PATENT DOCUMENT

Publication Number: US-10418741-B2
Application Number: US-201816214121-A
Country: US
Kind Code: B2

Title: Low-profile power and data contacts

Abstract:
Contact structures that are readily manufactured, where contacts in the contact structures consume a minimal amount of surface area, depth, and volume in an electronic device.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a device enclosure having a plurality of openings; 
 a plurality of electrical contacts, each electrical contact located in a corresponding one of the plurality of openings in the device enclosure such that a gap exists between an outside edge of each contact and an inside edge of the corresponding opening in the device enclosure, each electrical contact having a contacting surface for mating with a contact on a corresponding device when the electronic device and corresponding device are mated; 
 a housing comprising a plurality of insulating rings, each of the plurality of insulating rings filling the gap between the outside edge of an electrical contact and the inside edge of the corresponding opening in the device enclosure, the housing further comprising a plurality of alignment features on a back side; and 
 a flexible circuit board attached to the back side of the housing, the flexible circuit board comprising a plurality of openings, each opening to align with a corresponding alignment feature. 
 
     
     
       2. The electronic device of  claim 1  wherein each of the plurality of electrical contacts are soldered to the flexible circuit board. 
     
     
       3. The electronic device of  claim 2  further comprising a bracket positioned such that the plurality of electrical contacts are between the bracket and the device enclosure. 
     
     
       4. The electronic device of  claim 3  wherein the bracket comprises fastener openings at opposing ends, and further comprising a plurality of fasteners, each passing through a corresponding fastener opening and into a corresponding fastener opening in the device enclosure. 
     
     
       5. The electronic device of  claim 1  wherein the contacting surface of each of the plurality of electrical contacts is flat and is at least substantially flush with an outside surface of the device enclosure. 
     
     
       6. The electronic device of  claim 1  wherein the contacting surface of each of the plurality of electrical contacts is at least substantially flush with an outside surface of the device enclosure. 
     
     
       7. The electronic device of  claim 1  wherein the flexible circuit board is attached to the housing using an adhesive. 
     
     
       8. An electronic device comprising:
 a device enclosure having a plurality of openings; 
 a plurality of electrical contacts, each electrical contact located in a corresponding one of the plurality of openings in the device enclosure, each electrical contact having a contacting surface for mating with a contact on a corresponding device when the electronic device and corresponding device are mated; 
 a housing comprising a plurality of insulating rings, each insulating ring between a contact and the device enclosure, the housing further comprising a plurality of alignment features on a back side; and 
 a flexible circuit board attached to the back side of the housing, the flexible circuit board comprising a plurality of openings, where each of the alignment features pass through a corresponding opening in the plurality of openings in the flexible circuit board. 
 
     
     
       9. The electronic device of  claim 8  further comprising a bracket positioned such that the plurality of electrical contacts are between the bracket and the device enclosure. 
     
     
       10. The electronic device of  claim 9  further comprising a silicone gasket between the housing and the device enclosure. 
     
     
       11. The electronic device of  claim 8  wherein the contacting surface of each of the plurality of electrical contacts is at least substantially flush with an outside surface of the device enclosure. 
     
     
       12. The electronic device of  claim 8  wherein the contacting surface of each of the plurality of electrical contacts is flat and is at least substantially flush with an outside surface of the device enclosure. 
     
     
       13. An electronic device comprising:
 a device enclosure having a plurality of openings; 
 a plurality of electrical contacts, each electrical contact having a contacting surface on a first side and a contacting portion on a second side opposing the first side, each contacting surface for mating with a contact on a corresponding device when the electronic device and corresponding device are mated, and each electrical contact located in a corresponding one of the plurality of openings in the device enclosure; 
 a housing comprising a plurality of insulating rings, each insulating ring around an outside of a corresponding one the plurality of electrical contacts, wherein the housing fits in a recess in the device enclosure; 
 a bracket having fastener openings at opposing ends; 
 a flexible circuit board attached to a rear surface of the housing such that the flexible circuit board is between the housing and the bracket; and 
 a plurality of fasteners, each passing through a corresponding fastener opening in the bracket and into a corresponding fastener opening in the device enclosure. 
 
     
     
       14. The electronic device of  claim 13  wherein the housing is formed of plastic. 
     
     
       15. The electronic device of  claim 14  further comprising a seal between the housing and the device enclosure, wherein the seal is a gasket. 
     
     
       16. The electronic device of  claim 15  wherein the flexible circuit board is attached to contacting portions of each of the plurality of electrical contacts, and wherein the flexible circuit board is attached to the housing using a heat-activated film. 
     
     
       17. The electronic device of  claim 16  wherein the housing further comprises a plurality of posts and wherein the flexible circuit board comprises a plurality of openings, each of the posts extending through a corresponding one of the openings in the flexible circuit board. 
     
     
       18. The electronic device of  claim 17  further comprising a shim between the housing and the device enclosure. 
     
     
       19. The electronic device of  claim 13  wherein the contacting surface of each of the plurality of electrical contacts is at least substantially flush with an outside surface of the device enclosure. 
     
     
       20. The electronic device of  claim 13  wherein the contacting surface of each of the plurality of electrical contacts is flat and is at least substantially flush with an outside surface of the device enclosure.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/948,050, filed Apr. 9, 2018, which is a continuation of U.S. patent application Ser. No. 15/138,216, filed Apr. 26, 2016, now U.S. Pat. No. 9,948,018, issued Apr. 17, 2018, which is a nonprovisional of United States provisional patent application Ser. No. 62/215,714, filed Sep. 8, 2015, and Ser. No. 62/254,033, filed Nov. 11, 2015, which are incorporated by reference. 
    
    
     BACKGROUND 
     The number of types of electronic devices that are commercially available has increased tremendously the past few years and the rate of introduction of new devices shows no signs of abating. Devices, such as tablet, laptop, netbook, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors, and others, have become ubiquitous. 
     Power and data may be provided from one device to another over cables that may include one or more wire conductors, fiber optic cables, or other conductor. Connector inserts may be located at each end of these cables and may be inserted into connector receptacles in the communicating or power transferring devices. In other systems, contacts on the devices may come into direct contact with each other without the need for intervening cables. 
     In systems where contacts on two electronic devices come into contact with each other, the contacts may be located in a contact structure at a surface of an electronic device. It may be desirable that these contacts be substantially resistant to corrosion, otherwise such corrosion would be readily apparent to a user due to their surface location. Also, these contacts may often have a substantial depth and consume a relatively large volume of space in the electronic device. The loss of this space may mean that the electronic device is either larger, includes a reduced set of functionality, or both. 
     These electronic devices may be manufactured in large numbers. A corresponding number of contact structures may be manufactured for use in these devices. Any simplification in the manufacturing process of these contact structures may yield tremendous savings in the manufacturing of these electronic devices. 
     Thus, what is needed are contact structures that are readily manufactured, where contacts in the contact structures are resistant to corrosion and consume a minimal amount of surface area, depth, and volume in an electronic device. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide contact structures that are readily manufactured, where contacts in the contact structures are resistant to corrosion and consume a minimal amount of surface area, depth, and volume in an electronic device. 
     An illustrative embodiment of the present invention may provide a contact structure for an electronic device. The contact structure may include one, two, three, four, or more than four contacts. These contacts may be formed by machining, etching, printing, casting, forging, by using a deep drawn or other process. Each contact may be located in an opening in a device enclosure where a plastic insulator is placed between the contact and the device enclosure. The contacts and plastic insulators may be substantially flush with, or recessed a limited amount relative to, a surface of the device enclosure around the contacts. This surface may be curved or flat, or have other contours. Other contacts, such as fiber-optic contacts, may be included. 
     During assembly, a flexible circuit board may be attached to rear portions of each contact. These rear portions may be horizontal, vertical, or angled. Traces in the flexible circuit board may be soldered, spot, laser, or resistance welded, or otherwise electrically and mechanically attached to portions of each contact. Electrostatic discharge (ESD) diodes may be electrically connected between one or more traces of the flexible circuit board and the device enclosure for ESD protection. The contacts may be fit into plastic insulators and glued or otherwise fixed in place. The plastic insulators may be glued or otherwise fixed in place to an inside surface of the device enclosure such that the contacts are exposed at an outside surface of the device enclosure. A bracket or other attachment mechanism may be attached to backs of the contacts and an inside surface of the device enclosure and glued or otherwise fixed in place. 
     Another illustrative embodiment of the present invention may provide another contact structure for an electronic device. In this embodiment of the present invention, a number of contacts held in place by a carrier may be stamped. The contacts may be stamped to have contacting portions and a rear angled portion. After stamping, the contacts may be blasted and plated. The carrier may be split up and strips of the carrier may be placed on a dummy carrier such that the contacts may be placed in groups. A plastic insulator may be formed around each group of contacts or a plastic insulator may be glued to each group of contacts. The dummy carrier may be removed and a flexible circuit board may then be soldered to rear angled portions of contacts. The contacts may then be aligned with openings a device enclosure and the plastic insulator may be glued in place. A bracket may be placed behind the contacts and glued or otherwise fixed to an inside surface of device enclosure to further secure the contacts in place. 
     Another illustrative embodiment of the present invention may provide another contact structure for an electronic device. In this embodiment of the present invention, a contact may be in an opening in a device enclosure. A plastic insulator may be between the contact and the device enclosure. A silicone gasket or other seal may be between the plastic insulator and an inside surface of the device enclosure to provide protection against the ingress of liquids, moisture, and debris. An optional shim may be used to align a surface of the contact with a surface of the device housing the contact structure. The shim may be selected from a set of shims having different sizes in order to properly align the surfaces. The contact may include a contacting portion soldered or otherwise attached to a trace of a flexible circuit board. A heat-activated film or adhesive may be used to fix the flexible circuit board to the plastic insulator. A rear bracket or cowling may be used to secure the contact and plastic insulator in place in the device enclosure. 
     These contact structures may be formed in various ways. In one embodiment of the present invention, contacts at ends of a carrier may be coined, forged, or formed in other ways. A dummy carrier may be stamped and the carrier may be attached to the dummy carrier. The contacts may be polished, blasted, and plated. The contacts may then be over-molded and the carrier and the dummy carrier may be detached. 
     In another embodiment of the present invention, contacts may be stamped, turned, forged or machined. A carrier may then be formed, for example by stamping. The contacts may be placed on the carrier. The contacts may then be polished, blasted, and plated. The contacts may then be over-molded and the carrier and the carrier may be detached. 
     Embodiments of the present invention may provide contacts that are resistant to corrosion. These contacts may include a top plate to match a color of a device enclosure around the contacts. This top plate may be 0.25 to 1.0 microns, 0.5 to 1.0 microns, 0.5 to 0.85 microns, 0.75 to 0.85 microns thick, or it may have another thickness. At an exposed surface of the contact, gold plating layer may be below the top plate. On other portions of the contact, the top plate may be omitted and the gold plating layer may be the first layer. This layer may be between 0.01 to 0.5 microns or between 0.05 and 0.1 microns thick, or it may have another thickness. A copper layer in the range of 1.0, 2.0, 3.0 or 4.0 microns in thickness may be used. An optional palladium layer may be used above the copper layer. This layer may have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it may have another thickness. An optional SnCu (tin copper) layer may be used between a gold layer and a copper layer in areas where contacts may be soldered to flexible circuit boards. This optional SnCu layer may be between 4, 5, and 6 microns in thickness, for example, between 4 and 6 or between 5 and 6 microns in thickness, though it may have other thicknesses consistent with embodiments of the present invention. Another embodiment of the present invention may include a base layer of copper in the range of 1.0, 2.0, 1.0-2.0, 2.0-3.0, 3.0 or 4.0 microns in thickness. A palladium layer may be used above the copper layer. This layer may have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it may have another thickness. A gold flash may be placed on that layer. This may be followed by a top plating to match a color of a device enclosure around the contacts. This top plate may be 0.25 to 1.0 microns, 0.5 to 1.0 microns, 0.5 to 0.85 microns, 0.75 to 0.85 microns thick, or it may have another thickness. Other portions of the contacts may have the copper layer, a thinner Pd (palladium) layer in the range of one, two, or threes tenth of a micron may be used, followed by a gold flash. 
     Embodiments of the present invention may provide contact structures that may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These contact structures may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. In various embodiments of the present invention, the data signal may be unidirectional or bidirectional and the power supply may be unidirectional or bidirectional. 
     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 an electronic system according to an embodiment of the present invention; 
         FIG. 2  illustrates a contact structure in a device enclosure according to an embodiment of the present invention; 
         FIG. 3  illustrates a cutaway side view of a contact structure according to an embodiment of the present invention; 
         FIG. 4  illustrates the contact of  FIG. 3 ; 
         FIG. 5  illustrates a plastic insulator for the contact of  FIG. 3 ; 
         FIGS. 6-8  illustrate a method of assembling a contact structure in a device according to an embodiment of the present invention; 
         FIG. 9  illustrates a cutaway side view of another contact structure according to an embodiment of the present invention; 
         FIG. 10  illustrates the contact of  FIG. 9 ; 
         FIG. 11  illustrates a the contact of  FIG. 10  in a plastic insulator according to an embodiment of the present invention; 
         FIG. 12  illustrate an assembled contact structure in a device according to an embodiment of the present invention; 
         FIG. 13  illustrates a cutaway side view of another contact structure according to an embodiment of the present invention; 
         FIG. 14  illustrates the contact of  FIG. 13 ; 
         FIG. 15  illustrates a the contact of  FIG. 14  in a plastic insulator according to an embodiment of the present invention; 
         FIG. 16  illustrate an assembled contact structure in a device according to an embodiment of the present invention; 
         FIG. 17  illustrates another contact according to an embodiment of the present invention; 
         FIG. 18  illustrates contacts of  FIG. 17  in a plastic insulator according to an embodiment of the present invention; 
         FIGS. 19-24  illustrate a method of assembling a contact structure in a device according to an embodiment of the present invention; 
         FIG. 25  illustrates a contact structure in a device enclosure according to an embodiment of the present invention; 
         FIG. 26  illustrates a cutaway side view of a contact structure that may be used for the contact structure of  FIG. 25 ; 
         FIG. 27  illustrates a cutaway side view of another contact structure that may be used for the contact structure of  FIG. 25 ; 
         FIG. 28  illustrates a portion of a contact structure according to an embodiment of the present invention; 
         FIG. 29  is an exploded view of a contact structure according to an embodiment of the present invention; 
         FIGS. 30-33  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the present invention; 
         FIGS. 34-37  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the present invention; and 
         FIGS. 38-42  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates an electronic system according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, host device  110  may be connected to accessory device  120  in order to share data, power, or both. Specifically, contacts  112  on host device  110  may be electrically connected to contacts  122  on accessory device  120 . Contacts  112  on host device  110  may be electrically connected to contacts  122  on accessory device  120  via cable  130 . In other embodiments of the present invention, contacts  112  on host device  110  may be directly and electrically connected to contacts  122  on accessory device  120 . In still other embodiments of the present invention, one or more optical contacts supporting one or more optical connections between host device  110  and accessory device  120  may be included. 
     To facilitate a direction connection between contacts  112  on host device  110  and contacts  122  on accessory device  120 , contacts  112  may be part of a surface mount contact structure. Examples of surface mount contact structures that may include contacts  112  are shown in the following figures. 
       FIG. 2  illustrates a contact structure in a device enclosure according to an embodiment of the present invention. In this example, contacts  112  may be located at a surface of device enclosure  130 . An insulating ring formed by a plastic insulator  120  may surround an outside edge of contacts  112  and may be located between contacts  112  and device enclosure  130 . Plastic insulator  120  may electrically isolate contacts  112  from device enclosure  130 . In these and other embodiments the present invention, contacts  112  and the insulating ring formed by plastic insulator  120  may be substantially flush with, or recessed a limited amount relative to, a surrounding surface of device enclosure  130 . These surfaces may be curved, they may be substantially flat, or they may have other contours. 
       FIG. 3  illustrates a cutaway side view of a contact structure that may be used for the contact structure of  FIG. 2 . In this example, contact  112  may be located in an opening in device enclosure  130 . A plastic insulator  120  may be located between contacts  112  and device enclosure  130 . A flexible circuit board  320  may connect to contact  112 . A bracket  310  may be used to secure contacts  112  in place in device enclosure  130 . In various embodiments of the present invention, various adhesives may be used to secure these structures in place. Specifically, adhesive layers  370  may be used to secure contact  112  to plastic insulator  120 . Adhesive layers  370  may also be used to secure plastic insulator  120  to device enclosure  130 . Also, adhesive layers  370  may be used to secure bracket  310  in place in device enclosure  130 . 
       FIG. 4  illustrates the contact of  FIG. 4 . This contact  112  may include a contacting portion emerging from a front face  113 . Contacts  112  may further have a rear angle portion  114  that may connect to flexible circuit board  320 . 
     Contact  112  may be formed by machining, forging, printing, etching, stamping, or in other ways. In other embodiment of the present invention, contacts  112  may be formed by a deep drawn process. 
       FIG. 5  illustrates a plastic insulator according to an embodiment of the present invention. In this example, plastic insulator  120  may have openings  122  for accepting contacts  112 . Rear surfaces  124  may be covered with adhesives and contacts  112  may be joined to plastic insulators  120  at those locations. 
       FIGS. 6-8  illustrate a method of assembling a contacts structure according to an embodiment of the present invention. In  FIG. 6 , a number of contacts  112  may be mated to a flexible circuit board  320  according to an embodiment of the present invention. Contacts on flexible circuit board  320  may be attached to rear portions  114  of contacts  112  by soldering, laser, spot, or resistance welding, or by other method. In this example, flexible circuit board  320  may have three portions, each connected to an angled portion  114  of a contact  112 . Diodes  610  may be connected between flexible circuit board traces in flexible circuit board  320  and the device enclosure  130  (shown in  FIG. 3 ) to provide ESD protection. In this example, flexible circuit board  320  may be split into three portions as shown to provide a greater flexibility in attaching flexible circuit board  320  to rear portions  114  of contacts  112 . Contacts  112  may be aligned with openings  122  in plastic insulators  120 . 
     In  FIG. 7 , barrels including contacts  112  in plastic insulators  120  (as shown in  FIG. 6 ) may be aligned with openings  132  in device enclosure  130 . Plastic insulators  120  may be glued in place. In  FIG. 8 , bracket  310  may be glued in place in notch  134  in device enclosure  130 . 
     In various embodiments of the present invention, different portions of these contact structures and other contact structures may be formed of various materials. For example, bracket  310  and plastic insulators  120  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive or conductive material. Contacts  112  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. 
     In various embodiments of the present invention, different portions of these contact structures and other contact structures may be formed in various ways. For example, bracket  310  and plastic insulators  120  may be formed using injection or other molding, printing, or other technique. Contacts  112  may be machined, stamped, coined, forged, printed, or formed in different ways, such as by using a deep drawn process. Plastic insulator  120  may be formed around contacts  112  using injection molding. 
       FIG. 9  illustrates a cutaway side view of another contact structure that may be used for the contact structure of  FIG. 2 . In this example, contact  112  may be located in an opening in device enclosure  130 . A plastic insulator  120  may be located between contact  112  and device enclosure  130 . A flexible circuit board  320  may connect to contact  112  at rear portion  114 . An optional bracket (not shown) may be used to secure contacts  112  in place in device enclosure  130 , though in other embodiments of the present invention, contacts  112  and insulators  120  may be glued or otherwise fixed in place. In various embodiments of the present invention, various adhesives may be used to secure these structures in place. Specifically, adhesive layers may be used to secure contact  112  to plastic insulator  120 . Adhesive layers may also be used to secure plastic insulator  120  to device enclosure  130 . Also, adhesive layers  370  may be used to secure an optional bracket in place in device enclosure  130 . Support  910  may provide mechanical support for flexible circuit board  320 . Support  910  may include ESD diodes (as shown below in  FIG. 12 .) 
       FIG. 10  illustrates the contact of  FIG. 9 . In this example, a force may be applied at surface  512  to form contacts  112  in a deep drawn process. As before, contact  112  may include a rear angle piece  114  that may be mated with a flexible circuit board. In other embodiment of the present invention, contact  112  may be formed by machining, forging, printing, etching, stamping, or in other ways. 
       FIG. 11  illustrates the contact of  FIG. 10  in a plastic insulator according to an embodiment of the present invention. In this example, plastic insulator  120  may have openings  122  for accepting contacts  112 . Rear contact portions  114  may extend from insulator  120 . 
       FIG. 12  illustrates an assembled contact structure according to an embodiment of the present invention. A number of contacts  112  (not shown) in insulators  120  may be mated to flexible circuit board  320  according to an embodiment of the present invention. Contacts on flexible circuit board  320  may be attached to rear portions  114  of contacts  112  (as shown in  FIG. 9 ) by soldering, laser, spot, or resistance welding, or by other method. In this example, flexible circuit board  320  may have three portions, each connected to a rear portion  114  of a contact  112 . Diodes  610  may be connected between flexible circuit board traces in flexible circuit board  320  and the device enclosure  130  to provide ESD protection. In this example, flexible circuit board  320  may be split into three portions as shown to provide a greater flexibility in attaching flexible circuit board  320  to rear portions  114  of contacts  112 . 
       FIG. 13  illustrates a cutaway side view of another contact structure that may be used for the contact structure of  FIG. 2 . In this example, contact  112  may be located in an opening in device enclosure  130 . A plastic insulator  120  may be located between contact  112  and device enclosure  130 . A bridging piece  1310  may connect flexible circuit board  320  to contact  112  at rear portion  114 . An optional bracket (not shown) may be used to secure contacts  112  in place in device enclosure  130 , though in other embodiments of the present invention, contacts  112  and insulators  120  may be glued or otherwise fixed in place. In various embodiments of the present invention, various adhesives may be used to secure these structures in place. Specifically, adhesive layers may be used to secure contact  112  to plastic insulator  120 . Adhesive layers may also be used to secure plastic insulator  120  to device enclosure  130 . Also, adhesive layers  370  may be used to secure an optional bracket in place in device enclosure  130 . Support  910  may provide mechanical support for flexible circuit board  320 . Support  910  may include ESD diodes (as shown below in  FIG. 16 .) 
       FIG. 14  illustrates the contact of  FIG. 13 . In this example, a force may be applied at surface  512  to form contacts  112  in a deep drawn process. As before, contact  112  may include a rear angle piece  114  that may be mated with a flexible circuit board. In other embodiment of the present invention, contact  112  may be formed by machining, forging, printing, etching, stamping, or in other ways. 
       FIG. 15  illustrates the contact of  FIG. 10  in a plastic insulator according to an embodiment of the present invention. In this example, plastic insulator  120  may have openings  122  for accepting contacts  112 . Rear contact portions  114  may extend from insulator  120 . 
       FIG. 16  illustrates an assembled contact structure according to an embodiment of the present invention. A number of contacts  112  (not shown) in insulators  120  may be mated to flexible circuit board  320  according to an embodiment of the present invention. Contacts on flexible circuit board  320  may be attached to rear portions  114  of contacts  112  (as shown in  FIG. 9 ) by soldering, laser, spot, or resistance welding, or by other method. Diodes  610  may be connected between flexible circuit board traces in flexible circuit board  320  and the device enclosure  130  to provide ESD protection. In this example, flexible circuit board  320  may be routed laterally along the backside of contacts  112  to gain flexibility in attaching flexible circuit board  320  to bridging pieces  1310 . 
       FIG. 17  illustrates another contact according to an embodiment of the present invention. This contact  112  may include a contacting portion emerging from a front face  113 . Contacts  112  may further have a rear angle portion  114  that may connect to flexible circuit board  320 . 
     Contact  112  may be formed by machining, forging, printing, etching, stamping, or in other ways. In other embodiment of the present invention, contacts  112  may be formed by a deep drawn process. 
       FIG. 18  illustrates contacts of  FIG. 17  in a plastic insulator according to an embodiment of the present invention. In this example, plastic insulator  120  may have openings  122  for accepting contacts  112 . Rear contact portions  114  (not shown) may extend from insulator  120 . 
       FIGS. 19-24  illustrate a method of making another contact structure according to an embodiment of the present invention. In  FIG. 19 , a plurality of contacts  112  may be stamped at ends of carrier  1110 . Each contact  112  may include a rear angled portion  114 . The contacts may be blasted and plated. In  FIG. 20 , portions  1111  of the carrier  1110  may be split and placed on a dummy carrier  1200  such that contacts  112  may have the same special relationship to each other as they will when placed in a device enclosure. In  FIG. 21 , plastic insulators  120  may be formed around contacts  112 . In other embodiments of the present invention, plastic insulators  120  may be formed in a separate step and then placed around contacts  112 . In these and other embodiments of the present invention, instead of one plastic insulator  120 , three plastic insulators or insulators may be used, each around one of the contacts  112 . Plastic insulators  120  may be glued or otherwise fixed to contacts  112 . The dummy carrier  1200  may be removed. 
     In  FIG. 22 , flexible circuit board  320  may be attached, for example by soldering, to rear angled pieces  114  of contacts  112 . Contacts  112  may be insulated by plastic insulator  120 . In  FIG. 23 , contacts  112  may be aligned with openings  132  in device enclosure  130 . Plastic insulating piece  120  may be arranged to fit in notch  134  in device enclosure  130  and may be glued in place. In  FIG. 24 , bracket  310  may be placed behind contacts  112  in notch  134  of device enclosure  130  to secure contacts  112  in place. Bracket  310  may be glued in place to further secure contacts  120  to device enclosure  130 . 
       FIG. 25  illustrates a contact structure in a device enclosure according to an embodiment of the present invention. In this example, contacts  1712  may be located at a surface of device enclosure  1730 . An insulating ring formed by a plastic insulator  1720  may surround an outside edge of contacts  1712  and may be located between contacts  1712  and device enclosure  1730 . In these and other embodiments the present invention, contacts  1712  and the insulating ring formed by plastic insulator  1720  may be substantially flush with, or recessed a limited amount relative to, a surrounding surface of device enclosure  1730 . These surfaces may be curved, they may be substantially flat, or they may have other contours. 
       FIG. 26  illustrates a cutaway side view of a contact structure that may be used as the contact structure of  FIG. 25 . Again, contacts  1712  may be located in openings in device enclosure  1730 . Plastic insulator  1720  may be located between contact  1712  and device enclosure  1730 . A surface of contact  1712  and a surface of plastic insulator  1720  may be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  1730 . These surfaces may be curved, substantially flat, or they may have other contours. A silicone gasket or other seal  1810  may be located between plastic insulator  1720  and device enclosure  1730 . Silicone gasket  1810  may prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  1712  may include a contacting portion  1713  that may be soldered or otherwise attached to a trace on flexible circuit board  1820 . A heat-activated film or adhesive  1830  may be used to fix flexible circuit board  1820  to plastic insulator  1720 . Contact  1712  may further include tabs  1713  (of which contacting portion  1713  may be one of) and handle  1714 . Bracket  1840  may be located behind flexible circuit board  1820  and may hold contact  1712  in place in device enclosure  1730 . 
     In various embodiments of the present invention, it may be desirable that a surface of contacts in a contact structure to be at least substantially flush with, or recessed a limited amount relative to, a surface of a device housing the contacts. But the sizes of the various components of this connector structure each have a manufacturing tolerance associated with them. The accumulation of these tolerances may lead to the surface of one or more contacts not being flush with a surface of the device. Accordingly, embodiments of the present invention may employ shims or other adjustments features to account for the errors that these tolerances may create. An example is shown in the following figure. 
       FIG. 27  illustrates a cutaway side view of a contact structure that may be used as the contact structure of  FIG. 25 . Again, contacts  1712  may be located in openings in device enclosure  1730 . Plastic insulator  1720  may be located between contact  1712  and device enclosure  1730 . A surface of contact  1712  and a surface of plastic insulator  1720  may be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  1730 . The surface of contact  1712 , the surface of plastic insulator  1720 , and the surface of device enclosure  1730  may be curved, substantially flat, or they may have other contours. A silicone gasket or other seal  1810  may be located between plastic insulator  1720  and device enclosure  1730 . Silicone gasket  1810  may prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  1712  may include a contacting portion  1713  that may be soldered or otherwise attached to a trace or contact  1822  on flexible circuit board  1820 . A heat-activated film or adhesive  1830  may be used to fix flexible circuit board  1820  to plastic insulator  1720 . Contact  1712  may further include tabs  1713  (of which contacting portion  1713  may be one of) and handle  1714 . Bracket  1840  may be located behind flexible circuit board  1820  and may hold contact  1712  in place in device enclosure  1730 . 
     Again, it may be desirable that the surface of contact  1712  and a surface of plastic insulator  1720  be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  1730 . But the sizes of the various components of this connector structure each have a manufacturing tolerance associated with them. The accumulation of these tolerances may lead to the surface of one or more contacts  1712  not being flush with a surface  1730  of the device. Accordingly, embodiments of the present invention may employ shims  2110 . Shim  2110  may be selected from a set of shims having different sizes. Shim  2110  may have a size that is selected to compensate for the accumulated tolerances of the sizes of the different components in this connector structure such that the surface of contact  1712  and a surface of plastic insulator  1720  may be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  1730 . 
       FIG. 28  illustrates a portion of contact structure according to an embodiment of the present invention. This contact structure portion may include a number of contacts  1712  surrounded by plastic insulator  1720 . 
       FIG. 29  is an exploded view of a contact structure according to an embodiment of the present invention. Contacts  1712  (shown in  FIG. 28 ) may be housed in plastic insulator  1720 , and may be located in openings in device enclosure  1730 . A silicone gasket or other seal  1810  may be located between plastic insulator  1720  and device enclosure  1730 . Silicone gasket  1810  may prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  1712  may include a contacting portion  1713  (shown in  FIG. 18 ) that may be soldered or otherwise attached to a trace on flexible circuit board  1820 . A heat-activated film or adhesive (not shown) may be used to fix flexible circuit board  1820  to plastic insulator  1720 . Bracket or cowling  1840  may be located behind flexible circuit board  1820  and may hold contacts  1712  in place in device enclosure  1730 . Shim  2110  may be placed between plastic insulator  1720  and device enclosure  1730 . Shim  2110  may be selected from a set of shims having different sizes. Shim  2110  may have a size that is selected to compensate for the accumulated tolerances of the sizes of the different components in this connector structure such that the surface of contact  1712  and a surface of plastic insulator  1720  may be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  1730 . 
     These contacts structures portions including contacts  1712  and plastic insulators  1720  may be formed in various ways. Examples are shown in the following figures. 
       FIGS. 30-33  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the present invention. In  FIG. 30 , contacts  1712  may be coined. The coining process may leave tab  1713  and handle  1714  in place. Contacts  1712  may be formed at ends of carrier  2000 . Carrier  2000  may include openings  2010 . In  FIG. 31 , a carrier  2100  may be provided. Openings  2100  having raised edges may be stamped in carrier  2100 . In  FIG. 32 , carrier  2000  may be fixed to carrier  2100 . Specifically, raised edges of opening  2110  may be placed in openings  2010  of carrier  2000 . In  FIG. 33 , plastic insulator  1720  may be formed around contacts  1712 . In other embodiments of the present invention, plastic insulator  1720  may be formed elsewhere and glued or otherwise fixed to contacts  7012 . The carrier structure may be removed leaving behind handle  1714  (not shown.) 
       FIGS. 34-37  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the present invention. In  FIG. 34 , contacts  1712  may be turned or machined. In  FIG. 35 , carrier  2600  may be stamped. Carrier  2600  may include paddles  2610 . In  FIG. 36 , contacts  1712  may be attached to paddles  2610  of carrier  2600 . In  FIG. 37 , plastic insulator  7020  may be formed around contacts  1712 . In other embodiments of the present invention, plastic insulator  1720  may be formed elsewhere and then fixed to contacts  1712 , by using an adhesive or other technique. Carrier  2600  may be removed, again leaving behind handle  1714  (not shown.) 
       FIGS. 38-42  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the present invention. In  FIG. 38 , contacts  1712  and first carrier  3800  may be turned, or machined, forged, or formed in other ways. In  FIG. 39 , second carrier  3900  may be stamped or formed in other ways. Second carrier  3900  may include paddles  3910 . In  FIG. 40 , contacts  1712  may be attached to paddles  3910  of second carrier  3900  by spot, laser, or resistance welding, or other technique. In  FIG. 41 , the first carrier  3800  may be detached, and the contacts  1712  may be polished, blasted, and plated. In  FIG. 42  plastic insulator  1720  may be formed around contacts  1712  using an overmold or other process. In other embodiments of the present invention, plastic insulator  1720  may be formed elsewhere and then fixed to contacts  1712 , by using an adhesive or other technique. Carrier  2600  may be removed, again leaving behind handle  1714  (not shown.) 
     Embodiments of the present invention may provide contacts that are resistant to corrosion. These contacts may include a top plate to match a color of a device enclosure around the contacts. This top plate may be 0.25 to 1.0 microns, 0.5 to 1.0 microns, 0.5 to 0.85 microns, 0.75 to 0.85 microns thick, or it may have another thickness. At an exposed surface of the contact, gold plating layer may be below the top plate. On other portions of the contact, the top plate may be omitted and the gold plating layer may be the first layer. This layer may be between 0.01 to 0.5 microns or between 0.05 and 0.1 microns thick, or it may have another thickness. A copper layer in the range of 1.0, 2.0, 3.0 or 4.0 microns in thickness may be used. An optional palladium layer may be used above the copper layer. This layer may have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it may have another thickness. An optional SnCu layer may be used between a gold layer and a copper layer in areas where contacts may be soldered to flexible circuit boards. This optional SnCu layer may be between 4, 5, and 6 microns in thickness, for example, between 4 and 6 or between 5 and 6 microns in thickness, though it may have other thicknesses consistent with embodiments of the present invention. Another embodiment of the present invention may include a base layer of copper in the range of 1.0, 2.0, 1.0-2.0, 2.0-3.0, 3.0 or 4.0 microns in thickness. A palladium layer may be used above the copper layer. This layer may have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it may have another thickness. A gold flash may be placed on that layer. This may be followed by a top plating to match a color of a device enclosure around the contacts. This top plate may be 0.25 to 1.0 microns, 0.5 to 1.0 microns, 0.5 to 0.85 microns, 0.75 to 0.85 microns thick, or it may have another thickness. Other portions of the contacts may have the copper layer, a thinner Pd layer in the range of one, two, or threes tenth of a micron may be used, followed by a gold flash. 
     In various embodiments of the present invention, different portions of these contact structures and other contact structures may be formed of various materials. For example, bracket  1840  and plastic insulators  1720  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive or conductive material. Contacts  1712  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. 
     In various embodiments of the present invention, different portions of these contact structures and other contact structures may be formed in various ways. For example, bracket  1840  and plastic insulators  1720  may be formed using injection or other molding, printing, or other technique. Contacts  1712  may be machined, stamped, coined, forged, printed, or formed in different ways. Plastic insulator  1720120  may be formed around contacts  1720  using injection molding or other technique. 
     Embodiments of the present invention may provide contact structures that may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These devices may include contact structures that may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, HDMI, DVI, Ethernet, DisplayPort, Thunderbolt, Lightning, JTAG, TAP, DART, UARTs, clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. In this example, the data signal may be unidirectional or bidirectional and the power supply may be unidirectional or bidirectional. 
     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: 20181209
Publication Date: 20190917
Grant Date: 20190917
Priority Date: 20150908
Inventors: WAGMAN, Daniel C.
ROSS, OLIVER C.
JOL, ERIC S.
Esmaeili, Hani
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R12/77", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/707", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/65", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/77", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/40", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/61", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/77", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/40", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 56855296