  in that they include support members having a surface that faces a surface of tongue  1930  and the distance between those surfaces may vary along a portion of the length of tongue  1930  (e.g., the bending portion). However, there may be differences between support structure  1935  and the support structures of  FIGS. 19C-19F . 
     For example,  FIG. 19C  illustrates a support structure, including support members  1935   c  and  1935   d , which include opposing surfaces that face tongue  1930 . As compared with  FIGS. 19B  and  19 B 1 , the distance between these opposing surfaces vary to a greater extent along a portion of the length of tongue  1930 , resulting in a larger tapered opening. As shown in  FIG. 19C , support members  1935   c  and  1935   d  can also include recesses  1938   c ,  1938   d  shaped and sized as shown in  FIG. 19C . These recesses  1935   a ,  1935   b  may be otherwise sized and shaped in order to reduce stress concentrations at tongue  1930  while providing sufficient contact normal force. 
       FIG. 19D  illustrates a support structure, including support members  1935   e  and  1935   f  having opposing surfaces  1936   e  and  1936   f  that face tongue  1930  and have a curvature. Surfaces  1936   e ,  1936   f  can be described as having hills and a valley. In some embodiments, surfaces  1936   e ,  1936   f  can include a series of hills and valleys of various shapes and sizes. As with other embodiments described above, opposing surfaces  1936   e ,  1936   f  may be sized and shaped in order reduce stress concentrations at tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 19E  illustrates another support structure for use in an embodiment of connector  1910 . In contrast with the support structures above, support members  1935   g ,  1935   h  are not symmetric about a length direction of the tongue. For example, support member  1935   g  extends farther from base  1937  than support member  1935   h . In addition, support member  1935   g  includes a surface  1936   g  facing tongue  1930  and orientated in a plane parallel to the plane in which an opposing surface of tongue  1930  is oriented, whereas support member  1935   h  includes a surface  1936   h  facing tongue  1930  that is oriented in a plane that intersects the plane of the opposing surface of tongue  1930 . In addition, as shown in  FIG. 19E , support member  1935   h  does not include a recess while support member  1935   g  does include a recess  1938   g . As with other embodiments described above, opposing surfaces  1936   g ,  1936   h  may be sized and shaped in order to reduce stress concentrations at tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 19F  illustrates a support structure that includes a mix of the features of the support structures shown in  FIGS. 19C-19E . For example, the support structure shown in  FIG. 19F  includes support members  1935   i ,  1935   j  that are symmetric about a length direction of tongue  1930 . Support members  1935   i  and  1935   j  include opposing surfaces  1936   i  and  1936   j , respectively, which face tongue  1930 . A distance between these opposing surfaces varies along a portion of the length of tongue  1930  and is constant along another portion of the length of tongue  1930 . As with the other embodiments, support members  1935   i  and  1935   j  may be shaped and sized to distribute stress along the bending portion of tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIGS. 19G-19J  are cross sectional side views of the USB plug connector of  FIGS. 19A and 19A-1  with a support structure according to embodiments of the present invention. The support structures shown in  FIGS. 19G-19J  may be similar to support structure  1935 , as shown in  FIGS. 19B and 19B-1 , in that they include support members having surfaces that face a surface of tongue  1930  and the distance between the surfaces of the support members may be constant along a portion of the length of tongue  1930  (e.g., the bending portion). However, there are differences between support structure  1935  and the support structures of  FIGS. 19G-19J . 
       FIG. 19G  illustrates a support structure for use in an embodiment of connector  1910 . The support structure shown in  FIG. 19G  includes support members  1935   k ,  1935   l  that are symmetric about a length direction of tongue  1930 . Support member  1935   k  includes a surface  1936   k  facing tongue  1930  and is orientated in a plane parallel to the plane in which the opposing surface of tongue  1930  is oriented. Similarly, support member  1935   l  also includes a surface  1936   l  facing another opposing surface of tongue  1930  and is orientated in a plane parallel to the plane in which the other opposing surface of tongue  1930  is oriented. Varying the durometer of support members  1935   k ,  1935   l  or portions thereof and/or choosing an appropriate material for support members  1935   k ,  1935   l  (as shown in  FIG. 19G ) may distribute stress along the bending portion of tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 19H  illustrates another support structure for use in an embodiment of connector  1910 . The support structure shown in  FIG. 19H  includes support members  1935   m ,  1935   n  that are similar to support members  1935   k ,  1935   l  (as shown in  FIG. 19G ) except that the height of support members  1935   m ,  1935   n  varies along a portion of the length of tongue  1930 . More specifically, the surfaces opposite surfaces  1936   m ,  1936   n  are curved surfaces. As with other embodiments described herein, varying the durometer of support members  1935   m ,  1935   n  or portions thereof, choosing an appropriate material for support members  1935   m ,  1935   n  and/or shaping or sizing support members  1935   m ,  1935   n  may be used to allow stress to be distributed along the bending portion of tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 191  illustrates yet another support structure for use in an embodiment of connector  1910 . The support structure shown in  FIG. 19I  includes support members  1935   o ,  1935   p  that are similar to support members  1935   k ,  1935   l , except that support members  1935   o ,  1935   p  include recesses at the surfaces opposite surfaces  1936   o ,  1936   p . Support members  1935   o ,  1935   p  each include rectangular prism shaped recesses of varying sizes. These recesses, recesses  1938   m - 1938   p  may be sized and/or shaped such that support members  1935   o ,  1935   p  can distribute stress along the bending portion of tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 19J  illustrates yet another support structure for use in an embodiment of connector  1910 . The support structure shown in  FIG. 19J  includes support members  1935   q ,  1935   r  that are similar to support members  1935   k ,  1935   l  (as shown in  FIG. 19G ) except that the height of support members  1935   q ,  1935   r  varies about a portion of the length of tongue  1930 . More specifically, as shown in  FIG. 19J , the surfaces opposite surfaces  1936   q ,  1936   r  include flat and angled portions. As with other embodiments described herein, varying the durometer of support members  1935   q ,  1935   r  or portions thereof, choosing an appropriate material for support members  1935   q ,  1935   r  and/or shaping or sizing support members  1935   q ,  1935   r  may be used to allow stress to be distributed along the bending portion of tongue  1930  while providing sufficient contact normal force for the contacts of tongue  1930 . 
       FIG. 19K  is a cross sectional side view of the USB plug connector of  FIGS. 19A and 19A-1  with a one-piece support structure according to an embodiment of the present invention. The support structures shown in  FIG. 19K  may be similar to support structure  1935 , as shown in  FIGS. 19C-19J , except that support structure  1931  may be integrally formed as one piece. In some embodiments, support structure  1931  may be similarly sized and similarly shaped as of the aforementioned support structure. As shown in  FIG. 19K , support structure  1931  may include a slot. Tongue  1930  extends through base  1937  and support structure  1931  and between a surface  1941  of slot  1933  and towards opening  1925 . During a mating event, tongue  1930  may either deflect towards and make contact with a first portion  1941   a  of slot  1933  or defect towards and make contact with a second portion  1941   b  of slot  1933 . As such, slot  1933  may distribute stress across the bending portions of tongue  1930  (e.g., a portion of contact frames). 
     A person of skill in the art will recognize instances where the features of one of the above embodiments can be combined with the features of another of the above embodiments and where one of the above embodiments may be modified according to any of the other above embodiments. The structures and methods shown in  FIGS. 19A-19K  and discussed in relation thereto may also be implemented in various ways in other embodiments of the present invention. 
     It will be appreciated that connector  1910  is illustrative and that variations and modifications are possible. The shapes and number of contact frames of connector  1910  can be varied in ways not specifically described here. Further, while connector  1910  above was described with reference to a reversible USB plug connector, the invention may apply to other connectors male or female and reversible and otherwise. Further, the contact frames of connector  1810  may be replaced with a PCB, as discussed above with reference to other figures. 
     An example of another embodiment of the present invention is shown in the following figures. 
       FIGS. 12A and 12B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector  1210  according to one embodiment of the present invention. Connector  1210  includes a body  1215  and a shell  1220  extending longitudinally away from body  1215  in a direction parallel to the length of connector  1210 . Shell  1220  includes an opening  1225  that communicates with a cavity defined in part by first, second, left and right inner surfaces  1220   a - 1220   d  of shell  1220  and a tongue  1230 . As shown in  FIGS. 12A and 12B , tongue  1230  may be centrally located within shell  1220  and extend parallel to the length of connector  1210 . Contacts  1240   a - 1240   d  are disposed on a first major surface  1230   a  and four additional contacts (only contact  1240   g  is shown in  FIG. 1B ) are disposed on a second major surface  1230   b . As also shown in  FIGS. 12A and 12B , tongue  1230  may include a bullnose tip  1230   c  for reasons that will be explained again below. 
     As shown in  FIGS. 12A and 12B , connector  1210  can have a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a corresponding receptacle connector in both a first orientation where surface  1230   a  is facing up or a second orientation where surface  1230   a  is rotated 180 degrees and facing down. Specifics of general double or dual orientation design are discussed in greater detail above. Simply stated, contacts disposed on first surface  1230   a  (contacts  1240   a - 1240   d ) mate with contacts of the corresponding receptacle connector in one orientation and contacts disposed on second surface  1230   b  mate with contacts of the corresponding receptacle connector in the other orientation. 
     Tongue  1230  may be a PCB having contacts, which PCB may be overmolded with one or more of a variety of dielectric materials including flexible, wear resistant materials such as LCP, POM, Nylon and others. Tongue  1230  may vertically translate either toward first or second inner surfaces  1220   a ,  1220   b  of shell  1220  when connector  1210  is inserted into a corresponding receptacle connector. This vertical translation may be facilitated by an elevator mechanism  1290 , e.g., a spring or other vertical translation guide, that may not allow tongue  1230  to move horizontally or pivot. Elevator mechanism  1290  may be engaged as bullnose tip  1230   c  comes into contact with internal features of a corresponding receptacle connector during an insertion event and may vertically translate tongue  1230  to the appropriate region within a corresponding receptacle connector, allowing contacts disposed on either surface  1230   a  or  1230   b  of the plug connector  1210  to mate with contacts on the corresponding receptacle connector. 
     As mentioned earlier, tongue  1230  may be centrally located within opening  1225  of shell  1220 . For example, tongue  1230  may be positioned within opening  1225  such that its distance from first and second inner surfaces  1220   a ,  1220   b  causes connector  1210  to always vertically translate, with the assistance of bullnose tip  1230   c  and elevator mechanism  1290 , toward the appropriate region within a corresponding receptacle connector regardless of whether plug connector  1210  is in the first or second orientation, as described above. 
     Body  1215  is generally the portion of connector  1210  that a user will hold onto when inserting or removing connector  1210  from a corresponding receptacle connector. Body  1215  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. While not shown in  FIG. 12A or 12B , a cable and a portion of shell  1220  may extend within and be enclosed by body  1215 . In addition, electrical contact to the contacts of surfaces  1230   a ,  1230   b  can be made with individual wires in a cable within body  1215 . In one embodiment, a cable includes a plurality of individual insulated wires for connecting to contacts of surfaces  1230   a ,  1230   b  that are soldered to bonding pads on a PCB housed within body  1215  or on tongue  1230  when tongue  1230  is a PCB. The bonding pads on the PCB may be electrically coupled to corresponding individual contacts of surfaces  1230   a  and  1230   b . In some embodiments, contacts of one of surfaces  1230   a  and  1230   b  to be shorted through tongue  1230  to corresponding contacts on the other of surfaces  1230   a  and  1230   b  and then appropriately routed to the individual wires of a cable within body  1215 . 
     The contacts of tongue  1230  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material. In some embodiments, contacts can be printed on surfaces PCB  1232 . As with standard USB plug connectors, plug connector  1210  may include contacts for power, ground and a pair of differential data signals (e.g., data transmit). For example, contact  1240   a  (not shown in  FIG. 12A ) may be a ground pin, contact  1240   b  may be a Data+pin, contact  1240   c  may be a Data−pin, and contact  1240   d  may be a power pin (VBUS). As mentioned earlier, the four additional contacts disposed on second major surface  1230   b  can be positioned so that the contacts on first and second major surfaces  1230   a ,  1230   b  are arranged in a symmetric manner and have the same pinout. In this manner, either of two intuitive insertion orientations may result in the same plug connector  1210  pinout being mated with corresponding contacts of a receptacle connector during a mating event. 
     A sensing circuit as described above may be included with connector  1210  and/or a corresponding receptacle connector. 
     An example of another embodiment of the present invention is shown in the following figures. 
       FIGS. 13A and 13B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector  1310  according to one embodiment of the present invention. Connector  1310  includes a body  1315  and a shell  1320  extending longitudinally away from body  1315  in a direction parallel to the length of connector  1310 . Shell  1320  includes an opening  1325  that communicates with a cavity defined by first, second, left and right inner surfaces  1320   a - 1320   d  of shell  1320 , spring contacts  1340   a - 1340   d , and a support structure  1335 . As shown in  FIGS. 13A and 13B , spring contacts  1340   a - 1340   d  may be centrally located between first and second inner surfaces  1320   a ,  1320   b  and extend parallel to the length of connector  1310 . As also shown in  FIGS. 13A and 13B , a bullnose tip may be formed at the distal ends of spring contacts  1340   a - 1340   d.    
     As shown in  FIGS. 13A and 13B , connector  1310  can have a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a corresponding receptacle connector in both a first orientation where surface  1330   a  is facing up or a second orientation where surface  1330   a  is rotated 180 degrees and facing down. To allow for the orientation agnostic feature of connector  1310 , spring contacts  1340   a - 1340   d  are not polarized. Specifics of general double or dual orientation designs are discussed in detail above. Simply stated, one side of spring contacts  1340   a - 1340   d  mate with contacts of a corresponding receptacle connector in one orientation and the other side of spring contacts  1340   a - 1340   d  may mate with contacts of a corresponding receptacle connector in the other orientation. 
     Structural support  1335  may be made from a variety of dielectric materials, including flexible polymers. The materials used to form structural support  1335  may be chosen such that spring contacts  1340   a - 1340   d  deflects either toward first or second inner surfaces  1320   a ,  1320   b  of shell  1320  when connector  1310  is inserted into a corresponding receptacle connector. This deflection may occur as the distal tip of spring contacts  1340   a - 1340   d , which may be a bullnose tip, comes into contact with internal features of a corresponding receptacle connector and leads spring contacts  1340   a - 1340   d  to the appropriate region within a corresponding receptacle connector, allowing spring contacts  1340   a - 1340   d  to mate with contacts on the corresponding receptacle connector. 
     As mentioned earlier, spring contacts  1340   a - 1340   d  may be centrally located within opening  1325  of shell  1320 . For example, spring contacts  1340   a - 1340   d  may be positioned within opening  1325  such that its distance from first and second inner surfaces  1320   a ,  1320   b  causes spring contacts  1340   a - 1340   d  to always deflect, possibly with the assistance of bullnose tips, toward the appropriate region within a corresponding receptacle connector regardless of whether plug connector  1310  is in the first or second orientation, as described above. 
     Body  1315  is generally the portion of connector  10  that a user will hold onto when inserting or removing connector  1310  from a corresponding receptacle connector. Body  1315  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. While not shown in  FIG. 13A or 13B , a cable and a portion of shell  1320  may extend within and be enclosed by body  1315 . Also, electrical contact to spring contacts  1340   a - 1340   d  can be made with individual wires in a cable within body  1315 . In one embodiment, a cable includes a plurality of individual insulated wires for connecting to spring contacts  1340   a - 1340   d  that are soldered to bonding pads on a PCB housed within body  1315 . Thus, the bonding pads on the PCB may be electrically coupled to corresponding individual spring contacts  1340   a - 1340   d.    
     Spring contacts  1340   a - 1340   d  can be made from copper, nickel, brass, a metal alloy or any other appropriate conductive material. As with standard USB plug connectors, plug connector  1310  may include contacts for power, ground and a pair of differential data signals (e.g., data transmit). For example, contact  1340   a  may be a ground pin, contact  1340   b  may be a Data+pin, contact  1340   c  may be a Data−pin, and contact  1340   d  may be a power pin (VBUS). 
     A sensing circuit as described above may be included with connector  1310  and/or a corresponding receptacle connector. 
     An example of another embodiment of the present invention is shown in the following figures. 
       FIGS. 14A and 14B  are partial cross sectional perspective and cross sectional views, respectively, of a USB plug connector  1410  according to one embodiment of the present invention. Connector  1410  includes a body  1415  and a shell  1420  extending longitudinally away from body  1415  in a direction parallel to the length of connector  1410 . Shell  1420  contains a first and second pistoning contact blocks  1492   a ,  1492   b . Springs  1494   a  and  1494   b  may bias pistoning blocks  1492   a  and  1492   b , respectively, in the position shown in  FIG. 4B . When a pistoning contact blocks  1492   a  and/or  1492   b  are pressed into shell  1420  (e.g., during a mating event with a receptacle connector corresponding to plug connector  1410 ), springs  1494   a  and/or  1494   b  may compress in order to allow this movement. And when a pressing force is removed from pistoning contact blocks  1492   a  and/or  1492   b , springs  1494   a  and/or  1494   b  may cause pistoning contact blocks  1492   a  and/or  1492   b  to return to their positions as shown in  FIG. 14B . Additionally, when one of pistoning blocks  1492   a ,  1492   b  is pressed into shell  1420 , a tongue  1430  may be revealed. Tongue  1430  may be centrally located within shell  1420  and extend parallel to the length of connector  1410 . Four contacts (e.g., contacts  1440   a  and  1440   e  as shown in  FIG. 14B ) may be disposed on both of first and second major surfaces of tongue  1430 . 
     As shown in  FIGS. 14A and 14B , connector  1410  can have a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a corresponding receptacle connector in both a first orientation as shown in  FIG. 14A  and a second orientation where connector  1410  is rotated 180 degrees about its length axis. Specifics of general double or dual orientation designs are discussed in greater detail above. Simply stated, the dual orientation design of connector  1410  allows one set of four contacts of  1410  to mate with contacts of the corresponding receptacle connector in the first and in the second orientation. 
     Tongue  1430  may be any of the tongue embodiments previously described herein. However, a rigid embodiment of tongues according to the present invention may be useful for connector  1410 . The contacts of tongue  1430  may also be any of the contacts embodiments previously described herein. 
     Body  1415  is generally the portion of connector  1410  that a user will hold onto when inserting or removing connector  1410  from a corresponding receptacle connector. Body  1415  can be made out of a variety of materials and in some embodiments is made from a dielectric material, such as a thermoplastic polymer formed in an injection molding process. While not shown in  FIG. 14A or 14B , a cable and a portion of shell  1420  may extend within and be enclosed by body  1415 , as described in relation to other embodiments of the present invention. 
     A sensing circuit as described above may be included with connector  1410  and/or a corresponding receptacle connector. 
     Also, while a number of specific embodiments were disclosed with specific features, a person of skill in the art will recognize instances where the features of one embodiment can be combined with the features of another embodiment. For example, some specific embodiments of the invention set forth above were illustrated with specific tongue or tab designs. A person of skill in the art will readily appreciate that any of the tongues or tab described herein, as well as others not specifically mentioned, may be used instead of or in addition to the tongue or tab discussed with respect to specific embodiments of the present invention. As another example, some specific embodiments of the invention set forth above were illustrated with cable assemblies having a cable connected to a USB connector. A person of skill in the art will readily appreciate that any of the cable assemblies herein, as well as others not specifically mentioned, may be modified to be a USB flash drive or another device that includes a USB connector but does not include a cable. Also, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the inventions described herein.

Metadata:
Filing Date: 20140218
Publication Date: 20160524
Grant Date: 20160524
Priority Date: 20130124
Inventors: JONES WARREN Z.
SOOHOO ERIC T.
GOLKO ALBERT J.
LYNCH STEPHEN BRIAN
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/055", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R29/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/64", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/055", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/64", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/055", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R29/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/81", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 51208030