PATENT DOCUMENT

Publication Number: US-10298075-B2
Application Number: US-201715442209-A
Country: US
Kind Code: B2

Title: Inductive charging ports for portable computing devices

Abstract:
Connector assemblies may be space efficient, have a high corrosion resistance, are difficult to damage, reduce or prevent moisture leakage into an electronic device housing the connector assembly, are readily assembled, and are reliable. One example may provide an inductive charging port for transferring electrical energy from a first electric device to a second electronic device. As compared to conventional connector inserts and connector receptacles, these inductive charging ports may have a smaller form factor and consume a reduced volume in an electronic device. Corrosion resistance may be provided by including a protective layer or cover portion over what would otherwise be exposed surfaces of a transformer core. O-rings, gaskets, or other structures may be included to reduce moisture leakage into a device. The inductive charging port may include a low number of parts for a simplified assembly, and thermal management of various types may be used to improve reliability.

Claims:
What is claimed is: 
     
       1. An inductive charging port for an electronic device, the inductive charging port comprising:
 a first housing located in a first opening of an enclosure for the electronic device; and 
 an inductive coil around a transformer core, the transformer core fixed to the first housing and the enclosure such that a surface of the transformer core is exposed at the first opening of the enclosure, 
 wherein a cover portion of the first housing covers the surface of the transformer core, and 
 wherein the inductive charging port is sealed by a sealing structure between the enclosure and a sidewall of the first housing. 
 
     
     
       2. The inductive charging port of  claim 1  wherein the sealing structure is an O-ring. 
     
     
       3. The inductive charging port of  claim 1  further comprising a flexible circuit board electrically connected to the inductive coil. 
     
     
       4. The inductive charging port of  claim 3  further comprising a bracket such that the flexible circuit board is between the bracket and the transformer core. 
     
     
       5. The inductive charging port of  claim 3  further comprising a compliant piece such that the compliant piece is between the flexible circuit board and the transformer core. 
     
     
       6. An inductive charging port for an electronic device, the inductive charging port comprising:
 a first housing located in a first opening of an enclosure for the electronic device; 
 an inductive coil around a transformer core, the transformer core fixed to the first housing, wherein the first housing and first inductive coil are movable relative to the enclosure; 
 a second housing fixed to the enclosure; and 
 a first resilient member having a first end around a first tail portion of the first housing and a second end in a first supporting cavity formed by sidewalls of the second housing, such that the first resilient member biases the transformer core in a direction out of the electronic device when the electronic device is not mated to a second device, and such that the first resilient member compresses such that the transformer core is moved in a direction into the electronic device when the electronic device is mated to a second device. 
 
     
     
       7. The inductive charging port of  claim 6  further comprising a second resilient member having a first end around a second tail portion of the first housing and a second end in a second supporting cavity formed by sidewalls in the second housing. 
     
     
       8. The inductive charging port of  claim 7  wherein the first and second resilient members are springs. 
     
     
       9. The inductive charging port of  claim 8  wherein the springs bias the transformer core towards a surface of the enclosure when the electronic device is not mated to a second device and the springs compress allowing the transformer core to retract behind the surface of the enclosure when the electronic device is mated to a second device. 
     
     
       10. The inductive charging port of  claim 9  wherein the second device mates with the electronic device by moving laterally along the surface of the enclosure, wherein
 the first housing includes a front surface having sloped lead-in features on each side of the transformer core such that as the second device moves laterally along the surface of the enclosure, one of the lead-in features encounters the second device and pushes the first housing into the electronic device. 
 
     
     
       11. The inductive charging port of  claim 10  wherein a leading surface of the transformer core is recessed below peaks of the sloped lead-in features. 
     
     
       12. The inductive charging port of  claim 6  wherein the inductive charging port is sealed by a sealing structure between the enclosure and a sidewall of the second housing. 
     
     
       13. The inductive charging port of  claim 12  wherein the sealing structure is an O-ring. 
     
     
       14. An inductive charging port for an electronic device, the inductive charging port comprising:
 a first housing located in a first opening of an enclosure for the electronic device; 
 an inductive coil around a transformer core, the transformer core fixed to the first housing, wherein the first housing and first inductive coil are movable relative to the enclosure; 
 a first magnetic element fixed to the first housing; and 
 a proximity sensor fixed to the enclosure, wherein when the electronic device is not mated to a second device, the first housing and the first magnetic element move away from the proximity sensor, and 
 wherein when the electronic device is mated to a second electronic device, the first housing and the first magnetic element move towards the proximity sensor, 
 wherein the proximity sensor uses the movement of the first magnetic element to detect a presence of the second electronic device. 
 
     
     
       15. The inductive charging port of  claim 14  further comprising a second magnetic element fixed to the enclosure. 
     
     
       16. The inductive charging port of  claim 15  further comprising a second housing fixed to the enclosure, wherein the proximity sensor and the second magnetic element are attached to the second housing. 
     
     
       17. The inductive charging port of  claim 15  wherein the proximity sensor is a Hall-effect sensor. 
     
     
       18. The inductive charging port of  claim 17  further comprising a first spring and a second spring each having a first end around a corresponding tail portion of the first housing and a second end in a corresponding supporting cavity formed by sidewalls of the second housing. 
     
     
       19. The inductive charging port of  claim 18  wherein when the electronic device is not mated to a second device, the first spring and the second spring push the first housing and the first magnetic element away from the proximity sensor.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U. S. patent provisional patent application Nos. 62/399,179, filed Sep. 23, 2016, and 62/299,942, filed Feb. 25, 2016, which are incorporated by reference. 
    
    
     BACKGROUND 
     Electronic devices often include one or more connector receptacles though which they may provide and receive power and data. This power and data may be conveyed over cables that may include a connector insert at each end of a cable. The connector inserts may be inserted into receptacles in the communicating electronic devices. 
     In other electronic systems, contacts on a first electronic device may be in direct physical and electrical contact with contacts on a second electronic device without the need for an intervening cable. In such systems, a connector insert may be formed as part of the first electronic device, while a connector receptacle may be formed as part of the second electronic device. 
     The electrical contacts on these directly connecting connector inserts and connector receptacles may be substantially formed on outside surfaces of the electronic devices. These surfaces may come into direct contact to form electrical connections between electronic devices to convey power and data. 
     Like other connector systems, there are potential drawbacks to this arrangement. For example, these connectors may be large. Since electronic devices are becoming ever smaller, the presence of large connectors may be non-optimal. Also, since the contacts are at the surfaces of the electronic devices, they may be exposed to corroding fluids that may shorten device lifespan. Since the electronic devices come into physical contact, the connector contacts may become damaged when a connection is formed. Electronic devices may also have fluids spilled on them or they may become partially submerged. Resulting moisture leakage may damage the electronic device housing the connector assembly. Also, connector systems may be manufactured in the millions of units. Accordingly, any simplification in the assembly process may noticeably reduce manufacturing costs. Further, a failure of the connector system may render an entire electronic device inoperable, so reliability may be important for maintaining customer satisfaction. 
     Thus, what is needed are connector assemblies that may be space efficient, have a high corrosion resistance, are difficult to damage, reduce or prevent moisture leakage into an electronic device housing the connector assembly, are readily assembled, and are reliable. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide connector assemblies that may be space efficient, have a high corrosion resistance, are difficult to damage, reduce or prevent moisture leakage into an electronic device housing the connector assembly, are readily assembled, and are reliable. 
     An illustrative embodiment of the present invention may provide a space efficient connector assembly by using inductive charging ports for transferring electrical energy from a first electric device to a second electronic device. As compared to conventional connector inserts and connector receptacles, these inductive charging ports may have a smaller form factor and consume a reduced volume in an electronic device. This may allow the device to be smaller or to include an increased level of functionality, or combination of the two. These inductive charging ports may transmit or receive power, though in various embodiments of the present invention, an inductive charging port may be arranged to only transmit or receive power. In a transmitting port of an electronic device, a 0.5 MHz, 1.0 MHz, 1.2 MHz, 2.0 MHz, or other frequency signal may be applied to a winding around a transformer core. This may induce a current in a winding around a transformer core in a second, mated receiving port in a second electronic device. The induced current may then be used to operate the second electronic device, charge a battery in the second electronic device, or both. 
     These inductive charging ports may provide corrosion resistance by including a protective layer or cover portion over what would otherwise be exposed surfaces of a transformer core. Even where surfaces of a transformer core are exposed, the transformer core may be formed using a soft ferrite material. These materials may be less susceptible to corrosion damage than a conventional stainless-steel or other type of contact. 
     Another illustrative embodiment of the present invention may provide connector assemblies that are difficult to damage by including protective features for transformer cores. One such embodiment may provide an inductive charging port for an electronic device, the inductive charging port located in an opening of a device enclosure and having a transformer core supported by a housing. The transformer core may have a front near a surface of the device enclosure such that the front of the transformer core is near a mating (or complementary) transformer core of a second device when the electronic device is mated to the second device. The housing may include a protective layer or cover portion over the front of a transformer core in order to protect the front of the transformer core during mating. A front surface of the protective layer or cover portion may be recessed below a surface of the device, again to protect the front of the transformer core during mating with a second electronic device. The protective layer or cover portion may be formed in various ways. For example, the housing may be formed by injection molding, then the protective layer or cover portion may be compressed by coining. The final protective layer or cover portion may have a thickness between 0.07 and 1.0 mm, between 0.09 and 0.12 mm, or it may have a different range of thickness. The reduced thickness of the protective layer or cover portion may improve inductive coupling with a second mated connector. 
     The spacing between a front surface of the protective layer or cover portion and the device enclosure may have a tight tolerance in order to maximize inductive coupling between the transformer core and the mating transformer core of the second device, while still protecting the transformer core during device mating. This tolerance may be met by measuring a thickness of the housing, a portion of the housing or other portion or portions of one or more inductive charging ports, measuring a thickness of one or more device enclosures, and then matching inductive charging ports and device enclosures based on the measured thicknesses such that the narrow tolerance is met. In these and other embodiments of the present invention, a shim may be placed between a lateral extension of the housing and a back of the device enclosure to accurately locate relative positions of surfaces of the transformer core and the device enclosure to meet this tolerance. In these and other embodiments of the present invention, a housing may be put into a proper position in a device enclosure, then fixed in place using glue or other adhesive to meet the required tolerance. 
     These and other protective features may be included in other embodiments of the present invention. In another illustrative embodiment, a connector assembly for an electronic device may include a housing supporting a transformer core. The housing may retract into a device enclosure while the electronic device is being mated with a second device and move forward when the mating has been achieved to reduce the gap between the mating transformer cores. This may protect the transformer core while the devices are being mated. 
     More specifically, to improve inductive coupling between devices, the housing may extend beyond a surface of the device enclosure. During mating, the electronic device and the second device may move laterally relative to each other. To avoid damage to the housing, the housing may retract into the enclosure while the enclosure of the second device moves across the face of the enclosure for the electronic device. Sloped lead-ins at the surface of the housing on each side of the transformer core may gradually push the housing into the enclosure as they are engaged by the second device. To further protect the transformer core, a surface of the transformer core may be recessed behind a peak of the lead-ins on the housing. 
     Another illustrative embodiment of the present invention may provide a connector assembly that reduces moisture leakage into an electronic device housing the connector assembly by using potting techniques, sealing structures such as O-rings, gaskets, or other structures or combination thereof. 
     Another illustrative embodiment of the present invention may provide a connector assembly that is readily assembled by having a reduced number of parts. In one example, an inductive charging port may be located in an opening of an enclosure for an electronic device. The inductive charging port may include a housing supporting a transformer core. A wire coil may be wrapped around at least a portion of the transformer core. The housing may include a front protective layer or cover portion over what would otherwise be an exposed face of the transformer core. A bracket may secure the housing to the enclosure. A flexible circuit board may deliver current to the wire coil and may be located between the bracket and the transformer core. Pliable material, such as foam, may be inserted between the flexible circuit board and the transformer core. The pliable material may protect windings of the coil and the flexible circuit board. Moisture leakage may be reduced by using a sealing structure between the housing and device enclosure. The sealing structure may be an O-ring, gasket, or other such structure. A shim between a lateral extension of the housing and a back of the device enclosure may be used to accurately locate relative positions of surfaces of the transformer core and the device enclosure. 
     In another embodiment of the present invention that is readily assembled by having a reduced number of parts, a housing and transformer core may move relative to a device enclosure. Specifically, an electronic device may include a connector assembly, where the connector assembly includes an inductive charging port. The inductive charging port may include a transformer core fixed to a first housing. A coil may be wrapped around at least a portion of the transformer core. A second housing may be fixed to the device enclosure. The second housing may be fixed in place using a bracket that is secure to the device enclosure by a fastener. A flexible circuit board may be located between the bracket and the second housing. Conductors on the flexible circuit board may electrically connect to leads of the windings around the transformer core. The first housing may include one or more tail portions, while the second housing may include one or more cavities that may be formed by sidewalls of the second housing. One or more springs or other resilient members may have a first end around a corresponding tail of the first housing and a second end seated in a corresponding one of the cavities of the second housing. The first housing and transformer core may thus be free to move relative to the enclosure and second housing. In operation, the one or more springs or other resilient members may bias the first housing into a resting position such that a forward portion of the first housing extends through an opening in the second housing, while a force applied to a front surface of the first housing may move the first housing into a retracted position in which the first housing may be flush with or entirely within the second housing. A sealing structure, such as an O-ring, may be located between the second housing and the enclosures. Potting material may be used for further moisture protection. 
     Another illustrative embodiment of the present invention may provide connector assemblies, such as inductive charging ports, that may be reliable. One way to improve reliability of an electronic device is to limit its operating temperature. For example, thermal paste may be used as a potting material in a connector assembly. In these and other embodiments of the present invention, a duty cycle of operation may be monitored and adjusted to limit a connector assembly&#39;s temperature. In these and other embodiments of the present invention, a level of power being transferred may be monitored and adjusted. These various adjustments may be made based on a needed power level of a connected device, the operating temperature of the connector assembly, or other factors, or combination thereof. In these and other embodiments of the present invention, more than one inductive charging port may be used to transfer data from an electronic device to a second electronic device. 
     Another illustrative embodiment of the present invention may provide a connector assembly that may detect when it is being mated with a connector on a second device. In one embodiment, a first magnetic element, such as a magnet, may be fixed to a first housing. A proximity sensor, such as a Hall-effect sensor, may be fixed to a flexible circuit board that may be fixed to a second housing. The first housing may move relative to the second housing when the connector assembly is mated to a second connector. The change in magnetic flux may be detected by the proximity sensor, which may then activate the electronic device or invoke other action in the device. In these and other embodiments of the present invention, a second magnetic element may be fixed to the bracket housing such that the proximity sensor is between the first and second magnetic elements, and a differential sensing scheme may be used. 
     In these and other embodiments of the present invention, other types of connection detection apparatus may be used. For example, a proximity sensor, such as a Hall-effect sensor, may be placed on a connector assembly, while a magnet may be placed on a second, mating connector assembly. The electronic device with the proximity sensor may detect a change in magnetic flux indicating that the second connector assembly is coming into a mated position. As another example, the presence of a mating connector assembly may be detected by providing a stimulus to a connector assembly and then monitoring the result. For instance, a coil on an inductive charging port may be activated for a short burst. A 5 MHz or other frequency signal may be applied to the coil for a limited duration. Following the burst, the decay of the resulting signal may be monitored. If a second, mating inductive charging port is present, the transformer in the mating port may sustain the signal and the decay may take longer to reach a threshold level, while if no mating transformer is present, the signal may decay quicker and reach a threshold level in a shorter time. As another example, an optical detect may be used to detect mating, or attachment. A light-emitting diode (LED) in an electronic device may generate light, which may be reflected by a surface of a mating connector in a second device as the second device moves across the surface of the electronic device. The reflected light may be detected using a photodiode, which may generate a signal indicating that a connection has been made. The LED and photodiode may also be used for data communication when connectors of the first and second electronic devices are mated. As still another example, a user may provide an input via a user interface to the electronic device indicating that a connection has been made. Any combination of presence detection techniques may be used, and the first and second electronic devices may use the same technique or different techniques. 
     In various embodiments of the present invention, different types of transformer cores having various winding arrangements may be used. Typically, ferrite material may be used to form the transformer core. The core may be formed as a unit, or it may have inductive portions coupled by a return plate. The contours of the surfaces of the transformer cores may be splined to match a contour of a surface of a device enclosure, and a physical vapor deposition (PVD) process may be used to match a color to a device enclosure as desired. In these and other embodiments of the present invention, the windings may be insulated. If the insulation is damaged, noise may occur. To prevent this noise, the transformer cores may have their edges smoothed during manufacturing, for example by using a tumbling process. The transformer cores may also be coated using a material such as paralyne or soft plastic to prevent damage to the winding insulation during the winding process and during use. In these and other embodiments of the present invention, a thickness of the insulation around the windings may be increased. 
     In various embodiments of the present invention, data may be provided over a connector system along with, or instead, of power. For example, a signal may be applied and removed from a transformer coil of a connector assembly in an electronic device to send binary data to a second, mated transformer coil of a connector assembly of a second electronic device. The signal may have a frequency of 27 MHz, 40 MHz, 48 MHz, or a different frequency. As another example, data may be communicated using an RF carrier signal modulated by a data signal. The signals may be sent and received using a dedicated data port of the connector system. The carrier signal may have a frequency in the 2.4 GHz or 60 GHz frequency bands, or in another frequency band. The data rate may be in the tens or hundreds of Mbps. For instance, a Bluetooth connection may be formed using capacitive antennae. The capacitive antennae may be very low power such that it does not interfere with other wireless communications that may be occurring between the mated devices or between one of the mated devices and a third device. As another example, optical signaling may be used to communicate data between devices. For instance, an LED and a photodetector (e.g., a photodiode) may be placed in a connector assembly in an electronic device and in a second connector assembly in a second electronic device. 
     In these and other embodiments of the present invention, other circuitry of the electronic device may be able to make use of portions of the connector assembly. For example, a bracket may be used to convey current for a power supply, as an antenna, as a guide or housing for an antenna, or for other purposes. For example, the bracket may be a plastic housing for an antenna. 
     Another embodiment of the present invention may provide another space efficient connector assembly by using inductive charging ports for transferring electrical energy between a first electronic device and a second electronic device. A first electronic device may include a first inductive port having a transformer that includes a transformer core having one or more legs surrounded by windings. The transformer may be located in a sleeve that may move relative to an enclosure for the first electronic device. The transformer may be encapsulated, for example with epoxy of other potting material, to seal the transformer and prevent moisture leakage into the first electronic device. Specifically, an epoxy or other potting material may be placed between the transformer and its sleeve, as well as behind the transformer between the transformer and the internal portions of the first electronic device. 
     In these and other embodiments of the present invention, a surface of the ferrite material of the transformer core may be exposed at a surface of the first electronic device. In these embodiments, a surface of the transformer core, a surface of the sleeve, and a surface of the epoxy or other potting material may form a surface of the inductive port. During assembly, the transformer core and its windings may be placed in sleeve. A liner may be placed over surfaces of the transformer core and sleeve. An epoxy or other potting material may be inserted between the transformer core and sleeve to encapsulate the transformer core, where the liner protects the surface of the transformer core from being exposed to the epoxy or potting material. The epoxy or other potting material may be cured and the lining may then be removed. Afterward, for cosmetic and functional reasons, the surfaces of the transformer core, sleeve, and potting material may be polished or otherwise smoothed together as a unit. For example, a buffing wheel, polishing cloth, fine grit sand paper, blasting, tumbling, or other method may be used. These surfaces may also be colored, for example by ink jet printing, pad printing, physical vapor deposition, epoxy, or other method. They may be colored black, they may be colored to match a device enclosure, or they may have another color. In still other embodiments of the present invention, the sleeve may be extended to provide a covering layer over a surface of the transformer. 
     A dynamic wire assembly may connect the transformer core windings to internal electronics of the first electronic device. This dynamic wire assembly may include wires having sufficient slack to account for movement of the sleeve relative to the remainder of the first electronic device. 
     Again, the inductive port of the first electronic device may move relative to an enclosure for the first electronic device. For example, the inductive port of the first electronic device may move in a connection direction towards an inductive port of a second electronic device when the first electronic device and the second electronic device are mated. This movement may be facilitated by a spring mechanism pushing the sleeve in the connection direction. This spring mechanism may include one or more springs or flexures. In various embodiments of the present invention the sleeve may move 0.2, 0.4, 1.0 mm or other distance in the connection direction. 
     Embodiments of the present may employ retention clips to limit the travel of sleeve. Specifically, notches may be formed in the device enclosure adjacent to the sleeve. Retention clips on the sleeve may compress against sides of the sleeve during assembly and may then expand into the notches, thereby securing the sleeve in place in the device enclosure. The notches may have a greater lateral length along a side of the sleeve as compared to the retention clip. This may allow the sleeve the ability to move as needed. 
     Another embodiment of the present invention may provide a second electronic device having an inductive charging port for transferring power with the first electronic device. This inductive charging port may include a transformer that includes a transformer core having one or more legs surrounded by windings. The transformer may be located in a sleeve that may be fixed to an enclosure for the second electronic device. The transformer may be encapsulated, for example with epoxy of other potting material, to seal the transformer and prevent moisture leakage into the second electronic device. Specifically, an epoxy or other potting material may be placed between the transformer and its sleeve. An O-ring or other gasket may be placed between the sleeve and the device enclosure to further prevent moisture leakage into the second electronic device. A shim may be used to position a surface of the transformer with a surface of the device enclosure for improved energy transfer. 
     A surface of the transformer core may be covered with a thin protective layer. This protective layer may be formed by placing a transformer core in a tool holding a liquid plastic. A force may then be applied to the transformer core to create a thin layer plastic over a surface of the transformer core. The plastic may then be cured in place. By making the protective layer thin, the resulting energy transfer may be maximized while still protecting the transformer core. This layer may be formed of liquid crystal polymer or other material. This layer may be as thin as 0.5, 0.1, 0.2, or 0.5 mm. Autoclaving, degassing, or other steps may be employed to avoid separation of the layer from the surface of the transformer. 
     The inductive port for the second electronic device may include a transformer core having windings around one or more legs. The transformer core may be located in a sleeve. Leads from the windings may attach to landing pads. Dimple plates may form electrical contact with the landing pads. A flexible circuit board may connect to the dimple plates. The dimple plates may be held in place using a flexure or bracket. 
     In various embodiments of the present invention, a data port may incorporate various structural features adapted to the interior geometry an electronic device or connector system in which the data port is installed. For example, in the case of a 60-GHz data port, it may be desirable to place a transceiver chip in close proximity to an outer surface of the housing of the electronic device. Further, the transceiver chip may be an edge-fired chip for which a particular orientation of the transceiver chip within the data port is desirable for optimum signal strength. This orientation may dictate a particular path for electrical connections (e.g., a flexible printed circuit board connected between the transceiver chip and other components of the electronic device), which may entail an acute bend angle. In some embodiments, an interposer that includes leads with a 90-degree or other bend angle may be connected between the transceiver chip and the flexible printed circuit board, and this may reduce the bend angle and corresponding strain on the flexible printed circuit board. In other embodiments, the flexible printed circuit board may be connected directly to the transceiver chip, and a mandrel or similar structure may provide strain relief for the acute bend angle of the flexible printed circuit board. 
     In various embodiments of the present invention, the components of the connector assemblies may be formed in various ways of various materials. For example, conductive portions may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, palladium, palladium silver, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions, such as the housings and other portions, may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, Mylar, Mylar tape, rubber, hard rubber, plastic, nylon, elastomers, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The transformer cores may be formed of ferrite material, such as a soft ferrite. The transformer cores may be sintered or subjected to other manufacturing steps. The flexible circuit boards may be replaced with printed circuit boards (PCBs) or other appropriate substrates. 
     Embodiments of the present invention may provide connector assemblies that may be located in, or may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector assemblies may provide interconnect paths for signals that are compliant with various standards such as Universal Serial Bus (USB), 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 various embodiments of the present invention, these interconnect paths provided by these connectors may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a connector assembly according to an embodiment of the present invention; 
         FIG. 2  illustrates another connector assembly according to an embodiment of the present invention; 
         FIG. 3  illustrates a connected state between two connector assemblies according to an embodiment of the present invention; 
         FIG. 4  illustrates states of connector assemblies according to an embodiment of the present invention before a connection is made between two electronic devices; 
         FIG. 5  illustrates states of connector assemblies according to embodiments of the present invention while a connection is being made between two electronic devices; 
         FIG. 6  illustrates an exploded view of a connector assembly according to an embodiment of the present invention; 
         FIG. 7  illustrates an opening in the device enclosure into which an inductive charger port according to an embodiment of the present invention may be inserted; 
         FIG. 8  illustrates a rear view of an assembled inductive charging port according to an embodiment of the present invention; 
         FIG. 9  illustrates an exploded view of a connector assembly according to an embodiment of the present invention; 
         FIG. 10  illustrates an example of complementary transformer core shapes according to an embodiment of the present invention; 
         FIG. 11  illustrates an example of complementary transformer cores after winding of wires according to an embodiment of the present invention; 
         FIG. 12  illustrates another example of complementary transformer core shapes according to an embodiment of the present invention; 
         FIG. 13  illustrates additional examples of transformer core shapes that may be used in some embodiments of the present invention; 
         FIGS. 14A and 14B  illustrate additional examples of complementary transformer core shapes that may be used in some embodiments of the present invention; 
         FIG. 15  illustrates a connector assembly that may detect when it is being mated with a second connector assembly on a second device; 
         FIG. 16  illustrates a connector assembly that may detect when it is being mated with a second connector assembly on a second device; 
         FIG. 17  illustrates an exploded view of a connector assembly that may detect when it is being mated with a second connector assembly on a second device; 
         FIG. 18  illustrates a rear view of a connector assembly according to an embodiment of the present invention; 
         FIG. 19  illustrates a simplified cross-section view of complementary capacitive data ports according to an embodiment of the present invention; 
         FIG. 20  illustrates a simplified cross-section view of complementary 60-GHz data ports according to an embodiment of the present invention; 
         FIG. 21  illustrates a simplified cross-section view of complementary optical data ports according to an embodiment of the present invention; 
         FIG. 22  illustrates a simplified cross-section view of portions of two complementary connector assemblies according to an embodiment of the present invention; 
         FIG. 23  illustrates a front view of a portion of the connector assembly of  FIG. 22  according to an embodiment of the present invention; 
         FIG. 24  illustrates an exploded view of components of an optical data port according to an embodiment of the present invention; 
         FIG. 25  illustrates inductive charging ports that may be used to transfer power between devices according to an embodiment of the present invention; 
         FIG. 26  illustrates inductive charging ports that may be used to transfer power between devices according to an embodiment of the present invention; 
         FIG. 27  illustrates a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 28  is an exploded view of an inductive charging port according to an embodiment of the present invention; 
         FIGS. 29-32  illustrate sleeves for inductive charging ports according to embodiments of the present invention; 
         FIG. 33  illustrates a transparent view of an inductive charging port according to an embodiment of the present invention; 
         FIG. 34A  illustrates another transparent view of an inductive charging port according to an embodiment of the present invention, while  FIGS. 34B-34D  illustrate a retention clip for securing a sleeve to a device enclosure according to an embodiment of the present invention; 
         FIG. 35  illustrates an exploded view of another inductive charging port according to an embodiment of the present invention; 
         FIG. 36  illustrates a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 37  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 38  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 39  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 40  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 41  illustrates a portion of an inductive charging port according to an embodiment of the present invention; 
         FIG. 42  illustrates a simplified cross-section view of complementary 60-GHz data ports according to an embodiment of the present invention; 
         FIG. 43  illustrates another simplified cross-section view of the data ports of  FIG. 42 ; 
         FIG. 44  illustrates another simplified cross-section view of a 60-GHz data port according to an embodiment of the present invention; 
         FIG. 45  illustrates contact pads for a 60-GHz transceiver chip that may be used according to an embodiment of the present invention; 
         FIGS. 46-51  illustrate stages of an assembly process for a 60-GHz data port according to an embodiment of the present invention; 
         FIG. 52  illustrates an exploded view of an assembly for a 60-GHz data port according to an embodiment of the present invention; 
         FIG. 53  illustrates a simplified cross section view of a 60-GHz data port according to another embodiment of the present invention; 
         FIG. 54  illustrates a perspective view of a portion of the data port of  FIG. 53  according to an embodiment of the present invention; 
         FIG. 55  illustrates a perspective cutaway view of a portion of the data port of  FIG. 53  according to an embodiment of the present invention; 
         FIG. 56  illustrates a 60-GHz data port installed in an electronic device according to an embodiment of the present invention; 
         FIG. 57  illustrates a simplified side view of a 60-GHz data port according to another embodiment of the present invention; 
         FIG. 58  illustrates a perspective view of the 60-GHz data port of  FIG. 57  according to an embodiment of the present invention; and 
         FIG. 59  illustrates a simplified exploded view of a 60-GHz data port according to another embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE 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. 
     This figure illustrates a side view of a connector assembly for an electronic device. The connector assembly in this example may be an inductive charging port  100 . This inductive charging port may receive power from, or it may provide power to, a second electronic device (not shown). The inductive charging port  100  may include transformer core  130  supported by housing  120 , which may be located in an opening  112  of device enclosure  110 . Inductive charging port  100  may further include flexible circuit board  190 , compliant member  180 , bracket  170 , and an O-ring  160 . 
     When transmitting power, an oscillatory signal may be provided to flexible circuit board  190 . This signal may have a frequency of 0.5 MHz, 1.0 MHz, 1.2 MHz, 2.0 MHz, or other frequency. The oscillatory signal, generated by a crystal or other oscillating circuit, may be applied via conductors of flexible circuit board  190  to windings  132 . Windings  132  may be wrapped around transformer core  130  and may generate a magnetic field. This magnetic field may induce a current in a corresponding winding around a corresponding transformer core in a mated connector assembly in the second electronic device. When receiving power, a magnetic field induced in transformer  130  core by a mated connector assembly in the second device may generate a current in windings  132 . This current may be transferred via conductors of flexible circuit board  190 . This current may be used to charge a battery in the electronic device, it may be used to power circuitry in the electronic device, it may be used to charge a battery or power circuitry in a third electronic device, or a combination thereof. 
     Compliant member  180  may be a piece of foam or other compressible material to protect windings  132  and flexible circuit board  190 . Bracket  170  may be fixed to device enclosure  110  using fasteners, such as screws (not shown). Moisture or fluid leakage may be reduced or prevented by a sealing structure or gasket, in this example O-ring  160 . O-ring  116  may be located between housing  120  and device enclosure  110 . O-ring  160  may also reduce or prevent the ingress of debris and other substances into the electronic device. 
     In various embodiments of the present invention, it may be desirable to protect transformer core  130  from damage when the electronic device is being mated with a second electronic device. Accordingly, housing  120  may include a protective layer or cover portion  122  over a front surface  134  of transformer core  130 . This protective layer or cover portion  122  may also prevent corrosion of surface  134  of transformer  130 . This protective layer or cover portion  122  may be formed in various ways. For example, housing  120  may be insert molded around transformer core  130 . The housing may then be coined such that protective layer or cover portion  134  is compressed and thinned. In various embodiments of the present invention, protective layer or cover portion  134  may have a thickness between 0.07 and 1.0 mm, between 0.09 and 0.12 mm, or it may have a different range of thickness. By making the protective layer or cover portion  134  very thin, the efficiency of the transfer of energy between the inductive charging port  100  and a second inductive charging port on a second electronic device may be improved. 
     To further protect transformer core  130 , a surface of protective layer or cover portion  122  may be recessed relative to surface  114  of device enclosure  110 . However, it is desirable to maintain a tight control on the amount that the transformer core  130  is recessed. For example, if the recess is too deep, the efficiency of the energy transfer may suffer, while at the recess is too shallow, the transformer core may stand a greater chance of being damaged during the attachment of a second device. 
     Accordingly, embodiments of the present invention may provide various methods for precisely controlling the depth of this recess. In a specific embodiment of the present invention, a width of housing  120  may be measured for several inductive charging ports. Specifically, a width of housing  120  from an underside of lateral extension  128  of housing  120  to a surface of protective layer or cover portion  122  may be measured for several housings  120 . A width of device enclosure  110  at opening  112  may be measured for several device enclosures. Based on these measurements, inductive charging ports may be matched to properly sized device enclosures to maintain a tight control on the depth of the recess. In other embodiments of the present invention, a shim may be placed between the lateral extensions  128  of housing  120  and a back side  118  of device enclosure  110 . These shims may be selected in order to provide a recess having a proper depth. In other embodiments of the present invention, housing  120  and device enclosure  110  may be placed in proper positions and then fixed to each other using glue or other type of adhesive. 
     Inductive charging port  100  may be considerably smaller than a typical connector receptacle or insert typically used to transfer power. This space savings may allow a reduction in device size, thereby allowing a device to include additional functionality, or a combination of the two. 
       FIG. 2  illustrates another connector assembly according to an embodiment of the present invention. In various embodiments of the present invention, this connector assembly may mate with the connector assembly shown in  FIG. 1  above. As before, the connector assembly in this example may be an inductive charging port  200 . Inductive charging port  200  may receive power from, or it may provide power to, a second electronic device (not shown). The inductive charging port  200  may include transformer core  230  supported by first housing  220 , which may be located in an opening  212  of device enclosure  210 . Inductive charging port  200  may further include flexible circuit board  290 , second housing  240 , bracket  270 , resilient members or springs  250 , and O-ring  260 . 
     When transmitting power, a signal may be provided to flexible circuit board  290 . For example, an oscillatory signal, generated by a crystal or other oscillating circuit, may be applied via conductors of flexible circuit board  290  to windings  232 . This signal may have a frequency of 0.5 MHz, 1.0 MHz, 1.2 MHz, 2.0 MHz, or other frequency. Windings  232  may be wrapped around transformer core  230  and may generate a magnetic field. This magnetic field may induce a current in a corresponding winding around a corresponding transformer core in a mated connector assembly in a second electronic device. When receiving power, a magnetic field induced in transformer  230  core from a mated connector assembly in the second device may generate a current in windings  232 . This current may be transferred to conductors of flexible circuit board  290 . This current may be used to charge a battery in the electronic device, it may be used to power circuitry in the electronic device, it may be used to charge a battery or power circuitry in a third electronic device, or a combination thereof. 
     Bracket  270  may be fixed to the device enclosure  210  using fasteners, such as screws (not shown). Second housing  240  may also be fixed to the device housing  210 . Moisture or fluid leakage may be reduced or prevented by a sealing structure, in this example O-ring  260 . O-ring  260  may be located between second housing  240  and device enclosure  110 . O-ring  260  may also reduce or prevent the ingress of debris and other substances into the electronic device. Springs  250  or other resilient members may have a first end around tail portions  222  of housing  220  and a second end in cavities formed by sidewalls  242  in second housing  240 . Springs  250  may bias the first housing  220  forward and away from second housing  240 . Potting material may be placed between first housing  220  and second housing  240  to protect leads of windings  232 . Again, this potting material may be thermal paste to improve heat dissipation, though it may be epoxy of other potting material. 
     In various embodiments of the present invention, it may be desirable to protect transformer core  230  from damage when the electronic device housing this connector assembly is mated with a second electronic device. In this example, housing  220  and transformer core  230  may recess or be pushed into the electronic device while a second electronic device is being mated. Specifically, during mating, a second electronic device may pass along a surface  214  of the device enclosure  210 . When a leading edge of the second electronic device reaches first housing  220 , it may encounter one of the lead-in features  223  on a front surface of housing  220 . As an edge of the second electronic device continues to move laterally across the surface  214  of enclosure  210 , first housing  220  and transformer core  230  may be pushed into the electronic device, compressing springs  250 , and thereby protecting transformer core  230  from damage. 
     In this and other embodiments of the present invention, lead-in features  223  may include a peak  226 , which may extend further than a front surface  234  of transformer core  230 . This may further protect a surface  234  of transformer core  230  from damage when the electronic device is mated to second electronic device. 
     Again, inductive charging port  200  may be considerably smaller than a typical connector receptacle or insert typically used to transfer power. This space savings may allow a reduction in device size, thereby allowing a device to include additional functionality, or a combination of the two. 
       FIG. 3  illustrates a connected state between two connector assemblies according to an embodiment of the present invention. In this example, inductive charging port  100  in a first electronic device may be mated with inductive charging port  200  in a second electronic device. As before, the first electronic device may provide power to the second electronic device. Specifically, an oscillating signal, for example at 0.5 MHz, 1.0 MHz, 1.2 MHz, 2.0 MHz, or other frequency, may be applied to conductors of flexible circuit board  190  in inductive charging port  100 . This signal may drive windings  132 , thereby developing a magnetic field in transformer core  130 . This magnetic field may induce a magnetic field in transformer core  230  in inductive charging port  200 . This induced magnetic field may generate a current in windings  232 . This current may be conveyed using flexible circuit board  290 . This current may be used to charge a battery in the second electronic device, run circuitry in the second electronic device, or charger battery or run circuitry in a third electronic device, or combination thereof. Similarly, the second electronic device may provide power to the first electronic device. Specifically, an oscillating signal, for example at 0.5 MHz, 1.0 MHz, 1.2 MHz, 2.0 MHz, or other frequency, may be applied to conductors of flexible circuit board  290  in inductive charging port  200 . This signal may drive windings  232 , thereby developing a magnetic field in transformer core  230 . This magnetic field may induce a magnetic field in transformer core  130  in inductive charging port  100 . This induced magnetic field may generate a current in windings  132 . This current may be conveyed using flexible circuit board  190 . This current may be used to charge a battery in the first electronic device, run circuitry in the first electronic device, or charger battery or run circuitry in a third electronic device, or combination thereof. 
     Again, springs  250  may push or bias first housing  220  and transformer core  230  towards the opening  112  of device enclosure  110 . This forward travel may be limited by edges  115  of device enclosure  110  encountering points  227  of the leading features  223 . Again, for the purposes of efficient energy transfer, it may be desirable to position transformer cores  130  and  230  in close proximity when the two electronic devices are mated. In this example, the spacing may be determined by a thickness of protective layer or cover portion  122  and an air gap between a front surface of protective layer or cover portion  122  and a front surface of transformer core  230 . The spacing may be determined by the resting positions of edges  115  of the device enclosure  110  on points  227  of the lead-in features  223  of housing  220 . 
     Embodiments of the present invention may provide connector assemblies, such as these inductive charging ports, that may be reliable. One way to improve reliability of an electronic device is to limit its operating temperature. For example, thermal paste may be used as the potting material described herein. In these and other embodiments of the present invention, a duty cycle of operation may be monitored and adjusted to limit a connector assembly&#39;s temperature. In these and other embodiments of the present invention, a level of power being transferred may be monitored and adjusted. These various adjustments may be made based on a needed power level of a connected device, the operating temperature of the connector assembly, or other factors, or combination thereof. In these and other embodiments of the present invention, more than one inductive charging port may be used by each device to transfer power between the two electronic devices. 
     Again, a connection between the first electronic device and the second electronic device may be formed by sliding the surfaces of the enclosures of the two devices across each other. This motion may be relative, that is, the first device may be fixed and the second electronic device may be moved, the second electronic device may be fixed and the first electronic device may move, or some combination of the two may occur. An example of such a connection being made is shown in the following figures. 
       FIG. 4  illustrates states of connector assemblies according to an embodiment of the present invention before a connection is made between two electronic devices. In this example, a first electronic device having a first inductive charging port  100  in device enclosure  110  may be moved relative to a second electronic device having a second inductive charging port  200  in device enclosure  210 . The relative motion of the first electronic device may be from left to right. Edge  117  of enclosure  110  has yet to encounter lead-in features  223  of first housing  220  in inductive charging port  200 . Therefore, springs  250  are shown pushing housing  220  upward until lateral surfaces  225  of housing  220  reach lateral surfaces  219  of device enclosure  210 . 
       FIG. 5  illustrates states of connector assemblies according to embodiments of the present invention while a connection is being made between two electronic devices. In this example, edge  117  of housing  110  of connector assembly  100  has reached a leading edge  223  of housing  220  of inductive charging port (connector assembly)  200 . This encounter may push housing  220  downward into the second electronic device, thereby compressing springs  250 . This downward travel may also separate lateral surfaces  225  of housing  220  from lateral surfaces  219  of device enclosure  210 . 
       FIG. 6  illustrates an exploded view of a connector assembly according to an embodiment of the present invention. This connector assembly may be an inductive charging port  100 , as shown in the included examples. Inductive charging port  100  may include a housing  120  around transformer core  130 . Housing  120  may be insert molded around transformer core  130 . In other embodiments of the present invention, housing  120  and transformer core  130  may be formed as separate pieces and transformer core  130  may be press fit or otherwise located in housing  120 . Windings  132  may be wrapped around some or all of transformer core  130 . O-ring  160  may be placed around housing  120  and fit between housing  120  and device enclosure  100 , as shown in  FIG. 1 . An optional shim  660  may be placed between lateral projections on housing  120  and a rear of the device enclosure, as described herein. Flexible circuit board  190  may connect to leads of windings  122 . Compliant member  180  may be formed of foam or other material to protect leads of wings  132  and flexible circuit board  190 . Bracket  170  may be placed behind housing  120  and may be fixed to a device enclosure by fasteners, such as screw  610 . 
       FIG. 7  illustrates an opening in the device enclosure into which an inductive charger port according to an embodiment of the present invention may be inserted. Device enclosure may include opening  112 . Enclosure  110  may further include threaded nuts  710  to accept fasteners  610 , as shown in  FIG. 6 . 
       FIG. 8  illustrates a rear view of an assembled inductive charging port according to an embodiment of the present invention. In this example, bracket  170  has been secured in place relative to housing  110 . That is, bracket  170  may be been fixed to housing  110  by fasteners  610 . Flexible circuit board  190  may contact leads to windings  132 , which may be wrapped around transformer core  130 , as shown in  FIG. 1 . Transformer core  130  may be located in housing  220 . 
       FIG. 9  illustrates an exploded view of a connector assembly according to an embodiment of the present invention. In this example, the connector assembly may be the inductive charging port  200 . Inductive charging port  200  may include first housing  220  supporting transformer core  230 . Windings  232  may be wrapped around transformer core  230 . Optional capture plate  280  may be mated with first housing  220  to secure transformer  230  in place. In other embodiments of the present invention, capture plate  280  may be omitted. Bracket  270  may be fixed to a device enclosure  210  as shown in  FIG. 2 , by fastener or screw  960 . Fastener or screw  960  may pass through openings in bracket  270  and second housing  240 , and into a threaded opening in a rear of device enclosure  210 . O-ring  260  may be placed around second housing  240  and may be located between second housing  240  and an opening  212  in device enclosure  210 . Resilient members or springs  250  may have a first end around the tail portions  222  of first housing  220  and second ends that may be held in place in cavities in second housing  240 . Potting material  910  may fill the cavity between first housing  220  and second housing  240 , thereby protecting connections to windings  232 . As before, this potting material may be a thermal paste to improve head dissipation in the connector assembly. 
     In these and other embodiments of the present invention, a first transformer core  130  may be disposed within first inductive charging port  100 , and a second transformer core  230  may be disposed within second inductive charging port  200 . Each transformer core may be made of ferrite or similar materials. Some or all of the surfaces of the transformer cores may be coated to protect against damage to the wires that are wound around the cores (or portions thereof). The shapes of the transformer cores may be, e.g., C-shapes or U-shapes, and the cores may be but need not be symmetric. Examples of transformer core shapes and wire windings will now be described. 
       FIG. 10  shows an example of complementary transformer core shapes according to some embodiments of the present invention. Shown at  1000   a  are complementary transformer cores  1002  and  1004 . In some embodiments, transformer core  1002  may be used as transformer core  130  in first inductive charging port  100  while transformer core  1004  is used as transformer core  230  in second inductive charging port  200 . Transformer core  1002  may have a shape that is optimized for a small space, e.g., by providing short leg sections  1006  connected by a central yoke section  1008 . Transformer core  1004  may have longer leg sections  1010  and a yoke section  1012 . Leg sections  1010  and/or yoke section  1012  may be shaped to accommodate wire windings. One example of such shaping is shown in top view at  1000   b , in side view at  1000   c , and in perspective view at  1000   d . As shown, yoke sections  1008  and  1012  may include a central narrow region, and this may accommodate wire windings. In some embodiments, the ends of leg sections  1010  may be shaped for cosmetic effect. For instance, as seen at  1000   b  and  1000   c , the ends of leg sections  1010  may be rounded or splined to conform to the front face of a connector assembly in which transformer core  1004  is to be included. In embodiments where the front face of transformer core  1002  is visible, the ends of leg sections  1006  may also be shaped for cosmetic effect. 
       FIG. 11  shows an example of complementary transformer cores  1002  and  1004  after winding of wires  1102 ,  1104  around yoke sections  1008 ,  1012 . The number of turns of wires  1102 ,  1104  may be increased, e.g., by winding the wires in multiple layers and/or by using wire with a smaller gauge. In some embodiments, wire windings may extend along leg sections  1006  and/or  1010 . 
       FIG. 12  shows another example of complementary transformer core shapes. Transformer cores  1202 ,  1204  have thicker yoke sections and shorter leg sections than transformer cores  1002 ,  1004 . Wires  1206 ,  1208  may be wrapped around the yoke sections of transformer cores  1202 ,  1204 . In this example, transformer cores  1202 ,  1204  have the same shape, but this is not required. 
       FIG. 13  shows additional examples of transformer core shapes  1302 - 1310 , each designed to fit within the same housing (e.g., housing  120  of  FIG. 1 ). As shown, the thickness of the yoke section relative to the legs may be varied, and the shape of both the yoke section and the legs may be varied. Wires may be wrapped around the yoke and/or leg sections of each transformer core to form a wire coil. In some embodiments, the yoke may be shaped to have a narrow midsection, e.g., as shown for transformer cores  1306 ,  1308 ,  1310 . Where this is the case, the wire windings that form an inductive coil around the transformer core may be arranged such that they do not extend beyond a boundary defined by outer surfaces of the transformer core, as shown at  1312  and  1314 . 
     In some embodiments, the legs may be shaped to facilitate wire windings around the legs in addition to or instead of the yoke. Winding wire around the legs results in wire coils being located closer to the interface. This may reduce magnetic flux leakage at the interface, which may improve efficiency of the inductive charging port. For instance, the legs may have cylindrical shapes, as shown for transformer cores  1308 ,  1310 , which may facilitate winding of a wire. In the case of transformer core  1310 , the legs are narrower than the ends of the yoke section, and wire windings on the legs may be arranged such that they do not extend beyond a boundary defined by outer surfaces of the transformer core. In some embodiments, transformer core  1310  may be manufactured by forming the yoke and legs as separate parts, then attaching the parts to each other. 
     It should be noted that where the wire windings for coils do not extend beyond a boundary defined by outer surfaces of the transformer core, contact with the housing (e.g., housing  120  described above) is made by the ferrite material of the transformer core and not by the wires. Accordingly, to the extent that ferrite transformer cores may be produced with small manufacturing tolerances, preventing the wire windings from extending beyond the boundary defined by outer surfaces of the transformer core may allow for more consistent alignment between the transformer core and the housing. This in turn may provide more consistent alignment (and therefore more reliable power transfer performance) between complementary transformer cores in different devices. 
       FIG. 14A  shows another example of complementary transformer core shapes that may be used in some embodiments of the present invention. In this example, each of complementary transformer cores  1402  and  1404  has a U shape with wire windings  1406 ,  1408  disposed along the legs of each core. A single wire may be wrapped first around one leg, then around the other as shown. As shown, wire windings  1408 ,  1408  need not extend all the way to the ends of the legs, although in some embodiments they may. Cores  1402  and  1404  may be shaped similarly to core  1310  shown in  FIG. 13 , with legs that are narrower than the ends of the yoke section. In the example shown, core  1404  has longer legs and a thicker yoke than core  1402 ; these dimensions may be varied, and cores  1402  and  1404  may be the same size or different sizes, provided that the legs of the two cores are alignable with each other to support efficient transfer of magnetic flux. Narrow midsections of  1410 ,  1412  of the yokes may allow the ends of wire windings  1406 ,  1408  to pass through to the outside of housings  120 ,  220  to facilitate electrical connections. Wire windings  1406 ,  1408  may be arranged such that they do not extend beyond a boundary defined by outer surfaces of the transformer cores. In this arrangement, housings  120 ,  220  may make contact with the ferrite material cores  1402 ,  1404  but not with wire windings  1406 ,  1408 . As noted above, this may allow for more consistent alignment. 
       FIG. 14B  shows another example of complementary transformer core shapes that may be used in some embodiments of the present invention. In this example, each of complementary transformer cores  1422  and  1424  has a semicircular shape with wire windings  1426 ,  1428  disposed along nearly the entire length of each core. While this shape may provide somewhat higher power transfer efficiency than the U shapes shown in  FIGS. 10-13 , in some embodiments space constraints or other design considerations may preclude the use of semicircular transformer cores. 
     The various transformer core shapes shown in  FIGS. 10-14B  are illustrative and may be modified. The dimensions may be adapted to conform to the geometry of a particular connector assembly in which an inductive charging port is to be included. It should be noted that complementary transformer cores may have the same shape or different shapes as desired. For example, one transformer core may be U-shaped while the other is semicircular. Efficient transfer of magnetic flux from one transformer core to the other may occur as long as the ends of the legs are properly aligned between the two complementary transformer cores. Those skilled in the art with access to the present disclosure will be able to construct transformer cores in a variety of shapes and form factors suited for different connector assemblies. 
     The wire windings for coils described herein are illustrative and may be varied. In some embodiments, the wire winding scheme may be designed to maximize the number of turns of wire, subject to geometric constraints (e.g., keeping the windings within the form factor defined by the transformer core). For example, multiple layers of winding may be used. In some embodiments, one or more layers of a wrapping foil may be used in place of winding a wire; the foil layers may be laminated together and wrapped around all or part of the transformer core (e.g., just around the yoke). As another example, a tubular structure incorporating one or more layers of windings may be fabricated and slid over the transformer core, e.g., over the legs of transformer core  1310 . 
     In some embodiments, it may be desirable to use wires with thin insulation for the wire windings, e.g., in order to increase the number of turns of wire in a given space. If the insulation is damaged during the assembly process, electromagnetic noise or electrical shorting may result, impairing performance. Thicker insulation on the wires may reduce the likelihood of impaired performance but may also reduce the number of turns of wire that may be accommodated. Accordingly, in some embodiments, additional steps may be taken during manufacture to reduce the risk of damage to the wire insulation by preparing the surface of the ferrite prior to winding the wire. For example, the ferrite part may be tumbled or polished during manufacture to reduce surface roughness or sharp edges. In addition or instead, a coating material such as paralyne or soft plastic may be applied to the ferrite prior to winding the wire. Such preparations may improve reliability of the inductive charging port. 
     In these and other embodiments of the present invention, a connector assembly may detect when it is being mated with a second connector assembly on a second device. Examples will now be described. 
       FIG. 15  illustrates a connector assembly that may detect when it is being mated with a second connector assembly on a second device. The connector assembly in this example may be an inductive charging port  1500 . Inductive charging port  1500  may be substantially similar to, or the same as, inductive charging port  200  as shown herein. In this embodiment of the present invention, a first magnetic element, such as magnet  1570 , may be fixed to first housing  220 . Specifically, magnet  1570  may be at least partially housed in holder portion  224  of first housing  220 . A proximity sensor, such as Hall-effect sensor  1580 , may be fixed to flexible circuit board  290 . First housing  220  may move relative to flexible circuit board  290  while the connector assembly is being mated to a second connector assembly in a second electronic device. A change in magnetic flux may be detected by proximity sensor  1580 , which may then provide signals using conductors on flexible circuit board  290  to activate the electronic device or invoke other action in the electronic device. 
     As before, first housing  220  may be located in an opening  212  in device enclosure  210  of an electronic device. First housing  220  may support transformer core  230 , which may be at least partially surrounded by windings  232 . Second housing  240  may be fixed to device enclosure  210  by bracket  270 . Flexible circuit board  290  may be held in place between second housing  240  and bracket  270 . First housing  220  may move relative to second housing  240 , bracket  270 , and device enclosure  210 , which again may be fixed to each other. Resilient members or springs  250  may have first ends around tail portions  222  of first housing  220  and second ends that may be held in place in cavities in second housing  240  formed by side walls  242 . Magnet  1570  may be held in place by holder portion  224  of first housing  220 . Hall-effect sensor  1580  may be fixed to flexible circuit board  290 , which again may be fixed to second housing  240  and device enclosure  210  by bracket  270 . As before, a sealing structure, such as O-ring  260 , may be placed between second housing  240  and device enclosure  210 . 
     In these and other embodiments of the present invention, a second magnet element may be used to improve the detection capability of proximity sensor  1580 . An example is shown in the following figure. 
       FIG. 16  illustrates a connector assembly that may detect when it is being mated with a second connector assembly on a second device. The connector assembly in this example may be an inductive charging port  1600 . Inductive charging port  1600  may be substantially similar to, or the same as, inductive charging port  200  or  1500  as shown herein, with the addition of a second magnet. In this example, a first magnetic element, which may be magnet  1570 , may be fixed to first housing  220 . Specifically, magnet  1570  may be at least partially housed in holder portion  224  of first housing  220 . A proximity sensor, which may be Hall-effect sensor  1580 , may be fixed to flexible circuit board  290 . A second magnetic element, such as magnet  1690 , may be fixed to bracket  270 , such that Hall-effect sensor  1580  may be located between the first and second magnetic elements, in this case magnets  1570  and  1690 . In this configuration, magnet  1690  may be fixed to bracket  270 . Bracket  270  in turn may be fixed to flexible circuit board  290 , second housing  240 , and device enclosure  210 . Hall-effect sensor  1580 , being fixed to flexible circuit board  290 , may thus be fixed in position relative to magnet  1690 . First housing  220 , and therefore magnet  1570 , may move relative to flexible circuit board  290  when the connector assembly may be mated to a second connector assembly in a second electronic device. A change in magnetic flux may be detected by proximity sensor  1580 , which may then provide signals using conductors on flexible circuit board  290  to activate the electronic device or invoke other action in the electronic device. 
       FIG. 17  illustrates an exploded view of a connector assembly that may detect when it is being mated with a second connector assembly on a second device. The connector assembly in this example may again be inductive charging port  1600 . First housing  220  may be located in an opening  212  in device enclosure  210  of an electronic device, as show in  FIGS. 2 and 16 . First housing  220  may support transformer core  230 , which may be at least partially surrounded by windings  232 , as shown in  FIGS. 2 and 16 . Second housing  240  may be fixed to device enclosure  210  by bracket  270 . Flexible circuit board  290  may be held in place between second housing  240  and bracket  270 . First housing  220  may move relative to second housing  240 , bracket  270 , and device enclosure  210 , which again may be fixed to each other. Resilient members or springs  250  may have first ends around tail portions  222  of first housing  220  and second ends that may be held in place in cavities in second housing  240  formed by side walls  242 , as shown in  FIGS. 2 and 16 . Magnet  1570  may be held in place by holder portion  224  of first housing  220 . Hall-effect sensor  1580  may be fixed to flexible circuit board  290 , which again may be fixed to second housing  240  and device enclosure  210  by bracket  270 . As before, a sealing structure, such as O-ring  260 , may be placed around second housing  240  and between second housing  240  and device enclosure  210 , as shown in  FIGS. 2 and 16 . 
     In these and other embodiments of the present invention, other types of connection detection apparatus may be used. For example, a proximity sensor may be placed on a connector assembly, while a magnet may be placed on a second, mating connector assembly. In these and other embodiments of the present invention, the presence of a mating connector assembly may be detected by providing a stimulus to a connector assembly and then monitoring the result. For example, a coil on an inductive charging port may be activated for a short burst. A 5 MHz or other frequency signal may be applied to the coil for a limited duration. Following the burst, the decay of the resulting signal may be monitored. If a second, mating inductive charging port is present, the transformer in the mating port may sustain the signal and the decay may take longer to reach a threshold level, while if no mating transformer is present, the signal may decay quicker and reach a threshold level in a shorter time. In these and other embodiments of the present invention, an optical detect may be used. A light-emitting diode (LED) in an electronic device may generate light, which may be reflected by a surface of a mating connector in a second device as the second device moves across the surface of the electronic device. The reflected light may be detected using a photodiode, which may generate a signal indicating that a connection has been made. Details are shown below. In these and other embodiments of the present invention, a user may provide an input via a user interface to the electronic device indicating that a connection has been made. 
     In various embodiments of the present invention, it may be desirable for a first electronic device to be able to detect the presence of a second device. It may also be desirable for the second electronic device to be able to detect the presence of the first electronic device, though such detection may not be necessary. As applied to the above connector assemblies, in some systems inductive charging port  100  may need to be able to detect the presence of inductive charging port  200 , in some systems inductive charging port  200  may need to be able to detect the presence of inductive charging port  100 , in some systems both may be necessary, while in other systems, no detection may be necessary. 
     Inductive charging ports  1500  and  1600  shown in  FIGS. 15 and 16  may be used to detect a presence of inductive charging port  100  in systems where that may be required, though in other embodiments of the present invention, other detect techniques may be used. Since portions of inductive charging port  100  do not move when a connection is made, one or more of the other techniques listed here, or other such technique, may be employed by inductive charging port  100  to detect a connection by inductive charging port  200 . For example, a proximity sensor, such as a Hall-effect sensor, may be used in inductive charging port  100  to detect a magnet element, such as a magnet, in inductive charging port  200 . 
     In these and other embodiments of the present invention, it may be desirable for a first electronic device and a second electronic device to exchange data in addition to transferring power. Accordingly, a connector assembly that includes inductive charging port  100  or  200  may also include a separate data port. Examples of data ports will now be described. 
       FIG. 18  shows a rear view of a connector assembly  1800  according to an embodiment of the present invention. Connector assembly  1800  includes a power port  1802  and a data port  1804 . Power port  1802  may be an inductive charging port, which may be implemented as described above. Data port  1804  may be implemented using various contactless data transfer technologies, examples of which will now be described. 
     In some embodiments, data port  1804  may use inductive data transfer for carrier-free baseband signaling. Structures similar to the inductive charging structures described above may be used for data transfer in addition to or instead of power transfer. For example, current pulses in the wire windings on one side of the inductive interface may be detected on the other side and interpreted, e.g., as binary data. Conventional inductive data transfer techniques and protocols may be used. With a single data port, bidirectional communication may be supported using a half-duplex mode. 
     In other embodiments, data port  1804  may provide a capacitive antenna arrangement.  FIG. 19  shows a simplified cross-section view of complementary capacitive data ports  1902 ,  1904  according to an embodiment of the present invention. First capacitive data port  1902  may include a metal plate  1906  that is connected via metal tab  1908  to supporting circuity (e.g., flexible circuit board  1910 ) within a first electronic device, in which first capacitive data port  1902  is located. Plastic housing material  1912 , which may act as a dielectric, covers metal plate  1906 . Similarly, second capacitive data port  1904  may include a metal plate  1914  that is connected via metal tab  1916  to supporting circuitry (e.g., circuits  1918 ,  1920 ) within a second electronic device, in which second capacitive data port  1904  is located. Although no dielectric covering is shown on second capacitive data port  1904 , a dielectric covering may be provided if desired. 
     Capacitive data ports  1902 ,  1904  may each be installed in a connector assembly. Capacitive data ports  1902 ,  1904  may be arranged in their respective connector assemblies such that metal plates  1906  and  1914  become aligned parallel to and opposite each other (as shown in  FIG. 19 ) when the connector assemblies are attached to, or molded with, each other. Metal plates  1906  and  1914 , separated by insulating material  1906  (and, in some embodiments, an air gap), provide a capacitive antenna coupling that may support bidirectional radio-frequency (RF) signal transmission. Any RF signaling protocol may be used. For example, in some embodiments, capacitive data ports  1902 ,  1904  may support data transmission conforming to a wireless communication protocol such as Bluetooth® communication protocols and standards promulgated by the Bluetooth SIG (including Bluetooth® Classic and/or Bluetooth® Smart communication protocols). Other wireless communication protocols may also be used, including custom-designed application specific protocols. It should be noted that capacitive data ports  1902 ,  1904  may be optimized for short-range communication, on the assumption that they will be used only to communicate with a complementary data port. This may reduce or eliminate interference with other long-range wireless communication interfaces that may be present in either or both of the first and second electronic devices. 
     In other embodiments, data port  1804  may support RF data communication in the 60 GHz band, which may provide bandwidth of approximately 500 Mbps.  FIG. 20  shows a simplified cross-section view of complementary 60-GHz data ports  2002 ,  2004  according to an embodiment of the present invention. First data port  2002  may include a 60-GHz broadside antenna  2006  mounted on a printed circuit board  2008 , which may be a flexible circuit board that connects to other circuitry in a first electronic device, in which first data port  2002  is located. Also mounted on printed circuit board  2008  is a 60-GHz transceiver chip  2010 . Second data port  2004  may include a 60-GHz edge-fire antenna and transceiver chip  2012 , which may be connected to a circuit board  2014  or other supporting circuitry in a second electronic device, in which second data port  2004  is located. 
     In still other embodiments, data port  1804  of  FIG. 18  may support optical data communication, e.g., using infrared wavelengths or other wavelengths.  FIG. 21  shows a simplified cross-section view of complementary optical data ports  2102 ,  2104  according to an embodiment of the present invention. First data port  2102  may include a housing  2106 , which may be generally similar to housing  120  described above. Housing  2106  may include an optically transparent window portion  2108 . Optically transparent window  2108  may be made of any material that is transparent to light at the frequency of interest (e.g., various plastics that are transparent in the infrared). In some embodiments, all of housing  2106  (or all of the front surface of housing  2106 ) may be made of the same optically-transparent material. A light-emitting diode (LED)  2110  may be arranged to emit light of an appropriate wavelength toward optically transparent window  2108 , and a photodetector  2112 , which may be a photodiode or other device, may be arranged to receive light entering via optically transparent window  2108 . LED  2110  and photodetector  2112  may be connected, e.g., via circuit board  2114 , to supporting circuitry. For example, the reverse side of circuit board  2114  may connect to an interposer  2116 , which may connect to a flexible circuit board  2118 . Flexible circuit board  2118  may be connected to other circuitry in a first electronic device, in which first data port  2102  is located. 
     Similarly, second data port  2104  may include a housing  2120  with an optically transparent window  2122 . Optically transparent window  2122  may be made of any material that is transparent to light at the frequency of interest (e.g., various plastics that are transparent in the infrared). A light-emitting diode (LED)  2124  may be arranged to emit light of an appropriate wavelength toward optically transparent window  2122 , and a photodetector  2126 , which may be a photodiode or other device, may be arranged to receive light entering via optically transparent data window  2122 . LED  2124  and photodetector  2126  may be connected, e.g., via circuit board  2128 , to supporting circuitry. For example, the reverse side of circuit board  2128  may be connected to wire termination units  2130 , which may in turn be connected to wires  2132 . Other arrangements are also possible. 
     The LEDs and photodetectors may be arranged such that when a first connector assembly that includes first data port  2102  and a second connector assembly that includes second data port  2104  are attached to each other, LED  2110  is oriented toward photodetector  2126  while LED  2124  is oriented toward photodetector  2112 . This arrangement allows for bidirectional data transmission, as each of the connected electronic devices may operate its LED to send data and/or operate its photodetector to receive data. Conventional or other optical signaling technologies may be used. 
     In some embodiments, optical data ports  2102  and  2104  may also be used to detect attachment or mating between a first connector assembly that includes first optical data port  2102  and a second connector assembly that includes second optical data port  2104 .  FIG. 22  shows a simplified cross-section view of portions of two complementary connector assemblies according to an embodiment of the present invention. Shown are a portion of a first connector assembly  2202  and a portion of a second connector assembly  2204 . First connector assembly  2202  includes first optical data port  2102  and may also include an inductive charging port (not shown in  FIG. 22 ), such as inductive charging port  100  described above. Second connector assembly  2204  includes second optical data port  2104  and may also include an inductive charging port (not shown in  FIG. 22 ), such as inductive charging port  200  described above. The inductive charging port and optical data port in each connector assembly  2202 ,  2204  may be arranged relative to each other, e.g., as shown in  FIG. 18 . For instance, in  FIG. 22 , the inductive charging ports may be located out of view to the left of the connector assembly portions shown. 
     In the embodiment shown, attachment between first connector assembly  2202  and second connector assembly  2204  may be achieved by sliding second connector assembly  2204  relative to first connector assembly  2202  in the direction indicated by the arrows (this may be, e.g., along the length of connector assembly  1800  of  FIG. 18 ). An attachment operation may be detected using optical data ports  2102  and  2104 . For example, optically transparent window  2108  of first optical data port  2102  may include reflective zones  2230  disposed at either end of optically transparent window  2108 . Reflective zones  2230  are further shown in  FIG. 23 , which is a front view of a portion of connector assembly  2202 . Optically transparent window  2108  is disposed in housing  2106  and has reflective zones  2230  at either end. Reflective zones  2230  may be positioned at the inner surface of window  2108 , as shown in  FIG. 22 , at the outer surface of window  2108 , or embedded within the optically transparent material of window  2108 . Reflective zones  2230  may be made of or coated with a material that is highly reflective at a wavelength detectable by photodetector  2126 , such as aluminum or silver. Any material may be used, provided that the reflectivity of reflective zones  2230  is sufficiently different from the reflectivity of optically transparent window  2108  or the rest of housing  2106  that photodetector  2126  may reliably detect the difference. 
     Referring again to  FIG. 22 , as connector assembly  2204  moves relative to connector assembly  2202 , light from LED  2124  may shine onto housing  2106 . Some of the light may be reflected back to photodetector  2126 . When LED  2124  comes into approximate alignment with reflective zone  2230 , the amount of light from LED  2124  that is reflected back to photodetector  2126  may increase significantly. The increased light detected by photodetector  2126  may be used as an indication that second connector assembly  2204  is being attached to first connector assembly  2202 . Conversely, an increased signal may occur again as second connector assembly  2204  is being detached from first connector assembly  2202 . Such signals may be used by the second electronic device, of which second connector assembly  2204  is a part, to determine when to energize an inductive charging port or to take other actions that are to be performed based on attachment of second connector assembly  2204  to first connector assembly  2202 . 
     It is to be understood that the arrangement shown in  FIGS. 22 and 23  is illustrative and may be modified. For example, one or both of reflective zones  2230  may be replaced with light-absorbing zones (e.g., areas made of a material with measurably lower reflectivity than optically transparent window  2108  or the rest of housing  2106 ), and a decrease in light detected by photodetector  2126  may be used as an indicator that second connector assembly  2204  is being attached to or detached from first connector assembly  2202 . Reflective zones may also be placed in other portions of optically transparent window  2108 . For example, a reflective zone may be placed in the region between LED  2110  and photodiode  2112 . In some embodiments, optically transparent window  2122  may also include reflective (or light-absorbing) zones, and attachment may be detected by first data port  2102  of first connector assembly  2202  using LED  2110  and photodetector  2112 . Optical attachment detection may thus be performed by either or both of the first and second electronic devices. 
       FIG. 24  shows an exploded view of components of first optical data port  2102  according to an embodiment of the present invention. As shown, first optical data port  2102  may include a housing  2106 , which may be generally similar to housing  120  described above and may include an optically transparent window as described above. O-ring  2406  may be shaped to provide a seal between housing  2106  and a cavity in which housing  2106  is inserted, as described above. Optical transceiver module  2408  may incorporate LED  2110  and photodetector  2112 , along with appropriate driver and signal processing circuitry. Optical transceiver module  2408  may be connected via circuit board  2114  to interposer  2116 , which in turn may connect to a flexible circuit board  2118 . An insulating spacer  2420  may be provided between flexible circuit board  2118  and cover  2422 , which may be made of metal. Fasteners  2424  may hold the structure in place in the body of a connector assembly. Viewed from the rear, optical data port  2102  may be similar to data port  1804  shown in  FIG. 18 . Other types of data ports, including examples described above, may be constructed similarly. 
     The various data ports shown and described herein are illustrative and may be modified. The dimensions may be adapted to conform to the geometry of the connector assemblies in which the data ports are included, and a connector assembly may include zero or more data ports. For example, some connector assemblies may include one or two power ports and no data port. 
     In these and other embodiments of the present invention, other circuitry of the electronic device may be able to make use of portions of the connector assembly. For example, a bracket may be used to covey current for a power supply, it may be used as an antenna, a guide or housing for an antenna, or it may be used for other purposes. For example, the bracket may be a plastic housing for an antenna. 
       FIG. 25  illustrates inductive charging ports that may be used to transfer power between devices according to an embodiment of the present invention. A first inductive charging port  2510  may be housed in a device enclosure  2512  of a first electronic device. A second inductive charging port  2610  may be housed in a device enclosure  2612  for a second electronic device. In various embodiments of the present invention, power may be transferred from the first inductive charging port  2510  to the second inductive charging port  2610 , or power may be transferred from inductive charging port  2610  to inductive charging port  2510 . 
     Inductive charging port  2510  may include transformer core  2520  that may be at least partially surrounded by windings  2522 . For example, transformer core  2520  may have one or more legs surrounded by windings  2522 , a yoke of transformer  2520  may be surrounded by windings  2522 , or these or other portions or combinations of portions of transformer core  2520  may be surrounded by windings  2522 . Transformer core  2520  may be housed in a sleeve  2530 . Sleeve  2530  may move relative to device enclosure  2512 . Transformer core  2520  and windings  2522  may be encapsulated in place in sleeve  2530  by an epoxy or other potting material  2534 . Similarly, an area  2514  may be at least partially filled with an epoxy or other potting material. Potting material or epoxy  2534  and the potting material or epoxy in area  2514  may prevent moisture ingress into the first electronic device. 
     Inductive charging port  2610  may include transformer core  2620  that may be at least partially surrounded by windings  2622 . For example, transformer core  2620  may have one or more legs surrounded by windings  2622 , a yoke of transformer core  2620  may be surrounded by windings  2622 , or these or other portions or combinations of portions of transformer core  2620  may be surrounded by windings  2622 . Transformer core  2620  may be housed in sleeve  2630 . Sleeve  2630  may be fixed in place relative to the device enclosure  2612 . Transformer core  2620  and windings  2622  may be secured in place in sleeve  2630  by an epoxy or other potting material  2634 . O-ring  2640  may provide a seal to prevent the ingress of moisture into the second electronic device. 
     Sleeve  2630  may be at least partially molded around frame  2660 . Frame  2660  may provide mechanical support for sleeve  2630 . Shim  2650  may be placed between device enclosure  2612  and frame  2660  to mechanically align a front surface of transformer  2622  to a front surface of device enclosure  2612 . Flexible circuit board  2670  may provide an electrical conduit from transformer core  2620  to other circuitry (not shown) in the second electronic device. 
     In various embodiments the present invention, it may be desirable to align opposing faces of transformer cores  2520  and  2620  to each other and to minimize the spacing between them. This may improve the transfer of energy between the inductive charging ports  2510  and  2610 . Lateral alignment may be achieved as described above. The spacing between transformers  2520  and  2620  may be minimized by either exposing surfaces of transformers  2520  and  2620  at the surfaces of their electronic devices or by covering them with a very thin protective layer. In this example, a surface of transformer core  2520  may be exposed while a surface of transformer core  2620  may be covered by a thin protective layer  2632 . The gap may be further reduced by applying a spring force to move sleeve  2530  and transformer core  2520  towards transformer core  2620  in corresponding inductive charging port  2610 . The gap may be further reduced by using shim  2650  in inductive charging port  2610  to properly align a surface of transformer core  2620 , for example to a surface of device enclosure  2612  of the second electronic device. 
     Again, in this specific embodiment of the present invention, a surface of transformer core  2520  may be exposed while a surface of transformer core  2620  may be covered with a thin protective layer  2632 . Accordingly, surfaces of sleeve  2530 , epoxy or potting material  2534 , and transformer core  2520  may be exposed at a surface of device enclosure  2512 . 
     During assembly, transformer core  2520  and windings  2522  may be placed in sleeve  2530 . A liner may be placed over surfaces of transformer core  2520  and sleeve  2530 . Epoxy or other potting material  2534  may be inserted between transformer core  2520  and sleeve  2530 , where the liner protects the surface of transformer core  2520  and surface of sleeve  2530  from the epoxy or potting material  2534 . The epoxy or potting material  2534  may be cured and the liner may then be removed. Afterward, for cosmetic and functional reasons, the surfaces of transformer core  2520 , sleeve  2530 , and epoxy or potting material  2534  may be polished or otherwise smoothed together as a unit. For example, a buffing wheel, polishing cloth, sandpaper, blasting, tumbling, or other methods may be used to provide a cosmetic and functional finish to the combined surface. The surfaces of transformer core  2520 , sleeve  2530 , and potting material or epoxy  2534  may also be colored, for example by ink jet printing, pad printing, physical vapor deposition, epoxy, or other method. They may be colored black, they may be colored to match the device enclosure  2512 , or they may have another color. In still other embodiments of the present invention, sleeve  2530  may be extended to provide a protective layer over a surface of the transformer core  2520 . 
     A surface of the transformer core  2620  for the second electronic device may be covered with a thin protective layer  2632 . Protective layer  2632  may be formed either along with, or separately from, sleeve  2630  by placing transformer core  2620  in a die holding a plastic in a fluid or liquid state. A predetermined force may be applied to transformer core  2620 . The plastic in the die may be squeezed to provide a thin layer over the surface of transformer core  2620 . The plastic may then be cured in place. By making protective layer  2632  thin, the resulting energy transfer may be maximized while transformer core  2620  may still be protected by protective layer  2632 . Protective layer  2632  may be formed of liquid crystal polymer or other material. Protective layer  2632  may be as thin as 0.05, 0.1, 0.2, or 0.5 mm. Autoclaving, degassing, or other steps may be employed to avoid separation of the protective layer  2632  from the surface of transformer core  2620 . 
     Again, a surface of transformer core  2520  may similarly be covered by a protective layer. An example is shown in the follow figure. 
       FIG. 26  illustrates inductive charging ports that may be used to transfer power between devices according to an embodiment of the present invention. A first inductive charging port  2510  may include a transformer core  2520  in sleeve  2530 , where transformer core  2520  is held in place by epoxy or other potting material  2534 . A thin protective cover  2532  may be formed together with, or separately from, sleeve  2530 . Protective cover  2532  may cover a surface of transformer core  2520  and epoxy or potting material  2534 . Protective layer  2532  may be formed by placing transformer core  2520  in a die holding a plastic in a fluid or liquid state. A predetermined force may be applied to transformer core  2520 . The plastic in the die may be squeezed to provide a thin layer  2532  over the surface of transformer core  2520 . The plastic may then be cured in place. By making protective layer  2532  thin, the resulting energy transfer may be maximized while transformer core  2520  is still protected by protective layer  2532 . Protective layer  2532  may be formed of liquid crystal polymer or other material. Protective layer  2532  may be as thin as 0.05, 0.1, 0.2, or 0.5 mm. Autoclaving, degassing, or other steps may be employed to avoid separation of the protective layer  2532  from the surface of transformer core  2520 . 
       FIG. 27  illustrates a portion of an inductive charging port according to an embodiment of the present invention. Inductive charging port  2510  may include transformer core  2520  having one or more portions at least partially wrapped by windings  2522 . Transformer core  2520  and windings  2522  may be located in sleeve  2530 . Transformer core  2520  and windings  2522  may be secured in sleeve  2530  by epoxy or other potting material  2534 . During assembly, transformer core  2520  may be wrapped by windings  2522 . Transformer core  2520  and windings  2522  may be inserted into sleeve  2530 . A lining or other material may be placed over front surfaces of transformer core  2420  and sleeve  2530 . Epoxy or other potting material  2534  may be injected between transformer core  2520  and sleeve  2530 . The lining may protect front surfaces of transformer core  2520  and sleeve  2530  from being exposed to the epoxy or other potting material  2534 . The epoxy or other material  2534  may be cured and the liner may be removed. 
     For cosmetic and functional reasons, the surfaces of transformer core  2520 , sleeve  2530 , and epoxy or potting material  2534  may be polished or otherwise smoothed together as a unit. For example, a buffing wheel, polishing cloth, sandpaper, blasting, tumbling, or other methods may be used to provide a cosmetic and functional combined surface. The surfaces of transformer core  2520 , sleeve  2530 , and potting material or epoxy  2534  may also be colored, for example by ink jet printing, pad printing, physical vapor deposition, epoxy, or other method. They may be colored black, they may be colored to match the device enclosure  2512  (as shown in  FIG. 25 ), or they may have another color. In still other embodiments of the present invention, sleeve  2530  may be extended to provide a protective layer over a surface of the transformer core  2520 . 
       FIG. 28  is an exploded view of an inductive charging port according to an embodiment of the present invention. Charging port  2510  may include a sleeve  2530 . Sleeve  2530  may be inserted into an opening in device enclosure  2512  as shown in  FIG. 25 . Retention clips  2536  may secure sleeve  2530  in device enclosure  2512  while still allowing sleeve  2530  to move relative to device enclosure  2512 . Transformer core  2520  may include one or more legs and a yoke at least partially wrapped by windings  2522 . Transformer core  2520  may be inserted into sleeve  2530 . As before, an epoxy or potting material  2534  may be used to secure transformer core  2520  in place in sleeve  2530 . O-ring  2810  may be placed between sleeve portion  2530  and device enclosure  2512  to prevent moisture ingress into the electronic device. Contact plate  2820  may attach to transformer  2520  and provide contact areas for dynamic wires  2830 . Dynamic wires  2830  may include an amount of slack to compensate for the movement of sleeve  2530  relative to device enclosure  2512  and the remainder of the electronic device. 
     One or more spring elements may bias sleeve  2530  towards the front of device enclosure  2512  in order to limit a gap between transformer core  2520  and transformer core  2620 , as shown in  FIG. 25 . These spring members may include flexure  2840 . In other embodiments of the present invention, the spring members may include plate  2850  having posts  2852 , with springs  2860  positioned around posts  2852 . 
     In this example, retention clips  2536  may be used to secure sleeve  2530  to device enclosure  2512  while still allowing sleeve  2530  to move relative to device enclosure  2512 . In other embodiments of the present invention, other types of retaining features may be used. Examples are shown in the following figures. 
       FIG. 29  illustrates a sleeve for an inductive charging port according to an embodiment of the present invention. In this example, fasteners  2910  may be screwed into nuts  2920 . Nuts  2920  may be insert-molded into sleeve  2530 . Sleeve  2530  may include front openings  2532  for surfaces of transformer core  2520  as shown in  FIG. 28 , and a rear opening  2534  for the insertion of transformer core  2520  during assembly, also as shown in  FIG. 28 . 
       FIG. 30  illustrates a sleeve for an inductive charging port according to an embodiment of the present invention. In this example, bracket  3010  may provide support for fastener  3020  and nut  3030 . 
       FIG. 31  illustrates a sleeve for an inductive charging port according to an embodiment of the present invention. In this example, retention clip  3110  may be fixed to a rear of sleeve  2530 . O-ring  2810  is shown as well. Again, O-ring  2810  may be placed between sleeve  2530  and device enclosure  2512  to prevent ingress of moisture into the electronic device. 
       FIG. 32  illustrates a sleeve for an inductive charging port according to embodiments of the present invention. In this example, threaded recesses  3010  may be located in sleeve  2530 . Fasteners (not shown) may be inserted from the front of sleeve  2530  into threaded recesses  3210 . As before, sleeve  2530  may include openings  2532  for surfaces of transformer core  2520  and a rear opening  2534  for the insertion of the transformer core  2520 , as shown in  FIG. 28 . 
       FIG. 33  illustrates a transparent view of an inductive charging port according to an embodiment of the present invention. In this example, transformer core  2520  may be at least partially wrapped by windings  2522 . The legs of transformer core  2520  may be supported by yoke  2521 . Transformer core  2520  may be located in sleeve  2530 . Sleeve  2530  may be located in device enclosure  2512 , as shown in  FIG. 25 . Yoke  2521  of transformer core  2520  may interface with contact plate  2820 . Wires  2830  may be soldered at points  2832  to contact plates  2820 . Wires  2830  may further be connected to flexible circuit board  3320  at connections  2834 . Wires  2830  may be dynamic wires, that is they may have sufficient flex to allow sleeve  2530  to move relative to device enclosure  2512 . In various embodiments of the present invention, sleeve  2530  may move 0.2, 0.4, or 1.0 mm relative to device enclosure  2512 . 
     Again, sleeve  2530  may move relative to device enclosure  2512 . Retention clips  2536  may secure sleeve  2530  in place in device enclosure  2512 . Specifically, when sleeve  2530  is inserted into device enclosure  2512 , sides of retention clips  2536  may release and move away from sides of sleeve  2530 . Retention clips  2536  may be expanded and be located in notches  3310  in device enclosure  2512 . Notches  3310  may have a greater length along a side of sleeve  2530  than retention clips  2536 . This may limit the travel of sleeve  2530  relative to device enclosure  2512 , while allowing the necessary freedom of movement. 
     Again, it may be desirable to push transformer core  2520  towards a transformer core of a corresponding inductive charging port. Accordingly, this inductive charging port may include plate  2850  having posts  2852 . Springs  2860  may be located around posts  2852  and may be located between plate  2850  and device enclosure  2512 . In this configuration, spring  2860  may push sleeve  2530  in a direction such that transformer core  2520  is moved closer to a corresponding transformer core, such as transformer core  2620  in charging port  2610 , as shown in  FIG. 25 . As before, O-ring  2810  may be located between sleeve  2530  and device enclosure  2512  to prevent moisture leakage into the first electronic device. 
       FIG. 34A  illustrates another transparent view of an inductive charging port according to an embodiment of the present invention. Sleeve  2530  may be located in device enclosure  2512 . Retention clips  2536  may be expanded away from sides of sleeve  2530  and may be located in notches  3310 . This may allow retention clips  2536  to fix sleeve  2530  in an opening in device enclosure  2512  while allowing the necessary freedom of movement. O-ring  2010  may prevent moisture ingress into the first electronic device. Dynamic wires  2830  may make electrical connections through contacts  2834  to flexible circuit board  3320 . Springs  2860  may drive plate  2850  away from a bottom surface of device enclosure  2512 . Plate  2580  may include posts  2582  for stabilizing springs  2860  in place. 
       FIGS. 34B-34D  illustrate a retention clip for securing a sleeve to a device enclosure according to an embodiment of the present invention. In  FIG. 34B , retention clip  2536  may be attached to sleeve  2530 . Specifically, retention clip  2536  may include tabs  3402  that may fit in notches  3412  in sleeve  2530 . Retention clip  2536  and its flexures  3404  may be slid into groove  3414  in sleeve  2530 . Tabs  3402  and notches  3412  may secure retention clip  2536  in place in sleeve  2530 . 
     As sleeve  2530  is inserted into device enclosure  2512  (shown in  FIG. 34A ), retention clip  2536  may be compressed. This compression may allow sleeve  2530  to be inserted into device enclosure  2512 . After insertion, retention clip  2536  may expand thereby securing sleeve  2530  in place in device enclosure  2512 . 
     In  FIG. 34C , retention clip  2536  may be compressed from position  2536 A to position  2536 B. Retention clip flexures  3404  may move from position  3404 A to position  3404 B. This compression may occur when sleeve  2530  is inserted into device enclosure  2512 . This compression may be caused by a tool pushing retention clip  2536  against sleeve  2530 . In these and other embodiments of the present invention, the compression may be caused by a chamfered leading edge (not shown) of retention clip  2536  engaging device enclosure  2512  as sleeve  2530  is inserted. In these and other embodiments of the present invention, the compression may be caused by a chamfered leading edge (not shown) of device enclosure  2512  engaging retention clip  2536  during the insertion. Once sleeve  2530  is inserted into device enclosure  2512 , flexures  3404  may bias retention clip  2536  outward. That is, flexures  3404  may move from position  3404 B to position  3404 A, while retention clip  2536  may expand from position  2536 B to position  2536 A, thereby securing sleeve  2530  in place in device enclosure  2512 . In  FIG. 34D , retention clip  2536  may be compressed from position  2536 A to position  2536 B. Retention clip  2536  may be formed in various ways. For example, it may be stamped, forged, 3-D printed, molded, or formed in other ways. Retention clip  2536  may be formed of stainless steel or other flexible material. 
       FIG. 35  illustrates an exploded view of another inductive charging port according to an embodiment of the present invention. In this example, inductive charging port  2610  may include sleeve  2630 . Sleeve  2630  may be partially formed around bracket  2660 . Bracket  2660  may be fixed to device enclosure  2612  to hold the inductive charging port  2610  in place. Windings  2622  may be wrapped around one or more legs of transformer core  2620 . Yoke  2621  may support the legs of transformer core  2620 . Transformer core  2620  may be inserted into sleeve  2630 . Epoxy or other potting material  2634  may secure transformer core  2620  in place in sleeve  2630 . Landing pads  3510  may provide contact areas for leads  2623  from windings  2622 . Dimple plates  3520  may be used to form electrical connections between landing pads  3510  and flexible circuit board  2670 . Bracket  3530  may hold dimple plates  3520  in place against landing pad  3510 . Fasteners  3540  may pass through openings  3532  in bracket  3530 , opening  2662  in bracket  2660 , and opening  2652  in shim  2650 , and into a threaded opening in device enclosure  2612  (not shown). 
     Again, it may be desirable to align transformer core  2620  with transformer core  2520  of inductive charging port  2510  as shown in  FIG. 25 . To improve the alignment of transformer core  2620  to a surface of device enclosure  2612 , shim  2650  may be used. In various embodiments of the present invention, a number of shims  2650  having varying widths may be provided, where a shim  2650  having a desired width is selected from among them. 
       FIG. 36  illustrates a portion of an inductive charging port according to an embodiment of the present invention. Yoke  2621  may be located in sleeve  2630  and held in place epoxy or other potting material  2634 . Leads  2623  may be soldered to landing pads  3510  at solder point  3514 . Solder block regions  3512  may prevent solder from flowing onto the remainder of landing pads  3510 . Bracket  3660  may be partially encapsulated in sleeve  2630  and may include opening  2662  for a fastener  3540 , as shown in  FIG. 35 . 
       FIG. 37  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention. Again, leads  2623  may be soldered at solder points  3514  to landing pads  3510 . Sleeve  2630  may be formed at least partially around bracket  2660 . 
     In various embodiments of the present invention, it may be desirable to form a removable connection to landing pads  3510 . This may allow an easy rework of an inductive charging port, such as inductive charging ports  2510  and  2610 , as shown in  FIG. 25 . For example, a sleeve and transformer core can be easily removed and replaced with such a removable connection to landing pads  3510 . Accordingly, embodiments of the present invention may attach a dimple plate  3520  that may be held in place under force to form a connection to landing pads  3510 . An example is shown in the following figures. 
       FIG. 38  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention. In this example, dimple plates  3520  may be in contact with landing pads  3510 . Again, bracket  2660  may be partially encapsulated by sleeve  2630 . 
     Again, by not soldering dimple plates  3520  to landing pads  3510 , it may be easier to rework these inductive charging ports, such as charging ports  2510  and  2610  in  FIG. 25 . Accordingly, in various embodiments of the present invention, it may be desirable to apply a force to dimple plates  3520 . An example is shown in the following figure. 
       FIG. 39  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention. In this example, dimple plate  3520  may be in contact with landing pad  3510 . Dimple plate  3520  may be soldered by solder layer  2672  to flexible circuit board  2670 . Flexible circuit board  2670  may include a protective layer  2674 . Dimple plate  3520  may be pressed into contact with landing pads  3510  by bracket  3530 . Bracket  3530  may be held in place by bracket  3910  and fastener  3540 . As will be shown below, bracket  3910  may be a second bracket used in securing electronic components to device enclosure  2612 . 
       FIG. 40  illustrates a side view of a portion of an inductive charging port according to an embodiment of the present invention. Again, dimple place  3520  may be in contact with landing pads  3510 . Dimple plates  3520  may be soldered to flexible circuit board  2670 . Bracket  3530  may provide a force maintaining contact between dimple plates  3520  and landing pads  3510 . In various embodiments of the present invention, bracket  3530  may be a flexure, a rigid bracket, or other spring-like structure, which may include actual springs. Fasteners  3540  may be inserted through openings in brackets  2620  and  3910  into openings in the device enclosure  2612  to secure this assembly in place. 
       FIG. 41  illustrates a portion of an inductive charging port according to an embodiment of the present invention. Again, bracket  2620  may be partially enclosed by sleeve  2630 . Leads from windings (not shown) from transformer core may be soldered at solder points  3514  to landing pads  3510 . Dimple plates  3520  may be held in place against landing pads  3510  by bracket  3530 . Dimple plates  3520  may be in electrical contact with flexible circuit board  2670 . Protective layers  2674  may protect flexible circuit board  2670  from bracket  3530 . Bracket  3530  may be held in place relative to the device enclosure  2612  by fasteners  3540 , which may pass through openings in brackets  3530 ,  3910 , and  2620 , and into threaded recesses (not shown) in the device enclosure  2612 . 
     In various embodiments the present invention, bracket  3910  may be used to secure other ports, such as other inductive charging ports or data ports. Some examples of such data ports are described above. Additional examples of such data ports are shown in the following figures, which relate to embodiments of a 60-GHz data port similar to that shown in  FIG. 20  above. 
       FIG. 42  shows a simplified cross-section view of complementary 60-GHz data ports  4202 ,  4204  according to an embodiment of the present invention, and  FIG. 43  shows another simplified cross-section view along a direction orthogonal to that of  FIG. 42 . First data port  4202  may include a 60-GHz edge-fire antenna and transceiver chip  4206 . An interposer  4208  may connect transceiver chip  4206  to a printed circuit board  4210 , which may be a flexible circuit board that connects to other circuitry in a first electronic device in which first data port  4202  is located. Transceiver chip  4206  and interposer  4208  may be held in a housing  4212 , which may be made of a plastic (e.g., liquid crystal polymer (LCP)) or other dielectric material. An encapsulating material  4214 , such as epoxy or other resin, may hold transceiver chip  4206  and interposer  4208  in place within housing  4212 . In some embodiments, data port housing  4212  may be placed in an opening in a housing  4218  of the first electronic device. An O-ring  4216  may provide a watertight seal between the outer surface of housing  4212  and the opening in housing  4218 . 
     Second data port  4204  may also include a 60-GHz edge-fire antenna and transceiver chip  4226 , which may be similar or identical in design to transceiver chip  4206 . Transceiver chip  4226  may be connected to a printed circuit board  4230 , which may be a flexible circuit board that connects to other circuitry in a second electronic device in which second data port  4204  is located. Transceiver chip  4226  may be held in a housing  4232 , which may be made of a plastic or other dielectric material. An encapsulating material  4234 , such as epoxy or other resin, may hold transceiver chip  4226  in place. In some embodiments, data port housing  4232  may be placed in an opening in a housing  4238  of the second electronic device. O-rings or other seals (not shown) may be provided between housings  4232  and  4238  if desired. 
       FIG. 44  is another simplified cross-section view showing additional details of the electrical connections for first data port  4202  using interposer  4208  according to an embodiment of the present invention. Transceiver chip  4206  may have a number of electrical contact pads  4402  disposed on a back surface. For instance, as shown in  FIG. 45 , there may be seven contact pads  4402  arranged in two rows. Other configurations of contact pads may be used. Interposer  4208  may have a number of electrical leads  4404  corresponding to the number of contact pads  4402  Each electrical lead  4404  may be shaped as shown in  FIG. 44  and held in position by an electrically insulating material  4406 , which may be LCP or other plastic or other non-conductive material. Interposer  4208  may provide a right-angle bend in leads  4404 . This may facilitate connection of leads  4404  to contacts corresponding contacts  4408  of printed circuit board  4210 . Strain relief element  4410  (which may include, e.g., foam, rubber, or similar material) may be provided to protect printed circuit board  4210 . Foam  4412  or other spacing material may be provided to facilitate assembly of data port  4202  into the housing of the first electronic device. 
     Assembly of an embodiment of data port  4202  will now be further described with reference to  FIGS. 46-51 , which show stages of an assembly process for a data port according to an embodiment of the present invention.  FIG. 46  shows a simplified view of transceiver chip  4206 . Transceiver chip  4206  may be a packaged semiconductor device that incorporates antenna components to generate and detect RF signals as well as signal processing circuitry (amplifiers, digital-to-analog converters, analog-to-digital converters, encoders, decoders, modulators, demodulators, etc.). A back surface portion  4602  of transceiver chip  4206  may have electrical contacts disposed thereon (e.g., as shown in  FIG. 45 ) to supply power to transceiver chip  4206  and to provide signal input and output paths for data communication and control signals. 
       FIG. 47  shows an assembly stage  4700  in which interposer  4208  is bonded to back surface portion  4602  of transceiver chip  4206 . Portions of leads  4402  may be exposed to make electrical contact with contacts  4402  on back surface portion  4602  of transceiver chip  4206 . Top portions of leads  4402  may also be exposed. Other portions of leads  4402  may be encased in electrically insulating material (e.g., LCP or other plastic). In some embodiments, bonding of contacts  4402  to the contacts on the back surface portion  4602  of transceiver chip  4206  may be accomplished using soldering or sintering techniques. Soldering or sintering paste with a high reflow temperature may be used at this stage. 
       FIG. 48  shows a further assembly stage  4800 . At this stage, interposer  4208  and transceiver chip  4206  may be inserted into housing  4212  and surrounded by encapsulating material  4214 . In some embodiments, encapsulating material  4214  may be dispensed in a liquid form into housing  4212 , and then cured. Housing  4212  may incorporate attachment structure  4802 , which may include side tab regions  4804  with through-holes  4806  to facilitate attachment of assembled data port  4202  into the housing of an electronic device. Attachment structure  4802  may be made of stainless steel or other metals. The particular geometry of attachment structure  4802  and housing  4212  may be varied as desired. 
       FIG. 49  shows a further assembly stage  4900 . At this stage, strain relief element  4410  may be placed or attached to the exposed side surface of transceiver chip  4206 . 
       FIG. 50  shows a further assembly stage  5000 . At this stage, flexible printed circuit board  4210  may be bonded to the exposed surfaces of leads  4402  of interposer  4208  to provide an electrical connection. Soldering techniques may be used. In some embodiments, a low-temperature reflow solder may be used at this stage, with the reflow temperature being low enough not to cause further reflow of solder or sintering paste used at assembly stage  4700 . Strain relief element  4410  protects the bend radius of flexible printed circuit board  4210  to prevent damage. In some embodiments, strain relief element  4410  may be attached to flexible printed circuit board  4210  first, rather than to transceiver chip  4206 . 
       FIG. 51  shows a final assembly stage  5100 . At this stage, assembly stage  5000  has been inserted into housing  4218  of a first electronic device. Assembly stage  5000  may be held in place by cowling  5102 , which may be attached to housing  4218  using screws  5104  or other fasteners that may pass through holes  4806  in side tabs  4804 . Foam  4412  may be placed between assembly stage  5000  and cowling  5102 . A shim  5106  may be provided between side tabs  4804  and housing  4218 . In some embodiments, shim  5106  may facilitate precise alignment of an exterior-facing surface of data port  4202  with an exterior surface of housing  4218 . For example, in embodiments where the surface in which data port  4202  is installed slides laterally relative to a mating surface of a second electronic device, it may be desirable to provide a smooth exterior surface with no protrusions or indentations due to data port  4202 . Flexible printed circuit board  4210  may extend into the interior of the first electronic device and may provide electrical connections to other circuits and components of the first electronic device. As shown, the assembly may be similar to data port  1804  shown in  FIG. 18 . 
     A further understanding of assembly of data port  4202  may be had with reference to  FIG. 52 , which shows an exploded view of an assembly for data port  4202  according to an embodiment of the present invention. As shown, data port  4202  may include a housing  4212 , which may be generally similar to housing  120  described above. Housing  4212  may include attachment structure  4802  with side tabs  4804 . O-ring  4216  may be shaped to provide a seal between housing  4212  and a cavity in which housing  4212  is inserted, as described above. Transceiver chip  4206  may be connected to interposer  4208 , which in turn may connect to flexible circuit board  4210 . Strain relief element  4410  may provide protection for flexible circuit board  4210  where it bends to accommodate the shape of the first electronic device. Encapsulating material  4214  may surround and protect transceiver chip  4206  and a portion of interposer  4208 . Data port  4202  may be inserted into a cavity in a housing of an electronic device and held in place using screws  5104  (or other fasteners) inserted through holes  4806  in side tabs  4804 . Shim  5106  may be included between side tabs  4804  and the housing of the electronic device to provide precise alignment at an outer surface of the electronic device. 
     Data port  4202  may be used in an environment where a specific bend angle in flexible circuit board  4210  is desired, e.g., to accommodate the form factor (or internal geometry) of the electronic device in which data port  4202  is to be installed. In such environments, interposer  4208  may reduce the bend angle of flexible circuit board  4210 . However, as noted above, assembly may require two reflow operations, and it may be desirable to simplify the assembly process. 
     In some embodiments, assembly may be simplified by connecting flexible circuit board  4210  directly to transceiver chip  4206  and using a mandrel to provide strain relief for the larger bend angle of the flexible circuit board.  FIG. 53  shows a simplified cross section view of a 60-GHz data port  5302  according to an embodiment of the present invention. Data port  5302  may be generally similar to data port  4202  described above and may include a housing  4212  that holds 60-GHz transceiver chip  4206 . Housing  4212  may be inserted in a cavity in housing  4218  of a first electronic device. Flexible circuit board  5310  may be connected to the back surface of transceiver chip  4206  and may bend around the top of data port  5302 . In some embodiments, a mandrel  5308 , which may be made of LCP or other dielectric material, may be provided. Mandrel  5308  may have an outer surface that is shaped to provide strain relief for flexible circuit board  5310 . Glue  5320  or other adhesive may be used to secure flexible circuit board  5310  to mandrel  5308 . In some embodiments, additional strain relief pads may be provided in the region  5322  where flexible circuit board  5310  contacts transceiver chip  4206 . A stiffener  5324  may be applied to the back surface of flexible circuit board  5310  to provide additional mechanical strength for flexible circuit board  5310  and transceiver chip  4206 . Encapsulating material (not shown) may fill the region around transceiver chip  4206 , flexible circuit board  5310 , and stiffener  5324 , similar to encapsulating material  4214  described above. 
     In some embodiments, mandrel  5308  may be attached to beam  5326 .  FIG. 54  shows a perspective view of a portion of data port  5302  according to an embodiment of the present invention. Mandrel  5308  may be attached to beam  5326 , which in this example includes side tabs  5402  having through-holes  5404 . Beam  5326 , which may be made of stainless steel or the like, may provide additional alignment and mechanical strength for the assembly, as well as protection for transceiver chip  4206 . In some embodiments, instead of polymers or plastics, mandrel  5308  may be formed of the same material as beam  5326 , and mandrel  5308  and beam  5326  may be formed as a single integrated structure. 
     Further illustrating a data port assembly using a mandrel,  FIG. 55  shows a perspective cutaway view of a portion of data port  5302  according to an embodiment of the present invention. As shown, beam  5326  is placed over the top side of transceiver chip  4206 , and mandrel  5306  is opposite transceiver chip  4206 . Flexible circuit board  5306  connects to electrical contacts on the back surface of transceiver chip  4206  and bends around mandrel  5306 . Stiffener  5324  may be attached to the surface of flexible circuit board  5306  opposite transceiver chip  4206 . 
       FIG. 56  shows data port  5302  installed in an electronic device according to an embodiment of the present invention. Data port  5302  may be inserted into an opening in housing  4218  of a first electronic device so that the bottom edge (as seen in  FIG. 53 ) of transceiver chip  4206  is oriented toward the outside of the first electronic device. Housing  4212  may be sized and shaped to fit the opening in housing  4218  and may have attachment structure  4802  (as shown in  FIG. 48 ) or another attachment structure. Flexible circuit board  5310  extends into the interior of housing  4212  to connect with transceiver chip  4206 . The holes in side tabs  5402  of beam  5326  may align with holes in attachment structure  4802 , allowing data port  5302  to be secured to housing  4218  using screws  5602  or other fasteners. 
     In some embodiments, beam  5326  may be replaced using a stiffener tab.  FIG. 57  is a simplified side view of a data port  5702  according to an embodiment of the present invention. Data port  5702  may be similar to data port  5302 , except that beam  5326  is omitted and stiffener  5324  is replaced with a stiffener tab  5724 . Stiffener tab  5724  may have a forward portion  5726  that may attach to flexible circuit board  5310  and a rear portion  5728  that extends over the top of data port  5702 . 
       FIG. 58  is a perspective view of data port  5702  further illustrating a stiffener tab according to an embodiment of the present invention. As shown, rear portion  5728  of stiffener tab  5724  may be shaped to provide side tabs  5802  and through-holes  5804  that align with the through-holes of attachment structure  4802 . Screws or other fasteners (not shown) may be used to hold the assembly in place. 
     Data port configurations of the type shown in  FIGS. 44, 53, and 57  may be particularly useful in situations where the internal geometry of the electronic device in which the data port is included determines a particular exit path for a flexible circuit board or other electrical connection to the data port. For example, in  FIGS. 44, 53, and 57 , the angle between the back surface of transceiver chip  4206  and the exit path of flexible circuit board  4210  or  5310  is about 60 degrees. Use of an interposer (e.g., interposer  4208 ) or mandrel (e.g., mandrel  5306 ) may help to accommodate this angle while avoiding damage to the flexible circuit board or other components. 
     In other situations, the internal geometry of an electronic device may allow for less of a sharp bend in a flexible circuit board. Where this is the case, the assembly of a 60-GHz data port may be simplified. For example,  FIG. 59  shows a simplified exploded view of second data port  4204  (shown in cross section in  FIG. 42 ) according to an embodiment of the present invention. As shown, data port  4204  may include a housing  4232 , which may be generally similar to housing  220  described above. Housing  4232  may include mounting posts  5902  or other attachment structures to help hold data port  4204  in position in an electronic device. Transceiver chip  4226  may be connected to flexible circuit board  4230  and inserted into housing  4232 . Encapsulating material  4234  (which may be similar to encapsulating material  4214 ) may be used to surround and protect transceiver chip  4226  and flexible circuit board  4230 . Data port  4204  may be inserted into an opening in a housing of an electronic device. 
     The various 60-GHz data ports described above are illustrative, and variations and modifications are possible. The dimensions may be adapted to conform to the geometry of a particular connector assembly in which a data port is to be included. Materials may be varied as desired. In some embodiments, the performance of the transceiver chip may be affected by the dielectric coefficients of nearby dielectric materials. Accordingly, it may be desirable to make all plastic or other nonconductive materials in the data port from the same material (e.g., LCP) or from materials whose dielectric coefficients are similar to each other. For instance, where an interposer (e.g., interposer  4208 ) is used, the interposer may have the same dielectric coefficient as housing  4212 . 
     In some embodiments, it may be desirable to provide water sealing around the transceiver chips and other electrical connections. Water sealing may be provided using conventional potting techniques (e.g., applying epoxy or other resins to seal the opening of the housing. 
     In some of the embodiments described above, the data port assembly is designed to accommodate the geometry of an electronic device in which the data port is to be included, for instance by providing various elements (e.g., interposer, mandrel) to provide electrical connections and strain relief for a flexible circuit board connected to the data port. It is to be understood that the shapes and dimensions of interposers and/or mandrels may be adapted for the internal geometry of a particular electronic device. Further, an interposer or a mandrel may also be used in connection with other types of data ports, such as the capacitive data ports of  FIG. 19  or the optical data ports of  FIG. 21 , where it is desired to provide a data port with an electrical connection subject to particular geometric constraints. 
     In various embodiments of the present invention, the components of the connector assemblies may be formed in various ways of various materials. For example, conductive portions, and other portions such as the retention clips, may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive and other portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, palladium, palladium silver, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions, such as the housings and other portions, may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, Mylar, Mylar tape, rubber, hard rubber, plastic, nylon, elastomers, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The transformer cores may be formed of ferrite material, such as a soft ferrite. The transformer cores may be sintered or subjected to other manufacturing steps. The flexible circuit boards may be replaced with printed circuit boards (PCBs) or other appropriate substrates. 
     Embodiments of the present invention may provide connector assemblies that may be located in, or may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector assemblies may provide interconnect paths for signals that are compliant with various standards such as Universal Serial Bus (USB), 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 various embodiments of the present invention, these interconnect paths provided by these connectors may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20170224
Publication Date: 20190521
Grant Date: 20190521
Priority Date: 20160225
Inventors: KALLMAN, BENJAMIN J.
WITTENBERG, MICHAEL B.
GRAHAM, Christopher S.
Assignee: APPLE INC
CPC Classifications: [{"code": "H02J50/005", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01F27/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F38/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J50/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J50/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F38/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J7/0042", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J7/0042", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J7/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J50/90", "inventive": true, "first": true, "tree": "[]"}, {"code": "H02J7/0042", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F27/266", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J50/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F38/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02J50/005", "inventive": true, "first": true, "tree": "[]"}, {"code": "H02J50/90", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 58228599