PATENT DOCUMENT

Publication Number: US-10622756-B1
Application Number: US-201916373539-A
Country: US
Kind Code: B1

Title: Gaskets for sealing spring-loaded contacts

Abstract:
Structures and methods for connector assemblies and their spring-loaded contacts that can resist corrosion, consume a minimal volume in an electronic device, and are readily manufactured.

Claims:
What is claimed is: 
     
       1. A connector assembly comprising:
 a connector assembly housing having a first passage and a second passage; 
 a first spring-loaded contact in the first passage; 
 a second spring-loaded contact in the second passage, wherein each of the first spring-loaded contact and the second spring-loaded contact comprises:
 a barrel having a bottom surface at a first end and a front opening at a second end; 
 a plunger in the barrel and having a contacting portion extending from the front opening of the barrel and a top surface of the connector assembly housing; and 
 a spring between the bottom surface of the barrel and a back surface of the plunger; and 
 
 a first inner gasket around the plunger of the first spring-loaded contact; and 
 a second inner gasket around the plunger of the second spring-loaded contact, wherein each of the first inner gasket and the second inner gasket comprises:
 an outer ring located on the top surface of the connector assembly housing; and 
 an inner ring around the plunger of a corresponding spring-loaded contact. 
 
 
     
     
       2. The connector assembly of  claim 1  wherein each of the first inner gasket and the second inner gasket further comprises a bellows between the outer ring and the inner ring. 
     
     
       3. The connector assembly of  claim 2  wherein the first inner gasket and the second inner gasket further comprise a recessed portion between the outer ring and the inner ring. 
     
     
       4. The connector assembly of  claim 2  wherein the plunger for each of the first spring-loaded contact and the second spring-loaded contact comprises a circumferential groove to accept the inner ring of the corresponding inner gasket. 
     
     
       5. The connector assembly of  claim 2  further comprising an outer gasket comprising a rigid base and a pliable seal, wherein the first inner gasket and the second inner gasket are between the connector assembly housing and the rigid base. 
     
     
       6. The connector assembly of  claim 5  wherein the pliable seal is against a housing of an accessory when the accessory and an electronic device housing the connector assembly are mated. 
     
     
       7. An electronic device comprising:
 a device enclosure at least partially housing the electronic device; 
 a connector assembly housing located in the device enclosure and having a first passage and a second passage; 
 a first spring-loaded contact in the first passage; 
 a second spring-loaded contact in the second passage, wherein each of the first spring-loaded contact and the second spring-loaded contact comprises:
 a barrel having a bottom surface at a first end and a front opening at a second end; 
 a plunger in the barrel and having a contacting portion extending from the front opening of the barrel, a top surface of the connector assembly housing, and a surface of the device enclosure; and 
 a spring between the bottom surface of the barrel and a back surface of the plunger; and 
 
 a first inner gasket around the plunger of the first spring-loaded contact; 
 a second inner gasket around the plunger of the second spring-loaded contact; and 
 an outer gasket comprising a rigid base and a pliable seal, wherein the first inner gasket and the second inner gasket are between the connector assembly housing and the rigid base. 
 
     
     
       8. The electronic device of  claim 7  wherein each of the first inner gasket and the second inner gasket comprises:
 an outer ring located on the top surface of the connector assembly housing; and 
 an inner ring around the plunger of a corresponding spring-loaded contact. 
 
     
     
       9. The electronic device of  claim 8  wherein each of the first inner gasket and the second inner gasket further comprises a bellows between the outer ring and the inner ring. 
     
     
       10. The electronic device of  claim 8  wherein the first inner gasket and the second inner gasket further comprise a recessed portion between the outer ring and the inner ring. 
     
     
       11. The electronic device of  claim 8  wherein the plunger for each of the first spring-loaded contact and the second spring-loaded contact comprises a circumferential groove to accept the inner ring of the corresponding inner gasket. 
     
     
       12. The electronic device of  claim 8  wherein the first inner gasket and the second inner gasket are between the connector assembly housing and the rigid base. 
     
     
       13. The electronic device of  claim 12  wherein the pliable seal is against a housing of an accessory when the accessory and the electronic device are mated. 
     
     
       14. An electronic system comprising:
 an accessory having a first side and a first magnet having a north pole and a south pole laterally positioned along the first side; and 
 an electronic device comprising a first plurality of magnets, the first plurality of magnets comprising:
 a first magnet having a south pole proximately located to the north pole of the first magnet in the accessory when the accessory and the electronic device are mated; 
 a second magnet having a south pole proximately located to the north pole of the first magnet in the accessory and a north pole proximately located to the south pole of the first magnet in the accessory when the accessory and the electronic device are mated; and 
 a third magnet having north pole proximately located to the south pole of the first magnet in the accessory when the accessory and the electronic device are mated. 
 
 
     
     
       15. The electronic system of  claim 14  wherein the accessory further comprises a second magnet having a north pole near a side of the accessory and the electronic device further comprises a fourth magnet having south pole proximately located to the north pole of the second magnet in the accessory. 
     
     
       16. The electronic system of  claim 14  wherein the electronic device further comprises a case having a base portion and a lid, wherein the base portion includes a recess to accept the accessory, and the lid comprises a retention feature to provide a force pushing the accessory into the recess when the lid is closed. 
     
     
       17. The electronic device of  claim 16  wherein the retention feature is substantially hollow and has a plurality of support ribs. 
     
     
       18. The electronic system of  claim 14  wherein the electronic device further comprises:
 a connector assembly housing having a first passage and a second passage; 
 a first spring-loaded contact in the first passage; 
 a second spring-loaded contact in the second passage, wherein each of the first spring-loaded contact and the second spring-loaded contact comprises:
 a barrel having a bottom surface at a first end and a front opening at a second end; 
 a plunger in the barrel and having a contacting portion extending from the front opening of the barrel and a top surface of the connector assembly housing; and 
 a spring between the bottom surface of the barrel and a back surface of the plunger; and 
 
 a first inner gasket around the plunger of the first spring-loaded contact; and 
 a second inner gasket around the plunger of the second spring-loaded contact. 
 
     
     
       19. The electronic system of  claim 18  further comprising an outer gasket comprising a rigid base and a pliable seal, the rigid base against the first inner gasket and the second inner gasket. 
     
     
       20. The electronic system of  claim 19  wherein the pliable seal is against a housing of the accessory when the accessory and the electronic device are mated.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. provisional application No. 62/735,804, filed Sep. 24, 2018. 
    
    
     BACKGROUND 
     Power and data can be provided from one electronic device to another over contacts on the electronic devices. In some electronic systems, contacts of two electronic devices can come into direct contact with each other without the need for intervening cables. For example, spring-loaded contacts on a first electronic device can form physical and electrical connections with contacts on a surface of a second electronic device. The spring-loaded contacts of the first electronic device can be housed in a connector assembly, which can be located in a device enclosure that at least partially houses the first electronic device. 
     These contacts and connector assemblies can be exposed to liquids and fluids that can cause them to corrode. For example, a user can purposely or inadvertently submerge the first or second electronic device in a liquid. A user can spill a liquid or perspire on contacts of either or both of the first or second electronic devices. This moisture can cause one or more contacts to corrode, particularly where a voltage is present on the one or more contacts. This corrosion can impair the operation of an electronic device and in severe cases can render the electronic device inoperable. Even where operation is not fully impaired, device operation can become inconsistent or unreliable. Also, this corrosion can mar the appearance of the contacts. 
     Electronic devices using these connector assemblies can be small. As a result, these connector assemblies can consume a large amount of space inside the electronic device. Accordingly, it can be desirable that these connector assemblies be small. 
     Also, some of these electronic devices become tremendously popular. As a result, connector assemblies on electronic devices can be sold in very large quantities. Therefore, it can be desirable that these connector assemblies be readily manufactured such that customer demand for them can be met. 
     Thus, what is needed are structures and methods for connector assemblies that can resist corrosion, consume a minimal volume in an electronic device, and are readily manufactured. 
     SUMMARY 
     Accordingly, embodiments of the present invention can provide structures and methods for connector assemblies that can resist corrosion, consume a minimal volume in an electronic device, and are readily manufactured. 
     An illustrative embodiment of the present invention can provide connector assemblies that can provide movable contacts at a surface of an electronic device. The connector assemblies can include a nonconductive connector assembly housing supporting one, two, three, or more movable contacts. Each movable contact can be a spring-loaded contact. The spring-loaded contacts can have contacting portions that emerge from corresponding openings in the connector assembly housing. 
     The connector assembly can be located in a device enclosure, where the device enclosure can fully, substantially, or at least partially house the connector assembly and other electronic components for the electronic device. The connector assembly can include the connector assembly housing to support the spring-loaded contacts. The spring-loaded contacts can include a plunger located in a barrel, where the plunger can move in the barrel. The barrel can have a front opening that is narrowed to limit the travel of the plunger, which can have a widened base portion and a narrow contacting portion extending from the barrel. This can prevent the plunger from exiting the barrel. The barrel can include barbs along its side to help to secure the barrel in the connector assembly housing. A spring can be located in the barrel and between a backside of the plunger and a back of the barrel to bias the plunger out of the barrel. An inner gasket can be located between the connector assembly housing and the spring-loaded contact. This inner gasket can help to prevent the ingress of liquid, moisture, debris, or other substances into the connector assembly itself and the electronic device housing the connector assembly. 
     In these and other embodiments of the present invention, an inner gasket can be located between the connector assembly housing and the plunger of each spring-loaded contact. For example, the connector assembly housing can include a top surface. The top surface can be positioned around the plunger of a spring-loaded contact, where the plunger passes through an opening in the connector assembly housing. The inner gasket can have an outer ring that can be attached to the top surface of the connector assembly housing. The inner gasket can further have an inner ring that can fit around a circumference of the contacting portion of the plunger. The inner gasket can be formed of a pliable material such that the plunger can be depressed when a connection is formed with a corresponding contact on a second electronic device and extended when the connection is broken. 
     The contact assembly can be located in a device enclosure such that the outer ring of the inner gasket is between the top surface of the connector assembly housing and a bottom or inside surface of the device enclosure. This can help to secure the inner gasket in place, thereby improving the resulting seal. The device enclosure can include openings, recesses, and other features to allow access to the contacting portions of the spring-loaded contacts by contacts of a second electronic device, such as an accessory device. In these and other embodiments of the present invention, an interference rib can be formed on the top surface of the connector assembly housing and positioned under the outside ring of the inner gasket. This can help to seal the outside ring of the inner gasket to the connector assembly housing. Adhesives, such as pressure-sensitive adhesives, temperature-sensitive adhesives, or heat-activated adhesives can be used to attach the inner gaskets to any or all of a connector assembly housing, a device enclosure, or a plunger of the spring-loaded contact. 
     These inner gaskets can help to protect the ingress path from an outside of the device enclosure to the inside of the electronic device. For example, it can protect the ingress path from an outside of the device enclosure, though a spring-loaded contact between the plunger and barrel, and into the electronic device. This can help to reduce an amount of liquid or other substances that can enter and corrode the inside of the spring-loaded contact and electronic device. It can also protect the ingress path from an outside of the device enclosure, between the plunger and connector assembly housing, and into the electronic device. This can help to reduce an amount of liquid or other substances that can enter and corrode the outside of the spring-loaded contact and electronic device. 
     In these and other embodiments of the present invention, the inner gasket can further include a bellows between the outer ring and the inner ring. These bellows can form a recessed portion. Liquid or other material can flow away from the plunger and instead gather at this recessed portion. This can help to prevent or reduce the corrosion of the plunger. The liquid or other material can evaporate while it is located in the recessed portion of the bellows thereby reducing the corrosion of the plunger. 
     In these and other embodiments of the present invention, the inner gasket can be made of various materials, such as silicone, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or other elastomer or other material or combination of materials. The material can be a low compression set material that is flexible and soft. It can have a Shore durometer of 20A, 30A, 45A, or it can have another shore durometer. 
     In these and other embodiments of the present invention, an accessory device can include contacts that mate with the spring-loaded contacts of the electronic device. The accessory device contacts can be located on a surface of the accessory device. Moisture or other corrosion inducing substances can bridge two or more of the contacts of the accessory device thereby leading to damage of the accessory device. For example, moisture, such as sweat, can bridge a power and a ground contact on the accessory device. When the accessory device is charged, current can flow into the accessory device contacts in the presence of this moisture. This can cause the plating on the contacts to ionize and corrode. Accordingly, these and other embodiments of the present invention can provide an outer gasket that can provide a seal between contacts on the accessory device. 
     In these and other embodiments of the present invention, the outer gasket can be formed using a two-shot molding process. The first shot can form a rigid base, while the second shot can form a pliable seal over at least a portion of the rigid base. The outer gasket can be located between the inner gaskets and the electronic device housing. The rigid base of the outer gasket can provide support for the inner gaskets and can include openings for plungers of the spring-loaded contacts. The pliable seal of the outer gasket can form a seal between the rigid base of the outer gasket and an electronic device housing to prevent leakage into the electronic device. The pliable seal of the outer gasket can also form seals around contacts of the accessory device and around spring-loaded contacts of the electronic device. The pliable seal can include individual rings, each around an opening for a plunger of a spring-loaded contact of the electronic device and each around a circumference or perimeter of an accessory device contact. 
     The pliable outer seal can isolate contacts at a surface of the accessory device from each other to prevent moisture bridging. Accordingly, in these and other embodiments of the present invention, various structures and techniques can be used to improve this seal and to further isolate and protect accessory device contacts of the accessory device. 
     For example, the electronic device can be a docking station or charging case designed to hold and charge one, two, three, or more than three accessory devices. The charging case can have a lid that can close when the accessory devices are in place. Retention features can be included on an inside surface of the lid. These retention features can provide a force on the accessory devices pushing them into the pliable seals of the outer gaskets on the electronic device. This force can act to improve the seal and therefore the isolation between contacts of the accessory devices. 
     In these and other embodiments of the present invention, the retention features can be formed as part of the electronic device lid or other housing portion. The retention features can be formed separately from and attached to the electronic device lid or other housing portion. The retention features can be placed under a liner or other layer that holds them in place against the electronic device lid or other housing portion. There can be one or more retention features for each accessory device. Either or both of the retention features or electronic device lid can be pliable. The retention features can be substantially hollow pliable structures. The retention features can include one or more ribs or other support structures to assist them in holding their shape. 
     In these and other embodiments of the present invention, magnets can be used to improve this seal and to further isolate contacts of the accessory device. To save space in an accessory device, each accessory device can include a limited number of magnets, such as one or two magnets. A corresponding array of magnets can be used in the electronic device to hold the accessory device in place to improve the seal provided by the pliable seal of the outer gasket. For example, an accessory device magnet having a north pole and a south pole can be placed laterally along a side of an accessory device. Three magnets can be arranged in the electronic device. A south pole of a first magnet can be placed proximate to the north pole of the accessory device magnet. A second magnet can be placed such that its south pole is proximate to the north pole of the accessory device magnet and its north pole is proximate to the south pole of the accessory device magnet. A third magnet can be placed such that its north pole is proximate to the south pole of the accessory device magnet. Additional magnets can be used to supplement these magnets. For example, a second accessory device magnet can attract a fourth electronic device magnet, where these additional magnets are arranged to provide a magnetic direction in a direction that is orthogonal to the magnetic attraction provided by the above magnets to further secure the accessory device in place in the electronic device. Some or all of these magnets can be rare earth magnets or other types of magnets. 
     In these and other embodiments of the present invention, another gasket or O-ring can be located between the barrel of a spring-loaded contact and the connector assembly housing. Also, other structures, such as barbs on the barrels of the spring-loaded contacts, can be included to protect these leakage paths and help to reduce the amount of ingress of liquids or other substances into the spring-loaded contacts and electronic device. 
     In these and other embodiments of the present invention, the connector assemblies can be kept small by only using two spring-loaded contacts. These contacts can be used to convey power and ground. They can also be used to convey data, or data can be wirelessly transmitted and received by the electronic device. 
     Embodiments of the present invention can provide connector assemblies that can be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, docking stations, smart phones, media phones, storage devices, keyboards, covers, charging cases, portable media players, navigation systems, monitors, power supplies, adapters, audio devices and equipment, remote control devices, chargers, and other devices. These connector assemblies can provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the connector assemblies can be used to convey a data signal, a power supply, and ground. In various embodiments of the present invention, the data signal can be unidirectional or bidirectional and the power supply can be unidirectional or bidirectional. In these and other embodiments of the present invention, the connector assemblies can be used to convey power and ground, while data is transmitted wirelessly. 
     Various embodiments of the present invention can incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention can be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a connector assembly according to an embodiment of the present invention; 
         FIG. 2  illustrates the connector assembly of  FIG. 1  where the connector assembly housing is transparent; 
         FIG. 3  illustrates the connector assembly housing of  FIG. 1  in a device enclosure according to an embodiment of the present invention; 
         FIG. 4  illustrates a cutaway side view of a portion of a connector assembly according to an embodiment of the present invention; 
         FIG. 5  illustrates a spring-loaded contact according to an abundance of the present invention; 
         FIG. 6  illustrates a close-up view of a top of a connector assembly housing according to an embodiment of the present invention; 
         FIG. 7  illustrates a cutaway side view of an inner gasket according to an embodiment of the present invention; 
         FIG. 8  illustrates an exploded view of a portion of an electronic device according to an embodiment of the present invention; 
         FIG. 9  illustrates a cross-section of a portion of an electronic device according to an embodiment of the present invention; 
         FIG. 10  illustrates a cross-section of a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 11  illustrates a close-up view of a cross-section of a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 12  illustrates an electronic system according to an embodiment of the present invention; 
         FIG. 13  illustrates the electronic system of  FIG. 12  where a lid of an electronic device has been closed; 
         FIG. 14  illustrates a retention feature according to an embodiment of the present invention; 
         FIG. 15  illustrates a side view of a retention feature according to an embodiment of the present invention; 
         FIG. 16  illustrates an internal portion of an electronic device according to an embodiment of the present invention; 
         FIG. 17  illustrates the internal portion of an electronic device as shown in  FIG. 16 , where a cover for magnets has been removed; and 
         FIG. 18  illustrates an array of magnets that can be employed in an electronic system according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates a connector assembly according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, connector assembly housing  200  can support two spring-loaded contacts  100 , though one, three, or more than three spring-loaded contacts  100  can be included in connector assembly housing  200 . Connector assembly housing  200  can further include flanges  210  having openings  212  for fasteners (not shown.) Fasteners can be inserted into openings  212  and can secure connector assembly housing  200  to device enclosure  410  (shown in  FIG. 9 .) Connector assembly housing  200  can further include posts  214 . Posts  214  can be inserted into a corresponding opening (not shown) in device enclosure  410  or other housing portion. Connector assembly housing  200  can further include top surface  216 . Plungers  110  can extend through top surface  216  of connector assembly housing  200 . Inner gasket  300  can extend from around plunger  110  to top surface  216  of connector assembly housing  200  to form a seal. Inner gasket  300  can include bellows or recess  310 . 
     Connector assembly housing  200  can be formed in various ways in various embodiments of the present invention. For example, connector assembly housing  200  can be formed by injection molding, insert molding, 3-D printing, or other method. It can be formed of nylon, plastic, polycarbonate, liquid-crystal polymer (LCP), or other material. 
       FIG. 2  illustrates the connector assembly of  FIG. 1  where the connector assembly housing is transparent. Again, two spring-loaded contacts  100  can be located in passages in connector assembly housing  200 . Spring-loaded contacts  100  can include barb  122  and barb  124  on barrel  120 . Barb  122  and barb  124  can help to secure spring-loaded contacts  100  in connector assembly housing  200 . 
     Again, inner gaskets  300  can form a seal between top surface  216  of connector assembly housing  200  and plungers  110  of each spring-loaded contact  100 . Inner gaskets  300  can be pliable such that plunger  110  can be depressed and can extend as connections with corresponding contacts are made and broken. Inner gaskets  300  can include a bellows or recess (or reservoir)  310 . Liquid or other material can flow away from plunger  110  and gather instead in bellows or recess  310 . This can help to prevent or reduce the corrosion of plunger  110 . The liquid or other material can evaporate while it is located in the bellows or recess  310  thereby reducing the corrosion of plunger  110 . 
     Inner gaskets  300  can help to protect an ingress path from an outside of device enclosure  410  (shown in  FIG. 9 ) and into electronic device  400  (shown in  FIG. 12 .) For example, they can protect the ingress path from an outside of device enclosure  410 , though spring-loaded contact  100  between plunger  110  and barrel  120 , and into electronic device  400 . This can help to reduce an amount of liquid or other substance that can enter and corrode the inside of spring-loaded contact  100  and electronic device  400 . They can also protect the ingress path from an outside of device enclosure  410 , between plunger  110  and connector assembly housing  200 , and into electronic device  400 . This can help to reduce an amount of liquid or other substance that can enter and corrode the outside of spring-loaded contact  100  and electronic device  400 . 
       FIG. 3  illustrates the connector assembly housing of  FIG. 1  in a device enclosure according to an embodiment of the present invention. As before, spring-loaded contact  100  can be housed in connector assembly housing  200 . Plunger  110  of spring-loaded contact  100  can emerge through opening  270  in connector assembly housing  200 . Plunger  110  of spring-loaded contact  100  can also emerge through opening  402  in device enclosure  410 . 
     Inner gasket  300  can form a seal between top surface  216  of connector assembly housing  200  and plunger  110 . Inner gaskets  300  can also form seals between device enclosure  410  and connector assembly housing  200 . Inner gasket  300  can include bellows or recess  310  as before. 
       FIG. 4  illustrates a cutaway side view of a portion of a connector assembly according to an embodiment of the present invention. In this example, plungers  110  can emerge through openings  270  in connector assembly housing  200 . Inner gasket  300  can form a seal between connector assembly housing  200  top surface  216  and plunger  110 . Inner gaskets  300  can include outer ring  330 . Outer ring  330  can be located over interference rib  220  on top surface  216  of connector assembly housing  200 . Outer ring  330  can include surface  340 , which can mate with device enclosure  410  (shown in  FIG. 3 .) Inner gaskets  300  can further include inner ring  320 , which can fit in circumferential groove  112  around plunger  110 . Inner gaskets  300  can further include bellows or recess  310 . Again, liquid or other materials can accumulate in recess  310  and thus be kept away from plunger  110 . This can help to slow or reduce the corrosion of plunger  110 , as well as the remaining portions of spring-loaded contact  100  (shown in more detail in  FIG. 5 ) and electronic device  400  (shown in  FIG. 12 ) housed by device enclosure  410  (shown in  FIG. 9 .) 
       FIG. 5  illustrates a spring-loaded contact according to an embodiment of the present invention. Again, spring-loaded contact  100  can include plunger  110  emerging from front opening  130  in barrel  120 . Barb  122  and barb  124  can be located on barrel  120 . Barb  122  and barb  124  can help to secure spring-loaded contact  100  in connector assembly housing  200  (as shown in  FIG. 2 .) Spring-loaded contact  100  can further include a base portion  140  and tail  150 . Tail  150  can be soldered or otherwise connected to a wire, a trace on a board (not shown), or other conduit. Base portion  140  can form a rear wall of a cavity inside barrel  120 . Barrel  120  can have front opening  130  that is narrowed to limit the travel of plunger  110 , which can have a widened base portion  111  (shown in  FIG. 11 ) and a narrow contacting portion  113  (shown in  FIG. 11 ) extending from barrel  120 . A spring  102  (shown in  FIG. 9 ) can be located in barrel  120  and can be between plunger  110  and the rear wall. As plunger  110  forms a physical and electrical connection with a corresponding contacts of a corresponding accessory device  1100  (shown in  FIG. 10 ), plunger  110  can be pushed down into barrel  120 , thereby compressing spring  102 . As the corresponding device is removed, plunger  110  can be driven back out of barrel  120  by spring  102 . Again inner gaskets  300  may be flexible or pliable to accommodate these actions. 
       FIG. 6  illustrates a close-up view of a top of a connector assembly housing according to an embodiment of the present invention. Connector assembly housing  200  can include a top surface  216 . Plungers  110  of spring-loaded contacts  100  (shown in  FIG. 2 ) can emerge through opening  270 . Inner gasket  300  (details of which are shown in  FIG. 7 ) can have an outer ring  330  (shown in  FIG. 7 ) to mate with interference rib  220 . Device enclosure  410  (shown in  FIG. 3 ), can compress inner gasket  300  into interference rib  220 , thereby improving the seal formed by inner gasket  300 . Inner gasket  300  can also be located around circumferential groove  112  of plunger  110 . 
     Adhesives, such as pressure-sensitive adhesives, temperature-sensitive adhesives, or heat-activated adhesives can be used to attach inner gaskets  300  to any or all of a connector assembly housing  200 , device enclosure  410 , or plunger  110  of spring-loaded contact  100 . These adhesives can work together or separately with interference rib  220 . 
       FIG. 7  illustrates a cutaway side view of an inner gasket according to an embodiment of the present invention. Inner gasket  300  can include outer ring  330  and inner ring  320 . Inner ring  320  can define an opening  322 , which can allow access for plunger  110  (shown in  FIG. 6 .) Inner ring  320  can fit in circumferential groove  112  (shown in  FIG. 6 ) around plunger  110 . Inner gasket  300  can also include bellows or recess  310 . Bellows or recess  310  can form a reservoir for liquids or other substances in order to protect plunger  110 . Bellows or recess  310  can include a U-shaped portion joining inner ring  320  and outer ring  330 . In these and other embodiments of the present invention, bellows and recess  310  can have other shapes. 
     In these and other embodiments of the present invention, inner gaskets  300  can be made of various materials, such as silicone, thermoplastic polyurethane (TPU), thermoplastic elastomer (TPE), or other elastomer or other material or combination of materials. The material can be a low compression set material that is flexible and soft. It can have a Shore durometer of 20A, 30A, 45A, or it can have another shore durometer. This flexibility can allow plungers  110  on spring-loaded contacts to be depressed and extended while inner gaskets  300  maintain seals between connector assembly housing  200  and plungers  110 . 
     In these and other embodiments of the present invention, an accessory device can include contacts that mate with the spring-loaded contacts of the electronic device. The accessory device contacts can be located on a surface of the accessory device. Moisture or other corrosion inducing substances can bridge two or more of the contacts of the accessory device thereby leading to damage of the accessory device. For example, moisture can bridge a power and a ground contact on the accessory device. When the accessory device is charged, current can flow into the accessory device contacts in the presence of this moisture. This can cause plating on the contacts to ionize and corrode. Accordingly, these and other embodiments of the present invention can provide an outer gasket that can provide a seal between contacts on the accessory device. Examples are shown in the following figures. 
       FIG. 8  illustrates an exploded view of a portion of an electronic device according to an embodiment of the present invention. In this example, outer gasket  800  can be located between inner gaskets  300  of connector assembly  850  and device enclosure  410  of electronic device  400 . As before, connector assembly  850  can include spring-loaded contacts  100  housed in connector assembly housing  200 . Spring-loaded contacts  100  can include plungers  110 , which can physically and electrically connect to accessory device contacts  1020  (shown in  FIG. 10 ) of an accessory device  1000  (shown in  FIG. 12 ) when the accessory device and electronic device  400  are mated. Inner gaskets  300  can be located around plungers  110 . Outer gasket  800  can include openings  802  for plungers  110  of spring-loaded contacts  100 . 
     Connector assembly  850  can be attached to device enclosure  410  by fasteners (not shown), such as screws. These fasteners can pass through the openings  212  in flanges  210  of connector assembly housing  200  and into holes in tabs  414  in device enclosure  410 . 
     Accessory device  1000  can include accessory device contacts  1020  (shown in  FIG. 10 ) that can mate with plungers  110  of spring-loaded contacts  100 . These accessory device contacts  1020  can be located at a surface of accessory device  1000 . Moisture or other corrosive substances can bridge these accessory device contacts  1020 . Again, this can lead to corrosion or other damage to accessory device contacts  1020 . 
     Accordingly, embodiments of the present invention can employ outer gaskets  800 . Outer gaskets  800  can include a rigid base  810 . Rigid base  810  can provide a surface such that inner gaskets  300  can form a seal between rigid base  810  and a top surface  216  of connector assembly housing  200 . A pliable seal  820  can be formed on rigid base  810 . Pliable seal  820  can include raised portions or rings  822 . Rings  822  can engage a surface of a housing for accessory device  1000 . Each ring  822  can surround a circumference or perimeter of an accessory device contact  1020  at the surface of accessory device  1000 . This can prevent moisture bridging from one accessory device contact  1020  to another, thereby reducing corrosion. This is shown further in the following figures. 
       FIG. 9  illustrates a cross-section of a portion of an electronic device according to an embodiment of the present invention. One or more spring-loaded contacts  100  can be located in connector assembly housing  200 . Spring-loaded contacts  100  can include plungers  110 , which can be biased by springs  102 . Pistons  104  can provide an interface between plungers  110  and springs  102 . Further details of spring-loaded contacts  100  can be found in co-pending U.S. patent application Ser. No. 15/722,379, filed Oct. 2, 2017, which is incorporated by reference. 
     Inner gaskets  300  can provide a seal between plungers  110  and connector assembly housing  200 . Outer gaskets  800  can include a rigid base  810 . Inner gaskets  300  can further provide seals between rigid base  810  and connector assembly housing  200 . Pliable seal  820  of outer gasket  800  can be formed on rigid base  810 . Pliable seal  820  can provide a seal around accessory device contacts of an accessory device  1000  (shown in  FIG. 10 ) when the accessory device  1000  is mated with electronic device  400 . Pliable seal  820  can also form a seal between connector assembly housing  200  and device enclosure  410 . An example is shown in the following figure. 
       FIG. 10  illustrates a cross-section of a portion of an electronic system according to an embodiment of the present invention. In this example, accessory device  1000  has been mated with electronic device  400 . Accessory device contacts  1020  of accessory device  1000  can physically and electrically connect to plungers  110  of spring-loaded contacts  100 . Pliable seal  820  of outer gasket  800  can engage housing  1010  of accessory device  1000  to form seals around a circumference or perimeter of some or all of accessory device contacts  1020 . This can help to prevent moisture from bridging between accessory device contacts  1020  on accessory device  1000 . Accessory device contacts  1020  can include tabs  1022  that can be molded in housing  1010  of accessory device  1000  to hold accessory device contacts  1020  in place. 
       FIG. 11  illustrates a close-up view of a cross-section of a portion of an electronic system according to an embodiment of the present invention. Again, plungers  110  of spring-loaded contacts  100  can engage accessory device contacts  1020  of accessory device  1000 . Pliable seal  820  of outer gasket  800  can form a seal around a circumference or perimeter of each of accessory device contacts  1020 . Again, this can prevent moisture from bridging two or more accessory device contacts  1020  on accessory device  1000 . Specifically, pliable seal  820  can engage housing  1010  of accessory device  1000  at points  1110 ,  1112 ,  1114 , and  1116  to form a seal around two accessory device contacts  1020 . 
     With this configuration, inner gaskets  300  can provide a seal between plungers  110  and connector assembly housing  200 . This can prevent moisture leakage from entering the spring-loaded contact  100  and connector assembly housing  200 . Outer gasket  800  can prevent moisture from bridging between accessory device contacts  1020  on accessory device  1000 , as well as plungers  110  of spring-loaded contacts  100 . Pliable seal  820  of outer gasket  800  can also form a seal between rigid base  810  and device enclosure  410 . 
     The pliable outer seal can isolate contacts at a surface of the accessory device from each other to prevent moisture bridging. Accordingly, in these and other embodiments of the present invention, various structures and techniques can be used to improve this seal and to further isolate contacts of the accessory device. 
     For example, the electronic device can be a docking station or charging case designed to hold and charge one, two, three, or more than three accessory devices. The charging case can have a lid that can close when the accessory devices are in place. Retention features can be included on an inside surface of the lid. These retention features can provide a force on the accessory devices pushing them into the pliable seals of the outer gaskets on the electronic device. This force can act to improve the seal and therefore the isolation between contacts of the accessory devices. Examples are shown in the following figures. 
       FIG. 12  illustrates an electronic system according to an embodiment of the present invention. One or more accessory devices  1000  can be inserted into recesses  430  in electronic device  400 . Electronic device  400  can be a docking station or charging case. Accessory devices  1000  can be, or can contain, rechargeable batteries. Electronic device  400  can further include lid  450 , which can close over a top surface of base portion  419  of electronic device  400 . Lid  450  can be attached to base portion  419  of electronic device  400  at hinge  440 . An inside surface  452  of lid  450  can include one or more retention features  1200 . Inside surface  452  of lid  450  can include one or more retention features  1200  for each accessory device  1000 . Retention features  1200  can be formed of a compressible material. Retention features  1200  can apply a force on accessory devices  1000  pushing them into recesses  430 . This force can improve an engagement between accessory device contacts  1020  (shown in  FIG. 10 ) on accessory devices  1000  and plungers  110  (shown in  FIG. 10 ) in electronic device  400 . This force can also improve the seal provided by pliable seal  820  of outer gasket  800  (shown  FIG. 11 .) 
       FIG. 13  illustrates the electronic system of  FIG. 12 . In this figure, lid  450  has been closed and is shown as transparent. Retention features  1200  can provide a force as shown, thereby pushing accessory devices  1000  into recesses  430  in base portion  419  of electronic device  400 . 
     In these and other embodiments of the present invention, the retention features can be formed as part of the electronic device lid or other housing portion. The retention features can be formed separately from and attached to the electronic device lid or other housing portion. The retention features can be placed under a liner or other layer that holds them in place against the electronic device lid or other housing portion. There can be one or more retention features for each accessory device. One or both of the retention features or electronic device lid can be pliable. The retention features can be substantially hollow pliable structures. They can include one or more ribs or other support structures to assist them in holding their shape. Examples are shown in the following figures. 
       FIG. 14  illustrates a retention feature according to an embodiment of the present invention. Retention feature  1200  can be substantially hollow and can include one or more ribs  1210 . Ribs  1210  can help retention feature  1200  to maintain its shape after it is compressed when lid  450  of electronic device  400  is closed, as shown in  FIG. 13 . Top surface  1202  of retention feature  1200  can be attached to in inside surface  452  of lid  450 , as shown in  FIG. 12 . Retention feature  1200  be formed separately or as part of lid  450 . Retention feature  1200  can be held in place by a fabric or other lining on the inside surface  452  of lid  450 . 
       FIG. 15  illustrates a side view of a retention feature according to an embodiment of the present invention. Again, retention feature  1200  can be substantially hollow and can include one or more ribs  1210 , which can provide mechanical support to the retention feature  1200 . 
     In these and other embodiments of the present invention, magnets can be used to improve this seal and to further isolate contacts of the accessory device. To save space in an accessory device, each accessory device can include a limited number of magnets, such as one or two magnets. A corresponding array of magnets can be used in the electronic device to hold the accessory device in place to improve the seal provided by a pliable seal of an outer gasket. For example, an accessory device magnet having a north pole and a south pole can be placed laterally along a side of an accessory device. Three magnets can be arranged in the electronic device. A south pole of a first magnet can be placed proximate to the north pole of the accessory device magnet. A second magnet can be placed such that its south pole is proximate to the north pole of the accessory device magnet and its north pole is proximate to the south pole of the accessory device magnet. A third magnet can be placed such that its north pole is proximate to the south pole of the accessory device magnet. Additional magnets can be used to supplement these magnets. For example, a second accessory device magnet can attract a fourth electronic device magnet, where these additional magnets are arranged to provide a magnetic direction in a direction that is at least substantially orthogonal to the magnetic attraction provided by the above magnets to further secure the accessory device in place in the electronic device. Some or all of these magnets can be rare earth magnets or other types of magnets. Some or all of these magnets may have reversed polarities. Different numbers of magnets may be used in the electronic device and accessory device. Examples of such an arrangement are shown in the following figures. 
       FIG. 16  illustrates an internal portion of an electronic device according to an embodiment of the present invention. This figure illustrates an underside of recess  430  from an internal point in electronic device  400 . Cover  1600  can be attached to device enclosure  410  at points  1610  and can retain one or more magnets (shown in  FIG. 18 .) These one or more magnets can magnetically attract one or more magnets in accessory device  1000  when accessory device  1000  is placed in recess  430 . Housing portion  1634  can house an additional magnet  1650 , which can also attract one or more magnets in accessory device  1000 . Spring-loaded contacts  100  (shown in  FIG. 10 ) can be located in connector assembly housing  200 . Plungers of these spring-loaded contacts  100  can engage contacts on accessory device  1000 , when accessory device  1000  is placed in recess  430 . Connector assembly housing  200  can be attached to device enclosure  410  by using fasteners passed through openings in holes in flanges  210  and tabs  414 , as shown in  FIG. 9 . 
       FIG. 17  illustrates the internal portion of an electronic device as shown in  FIG. 16 , where a cover for magnets has been removed. Specifically, cover  1600  has been removed thereby exposing a plurality of magnets including magnet  1710 , magnet  1720 , and magnet  1730 . Magnet  1710 , magnet  1720 , and magnet  1730  can attract one or more magnets in an accessory device  1000  (shown in  FIG. 10 ), when accessory device  1000  is inserted in recess  430 . Magnet  1650  can also attract one or more magnets in accessory device  1000 . The magnetic attraction provided by magnet  1650 , magnet  1710 , magnet  1720 , and magnet  1730 , can improve the seal provided by pliable seal  820  (shown in  FIG. 8 .) 
       FIG. 18  illustrates a plurality of magnets that can be employed in an electronic system according to an embodiment of the present invention. This figure illustrates magnet  1710 , magnet  1720 , magnet  1730 , and magnet  1650  from  FIG. 17 , which can be located in electronic device  400 . Accessory device  1000  can include magnets  1800  and  1820 . Magnet  1800  can be placed laterally along a side  1002  of accessory device  1000 . A south pole of magnet  1650  can attract a north pole of magnet  1820 . A south pole of magnet  1710  can be proximately located to a north pole of magnet  1800 . A south pole of magnet  1720  can also be proximately located to a north pole of magnet  1800 . The south poles of magnets  1710  and  1720  can attract the north pole of magnet  1800 . A north pole of magnet  1720  can be proximately located to a south pole of magnet  1800 . Also, a north pole of magnet  1730  can be proximately located with the south pole of magnet  1800 . In this way, the north poles of magnet  1720  and magnet  1730  can attract the south pole of magnet  1800 . Again, this can help to retain accessory device  1000  in recess  430 . This can help to improve a seal provided by pliable seal  820  around accessory device contacts  1020  on accessory device  1000 . Magnet  1800  can attract magnet  1710 , magnet  1720 , and magnet  1730  in a first direction while magnet  1820  can attract magnet  1650  in a second direction, where the first direction and the second direction are at least substantially orthogonal to each other. In these and other embodiments of the present invention, some of all of these magnets can be reversed in polarity. Also, in these and other embodiments of the present invention, other numbers of magnets may be used in either or both electronic device  400  and accessory device  1000 . 
     In these and other embodiments of the present invention, an additional inner gasket or O-ring (not shown) can be located between the barrel of a spring-loaded contact and the connector assembly housing. Also, other structures, such as barbs  122  and  124  on barrels  120  of spring-loaded contacts  100 , can be include to protect these leakage paths and help to reduce the amount of ingress of liquids or other substances into the spring-loaded contacts and electronic device. 
     In these and other embodiments of the present invention, a connector assembly housing  200  may support one, two, three, or more than three spring-loaded contacts  100 . Each spring loaded contact  100  may correspond to an individual inner gasket  300 , or more than one spring loaded contact  100  may share an inner gasket  300 . Such a shared inner gasket  300  may include multiple openings  322 , one for each plunger  110  on a spring-loaded contact  100 . Each connector assembly housing  200  may correspond to one or more than one such individual or shared inner gasket  300 , or combination thereof. Also, each spring-loaded contact  100  may have an individual outer gasket  800 , or more than one spring loaded contact  100  may share an outer gasket  800 . Such a shared outer gasket  800  may include multiple openings  802 , one for each plunger  110  on a spring-loaded contact  100 . Each connector assembly housing  200  may correspond to one or more than one such individual or shared outer gasket  800 , or combination thereof. 
     In these and other embodiments of the present invention, connector assemblies can be kept small by only using two spring-loaded contacts  100 . The two spring-loaded contacts  100  can be used to convey power and ground. They can also be used to convey data, or data can be wirelessly transmitted and received by the electronic device (not shown.) 
     Embodiments of the present invention can provide connector assemblies that can be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, charging cases, portable media players, navigation systems, monitors, power supplies, adapters, audio devices and equipment, remote control devices, chargers, and other devices. These connector assemblies can provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus standards including USB Type-C, High-Definition Multimedia Interface, Digital Visual Interface, Ethernet, DisplayPort, Thunderbolt, Lightning, Joint Test Action Group, test-access-port, Directed Automated Random Testing, universal asynchronous receiver/transmitters, clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the connector assemblies can be used to convey a data signal, a power supply, and ground. In various embodiments of the present invention, the data signal can be unidirectional or bidirectional and the power supply can be unidirectional or bidirectional. In these and other embodiments of the present invention, the connector assemblies can be used to convey power and ground, while data is transmitted wirelessly. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20190402
Publication Date: 20200414
Grant Date: 20200414
Priority Date: 20180924
Inventors: TZIVISKOS, GEORGE
KONERU, Vijay Karthik
WIITA, CHRISTOPHER
LE, DUY P.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/17", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2421", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01F7/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2421", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/17", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/2421", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01F7/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/17", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 69885634