PATENT DOCUMENT

Publication Number: US-9142925-B2
Application Number: US-201113700664-A
Country: US
Kind Code: B2

Title: D-shaped connector

Abstract:
The present disclosure relates generally to connector plugs and jacks and in particular to an audio connector plug and jack that can be used in place of the a standard low profile plug and electronic devices using low profile plug receptacles. The connector plug has a reduced plug length and thickness, an intuitive insertion orientation and a smooth, consistent feel when inserted and extracted from its corresponding receptacle connector. A portion or all of the plug connector may include a flexible material that allows the connector to bend with respect to an insertion axis along which the plug connector is designed to be inserted into a corresponding receptacle connector. A corresponding connector jack may be configured to receive the reduced length and thickness connector plug.

Claims:
What is claimed is: 
     
       1. A plug connector comprising:
 a shell; 
 a sleeve coupled to the shell at its base and having a D-shaped cross section, the sleeve having a ground contact at its distal tip, a plurality of external contacts arranged around a periphery of the sleeve, a plurality of dielectric strips that electrically isolate the plurality of contacts from each other and an insulation ring between the distal tip and the plurality of contacts and plurality of dielectric strips; wherein each of the plurality of contacts and plurality of dielectric strips extend from the insulation ring to the shell. 
 
     
     
       2. The plug connector of  claim 1  wherein the plurality of external contacts comprise three contacts: a left audio contact, a right audio contact and a microphone contact. 
     
     
       3. The plug connector of  claim 2  wherein the microphone contact is formed on a flat surface of the sleeve. 
     
     
       4. The plug connector of  claim 2  wherein the left audio contact and the right audio contact are formed on a curved surface of the sleeve. 
     
     
       5. The plug connector of  claim 1  wherein the plurality of external contacts have a length which is greater than a width of the plurality of external contacts. 
     
     
       6. The plug connector of  claim 1  wherein the sleeve has an outer diameter of about 2.4 mm and an insertion depth of about 8 mm. 
     
     
       7. The plug connector of  claim 1  wherein at least one of the plurality of external contacts have a width that is different than at least another of the plurality of external contacts. 
     
     
       8. The plug connector of  claim 1  wherein the insulation strips are integrally formed. 
     
     
       9. The plug connector of  claim 1  wherein the sleeve has another insulation ring which divides at least one of the plurality of external contacts into two separate contacts. 
     
     
       10. A plug connector comprising:
 a shell; 
 a sleeve coupled to the shell at its base and having a D-shaped cross section, the sleeve having a ground contact at its distal tip, a plurality of external contacts arranged around a periphery of the sleeve, a plurality of flexible dielectric strips that electrically isolate the plurality of contacts from each other and an insulation ring between the distal tip and the plurality of contacts and plurality of dielectric strips; wherein each of the plurality of contacts and plurality of dielectric strips extend from the insulation ring to the shell. 
 
     
     
       11. The plug connector set forth in  claim 10  wherein the plurality of external contacts arranged around the periphery of the sleeve are formed on a flex circuit adhered to the sleeve. 
     
     
       12. The plug connector set forth in  claim 10  further comprising an inner flexible member traversing a length of the sleeve between the distal end and the shell. 
     
     
       13. The plug connector set forth in  claim 10  wherein the flexibility of the sleeve changes between its distal and proximal ends. 
     
     
       14. The plug connector of  claim 10  wherein the plurality of external contacts comprise three contacts: a left audio contact, a right audio contact and a microphone contact. 
     
     
       15. The plug connector of  claim 10  wherein the sleeve has an outer diameter of about 2.4 mm and an insertion depth of about 8 mm. 
     
     
       16. A plug connector comprising:
 a shell; 
 a sleeve coupled to the shell at its base and having a non-regular polygon cross section, the sleeve having a ground contact at its distal tip and a plurality of external axial contacts that extend from the ground contact to the shell, wherein each of the axial contacts are separated by a dielectric material. 
 
     
     
       17. The plug connector set forth in  claim 16  wherein the shell is flexible. 
     
     
       18. The plug connector set forth in  claim 16  wherein the dielectric material is flexible. 
     
     
       19. The plug connector set forth in  claim 16  further comprising a flexible inner member traversing a length of the connector between the distal end and the shell, wherein the external axial contacts and dielectric material surround the flexible inner member. 
     
     
       20. The plug connector set forth in  claim 19  wherein the flexible inner member comprises a flexible rod. 
     
     
       21. The plug connector set forth in  claim 16  wherein the flexibility of the shell and the sleeve changes between a distal end and a proximal end of the plug connector. 
     
     
       22. The plug connector of  claim 16  wherein the plurality of external contacts comprise three contacts: a left audio contact, a right audio contact and a microphone contact.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a U.S. National Stage Application of PCT/US2011/038451, filed May 27, 2011, which claims the benefit of U.S. Provisional Patent Applications No. 61/349,737, filed May 28, 2010; 61/353,126, filed Jun. 9, 2010; and 61/356,499, filed Jun. 18, 2010, each of which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to connectors such as audio jacks and in particular to an audio connector that can be used in place of the a standard low profile plug receptacles and electronic devices using low profile plug receptacles. 
     Standard audio connectors or plugs are available in three sizes according to the outside diameter of the plug: a 6.35 mm (¼″) plug, a 3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. The plugs include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions between the tip and sleeve resulting in the connectors often being referred to as TRS (tip, ring and sleeve) connectors. 
       FIGS. 1A and 1B  illustrate examples of audio plugs  10  and  20  having three and four conductive portions, respectfully. As shown in  FIG. 1A , plug  10  includes a conductive tip  12 , a conductive sleeve  14  and a conductive ring  16  electrically isolated from the tip  12  and the sleeve  14  by insulating rings  17  and  18 . The three conductive portions  12 ,  14 , and  16  are for left and right audio channels and a ground connection. Plug  20 , shown in  FIG. 1B , includes four conductive portions: a conductive tip  22 , a conductive sleeve  24  and two conductive rings  25  and  26  and is thus sometimes referred to as a TRRS (tip, ring, ring, sleeve) connector. The four conductive portions are electrically isolated by insulating rings  27 ,  28  and  29  and are typically used for left and right audio, microphone and ground signals. 
     When plugs  10  and  20  are 3.5 mm miniature connectors, the outer diameter of conductive sleeve  14  and  24  and conductive rings  16 ,  25 , and  26  is 3.5 mm and the connector is 14 mm long, and for a 2.5 mm subminiature connector the outer diameter of the conductive sleeve is 2.5 mm and the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MP3 players and smart phones as well as other electronic devices. Electronic devices such as MP3 players and smart phones are continuously being designed to be thinner and smaller and/or to include video displays with screens that are pushed out as close to the outer edge of the devices as possible. The diameter and length of current 3.5 mm and even 2.5 mm audio connectors are limiting factors in making such devices smaller, thinner and allowing the displays to be larger. 
     Some manufacturers have used USB, mini-USB and micro-USB connectors as audio connectors to connect headphones and similar audio components to electronic devices.  FIG. 2  is an example of a micro-USB connector  30 , the smallest of the USB connectors. Connector  30  includes an outer housing  32  and a metallic shell  34  that is inserted into a corresponding receptacle connector. Shell  34  defines an interior cavity  38  and includes five contacts  36  formed within the cavity. The insertable shell portion  34  of connector  30  is both thinner and shorter than even the 2.5 mm subminiature version of connectors  10  and  20 . Connector  30 , however, suffers from other drawbacks that detract from the overall user experience. For example, connector  30  must be inserted into its respective receptacle connector in a particular orientation, yet it is difficult for the user to determine when connector  30  is oriented in the correct insertion position. Also, even when connector  30  is properly aligned, the insertion and extraction of the connector is not precise, has an inconsistent feel and, even when the connector is fully inserted, has an undesirable degree of wobble that may result in either a faulty connection or breakage. Additionally, cavity  38  is prone to collecting and trapping debris within the cavity which may interfere with the signal connections. 
     BRIEF SUMMARY OF THE INVENTION 
     In view of the shortcomings in currently available audio connectors as described above, the present invention provides an improved audio plug connector having a reduced plug length and thickness, an intuitive insertion orientation and a smooth, consistent feel when inserted and extracted from its corresponding receptacle connector. In some embodiments, a portion or all of the plug connector may include a flexible material that allows the connector to bend with respect to an insertion axis along which the plug connector is designed to be inserted into a corresponding receptacle connector. Additionally, audio plug connectors according to the present invention have external contacts instead of internal contacts and thus do not include a cavity that is prone to collecting and trapping debris. 
     In one embodiment, a plug connector according to the present invention includes a shell and a sleeve coupled to the shell at its base and having a D-shaped cross section. The sleeve has a ground contact at its distal tip, a plurality of contacts are arranged around a periphery of the sleeve and a plurality of dielectric strips that electrically isolate the plurality of contacts from each other. An insulation ring is positioned between the distal tip and the plurality of contacts and each of the plurality of contacts and plurality of dielectric strips extend from the insulation ring to the shell. 
     In another embodiment, a plug connector according to the present invention includes a flexible shell and a sleeve coupled to the shell at its base. The sleeve has a D-shaped cross section, a ground contact at its distal tip, a plurality of contacts arranged around a periphery of the sleeve, and a plurality of flexible dielectric strips that electrically isolate the plurality of contacts from each other and an insulation ring between the distal tip and the plurality of contacts and plurality of dielectric strips where each of the plurality of contacts and plurality of dielectric strips extend from the insulation ring to the shell. 
     In still another embodiment, a connector jack that can be used in conjunction with plug connectors according to the present invention includes a housing that defines an interior cavity into which a plug connector can be inserted. The cavity has a D-shaped cross-section, a ground contact at the rear portion and a plurality of contacts arranged around the walls of the interior cavity to match the locations of the contacts on a corresponding connector plug. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A and 1B  show perspective views of previously known TRS audio plug connectors; 
         FIG. 2A  shows a perspective view of a previously known micro-USB plug connector while  FIG. 2B  shows a front plan view of the micro-USB connector shown in  FIG. 2A ; 
         FIG. 3  is a simplified illustrative block diagram of an electronic media device suitable for use with embodiments of the present invention; 
         FIG. 4  depicts an illustrative rendering of one particular embodiment of an electronic media device suitable for use with embodiments of the present invention; 
         FIGS. 5A-5C  are simplified perspective and side views of a D-shaped plug connector according to one embodiment of the present invention; 
         FIG. 6A  is top view of the D-shaped connector according to embodiments of the invention wherein a flexible inner member is included while  FIGS. 6B and 6C  are simplified cross-sectional views of particular embodiments of the D-shaped connector shown in  FIG. 6A ; 
         FIG. 7A  is a simplified perspective view of a connector jack that can be used in conjunction with plug connectors according to the present invention while  FIG. 7B  is a cross-sectional view of the connector jack shown in  FIG. 7A  and a side view of a complementary plug mated with the connector jack; and 
         FIGS. 8A-8C  are simplified cross-sectional views of connector plugs according to embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Embodiments of the present invention pertain to connectors such as audio jacks and in particular to an audio connector that can be used in place of the a standard low profile plug receptacles and electronic devices using low profile plug receptacles. These connectors may be suitable for a multiplicity of electronic devices, including any device with audio out signals (e.g., radio, landline phone, stereo). In some embodiments, the invention is particularly well suited for portable electronic media devices because of its potentially small form factor. 
     As used herein, an electronic media device includes any device with at least one electronic component that may be used to present human-perceivable media. Such devices may include, for example, portable music players (e.g., Apple&#39;s iPod devices), portable video players (e.g., portable DVD players), cellular telephones (e.g., Apple&#39;s iPhone devices), video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, PDAs, desktop computers, as well as tablet or other mobile computers (e.g., Apple&#39;s iPad devices). Some of these devices may be configured to provide audio, video or other sensory output. 
       FIG. 3  is a simplified illustrative block diagram representing an electronic media device  100  that includes an audio plug receptacle  105  according to embodiments of the present. Electronic media device  100  may also include, among other components, connector receptacle  110 , one or more user input components  120 , one or more output components  125 , control circuitry  130 , graphics circuitry  135 , a bus  140 , a memory  145 , a storage device  150 , communications circuitry  155  and POM (position, orientation or movement sensor) sensors  160 . Control circuitry  130  may communicate with the other components of electronic media device  100  (e.g., via bus  140 ) to control the operation of electronic media device  100 . In some embodiments, control circuitry  130  may execute instructions stored in a memory  145 . Control circuitry  130  may also be operative to control the performance of electronic media device  100 . Control circuitry  130  may include, for example, a processor, a microcontroller and a bus (e.g., for sending instructions to the other components of electronic media device  100 ). In some embodiments, control circuitry  130  may also drive the display and process inputs received from input component  120 . 
     Memory  145  may include one or more different types of memory that may be used to perform device functions. For example, memory  145  may include cache, flash memory, ROM, RAM and hybrid types of memory. Memory  145  may also store firmware for the device and its applications (e.g., operating system, user interface functions and processor functions). Storage device  150  may include one or more suitable storage mediums or mechanisms, such as a magnetic hard drive, flash drive, tape drive, optical drive, permanent memory (such as ROM), semi-permanent memory (such as RAM) or cache. Storage device  150  may be used for storing media (e.g., audio and video files), text, pictures, graphics, advertising or any suitable user-specific or global information that may be used by electronic media device  100 . Storage device  150  may also store programs or applications that may run on control circuitry  130 , may maintain files formatted to be read and edited by one or more of the applications and may store any additional files that may aid the operation of one or more applications (e.g., files with metadata). It should be understood that any of the information stored on storage device  150  may instead be stored in memory  145 . 
     Electronic media device  100  may also include input component  120  and output component  125  for providing a user with the ability to interact with electronic media device  100 . For example, input component  120  and output component  125  may provide an interface for a user to interact with an application running on control circuitry  130 . Input component  120  may take a variety of forms, such as a keyboard/keypad, trackpad, mouse, click wheel, button, stylus or touch screen. Input component  120  may also include one or more devices for user authentication (e.g., smart card reader, fingerprint reader or iris scanner) as well as an audio input device (e.g., a microphone) or a video input device (e.g., a camera or a web cam) for recording video or still frames. Output component  125  may include any suitable display, such as a liquid crystal display (LCD) or a touch screen display, a projection device, a speaker or any other suitable system for presenting information or media to a user. Output component  125  may be controlled by graphics circuitry  135 . Graphics circuitry  135  may include a video card, such as a video card with 2D, 3D or vector graphics capabilities. In some embodiments, output component  125  may also include an audio component that is remotely coupled to electronic media device  100 . For example, output component  125  may include a headset, headphones or ear buds that may be coupled to electronic media device  100  with a wire or wirelessly (e.g., Bluetooth headphones or a Bluetooth headset). 
     Electronic media device  100  may have one or more applications (e.g., software applications) stored on storage device  150  or in memory  145 . Control circuitry  130  may be configured to execute instructions of the applications from memory  145 . For example, control circuitry  130  may be configured to execute a media player application that causes full-motion video or audio to be presented or displayed on output component  125 . Other applications resident on electronic media device  100  may include, for example, a telephony application, a GPS navigator application, a web browser application and a calendar or organizer application. Electronic media device  100  may also execute any suitable operating system, such as a Mac OS, Apple iOS, Linux or Windows and can include a set of applications stored on storage device  150  or memory  145  that is compatible with the particular operating system. 
     In some embodiments, electronic media device  100  may also include communications circuitry  155  to connect to one or more communications networks. Communications circuitry  155  may be any suitable communications circuitry operative to connect to a communications network and to transmit communications (e.g., voice or data) from electronic media device  100  to other devices within the communications network. Communications circuitry  155  may be operative to interface with the communications network using any suitable communications protocol such as, for example, Wi-Fi (e.g., a 802.11 protocol), Bluetooth, high frequency systems (e.g., 900 MHz, 2.4 GHz and 5.6 GHz communication systems), infrared, GSM, GSM plus EDGE, CDMA, quadband and other cellular protocols, VOIP or any other suitable protocol. 
     In some embodiments, communications circuitry  155  may be operative to create a communications network using any suitable communications protocol. Communications circuitry  155  may create a short-range communications network using a short-range communications protocol to connect to other devices. For example, communications circuitry  155  may be operative to create a local communications network using the Bluetooth protocol to couple with a Bluetooth headset (or any other Bluetooth device). Communications circuitry  155  may also include a wired or wireless network interface card (NIC) configured to connect to the Internet or any other public or private network. For example, electronic media device  100  may be configured to connect to the Internet via a wireless network, such as a packet radio network, an RF network, a cellular network or any other suitable type of network. Communication circuitry  145  may be used to initiate and conduct communications with other communications devices or media devices within a communications network. 
     Electronic media device  100  may also include any other component suitable for performing a communications operation. For example, electronic media device  100  may include a power supply, an antenna, ports or interfaces for coupling to a host device, a secondary input mechanism (e.g., an ON/OFF switch) or any other suitable component. 
     Electronic media device  100  may also include POM sensors  160 . POM sensors  160  may be used to determine the approximate geographical or physical location of electronic media device  100 . As described in more detail below, the location of electronic media device  100  may be derived from any suitable trilateration or triangulation technique, in which case POM sensors  160  may include an RF triangulation detector or sensor or any other location circuitry configured to determine the location of electronic media device  100 . 
     POM sensors  160  may also include one or more sensors or circuitry for detecting the position orientation or movement of electronic media device  100 . Such sensors and circuitry may include, for example, single-axis or multi-axis accelerometers, angular rate or inertial sensors (e.g., optical gyroscopes, vibrating gyroscopes, gas rate gyroscopes or ring gyroscopes), magnetometers (e.g., scalar or vector magnetometers), ambient light sensors, proximity sensors, motion sensor (e.g., a passive infrared (PIR) sensor, active ultrasonic sensor or active microwave sensor) and linear velocity sensors. For example, control circuitry  130  may be configured to read data from one or more of POM sensors  160  in order to determine the location orientation or velocity of electronic media device  100 . One or more of POM sensors  160  may be positioned near output component  125  (e.g., above, below or on either side of the display screen of electronic media device  100 ). 
       FIG. 4  depicts an illustrative rendering of one particular electronic media device  180 . Device  180  includes a click wheel  182  as an input component and an LED display  184  as an output component. Device  180  also includes connector receptacle  186  and audio plug receptacle  188 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 4 . 
     In one particular embodiment, the present invention pertains to connectors that have a single insertion orientation. As an example,  FIGS. 5A-5C  illustrate a D-shaped plug connector  210  that has a ground contact  212  at its tip and three contacts  214   a  (left audio),  214   b  (right audio) and  214   c  (microphone) that are separated from the tip by an insulation ring  216  and extend along the length of the connector from insulation ring  216  to its base. Contacts that extend along the length of the connector from insulation ring  216  to its base are also referred to as axial contacts. Additional insulation strips  218   a ,  218   b  and  218   c  separate contacts  214   a - 214   c  from each other. The flat surface, upon which contact  214   c  if formed, acts as a keyed feature of connector  210 , which when aligned with a matching flat surface of a corresponding receptacle connector (shown in  FIGS. 7A and 7B ) having a matching D-shaped cavity, ensures that plug connector  210  only can be inserted into the connector jack in a single orientation thus aligning each of the contacts  214   a - 214   c  with respective contacts in the receptacle connector. As shown in  FIG. 5A-5C , contacts  214   a  and  214   b  may be curved and formed on a curved surface, while contact  214   c  may be flat and formed on a flat surface. The lengths of contacts  214   a - 214   c  may be longer than their widths. 
     In other embodiments, contacts do not extend along the full length of the connector from insulation ring  216  to its base. For example, contacts  214   a  (left audio),  214   b  (right audio) and  214   c  (microphone) may run only a half, a third, a fourth, or another suitable portion of the length of the connector, from the insulation ring to its base. In some embodiments, the ends of the axial contacts may be equidistant from the insulation ring and the base of the connector or shell. In some embodiments, the ends of the axial contacts may not be equidistant from the insulation ring and the base of the connector or shell. In some embodiments, contacts have a different length and are positioned differently between the insulation ring and the base of the connector as compared to at least one other contact. 
     In one particular embodiment, connector  210  has an insertion length, X, of about 8 mm; a diameter, Y, of about 2.4 mm; a height, Z, of about 2.0 mm and a volume of about 29.1 mm 3 . 
     The geometry of the insertion portion or sleeve of connector  210  may be selected to create a press fit plug and jack interface that requires specific insertion and extraction forces such that the retention force required to insert connector  210  into a matching connector jack (shown in  FIGS. 7A and 7B ) is higher than the extraction force required to remove the plug connector from the jack. Aside from thickness, Z, the dimensions of connector  210  may be similar to that of the standard audio connector (TRS and TRRS) mentioned above in the “Background of the Invention” section. 
     In some embodiments, the width of the contacts, insulation strips and rings, and other elements of connector  210  may be varied as compared to the relative widths illustrated in  FIGS. 5A-5C . 
     In one embodiment, connector  210  is made exclusively or primarily from rigid and relatively inflexible materials. Contacts  212 ,  214   a - 214   c  can be made from a copper, nickel, brass, a metal alloy or any other appropriate conductive material. Thermoplastic polymer or similar material to provide strain relief and insulation, e.g., POM, may be injected around the contacts to create the insulation ring  216  and insulation strips  218   a ,  218   b  and  218   c . An ABS or similar material can be used to create shell  220 , which is positioned over and fastened to the base of the connector as shown in  FIG. 5A . In some embodiments, Shell  220  may be thicker than the sleeve, i.e., the dimensions of shell  220  may be greater than diameter, Y, and height, Z. 
     In another embodiment, connector  210  includes a flexible inner member that gives connector  210  increased flexibility, allowing it to deform in order to prevent breakage. Additional advantages provided by the inclusion of a flexible inner member may include increased ease of insertion for the user as there would be more leeway in the insertion orientation required to successfully insert the connector into a corresponding connector receptacle.  FIG. 6A  is top view of the D-shaped connector according to embodiments of the invention wherein a flexible inner member is included while  FIGS. 6B and 6C  are simplified cross-sectional views of particular embodiments of the D-shaped connector shown in  FIG. 6A . In addition to providing a top view of connector  210 ,  FIG. 6A  also shows an internal element, namely flexible inner member  225 . Flexible inner member  225  may be made out of a flexible material, such as nitinol, coated with a conductive layer to carry the ground signal that extends along at least a portion of the length of the connector. The flexible inner member  225  may be a circular rod, may have a D-shaped cross-section or other appropriate shapes. In some embodiments, contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ) can be brass or other metal contacts formed on flexible elastomer  222   a  so that each axial section serves as a bending plate allowing connector  210  to bend in order to relieve stress when the connector is inserted or extracted off-axis. Flexible elastomer  222   a  may be polypropylene or polyoxymethylene which is injection molded to capture and insulate components, e.g., contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ). In another embodiment, contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ) and dielectric material may all be part of a flex circuit that is slid over flexible inner element  225 . This arrangement allows connector  210  to flex relatively evenly along much of its length. Also, insulation strips  218   a - 218   c  (shown in  FIGS. 5A and 5B ) may be made from a flexible elastomer and contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ) may be flex circuits that are adhered to flexible inner member  225  or adhered to elastomer that is injection molded around the inner member. The shell  220  (shown in  FIGS. 5A and 5B ) of connector  210  can be overmolded with a thermoplastic elastomer to give it elastic properties as well. 
     In one particular embodiment, flexible inner member  225  is a sheet of superelastic material, such as nitinol (an alloy of nickel and titanium present in roughly equal amounts) and the flexible contacts are part of a flex circuit adhered to the superelastic sheet. Nitinol alloys exhibit elasticity some 10-30 times that of ordinary metal which enables it to flex under very high strain without breaking. The flex circuit may include, for example, metal contacts  214   a - 214   c  screen printed on a thin polymide or PEEK (polyether ether ketone) layer. The flex circuit may be made from two separate pieces each of which is directly adhered to one side of the nitinol sheet or may be a single piece wrapped around the perimeter of the nitinol sheet or made into a sleeve that fits over the nitinol sheet. 
     The invention is not limited to the use of any particular superelastic material and can instead use any material that deforms reversibly to very high strains and returns to its original shape when the load is removed without requiring a change of temperature to regain its original shape. Also, some embodiments of the invention may use flexible materials for flexible inner member  225  that are not superelastic. For example, flexible inner member  225  can be made from an elastomer or polyurethane in some embodiments. 
     In another embodiment contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ) can be surrounded by flexible elastomer  222   b  so that each axial section serves as a bending plate allowing connector  210  to bend in order to relieve stress when the connector is inserted or extracted off-axis. Flexible elastomer  222   b  may be polypropylene or polyoxymethylene which is injection molded to capture and insulated components, e.g., contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ). In these embodiments, flexible elastomer  222   b  replaces the need for insulation strips  218   a - 218   c . In order to injection mold flexible elastomer  222   b  where insulation strips are not present, contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ) may be positioned in a frame or mold until flexible elastomer  222   b  is injection molded around the contacts. Thus, elastomer  222   b  may provide structural support as well as to capture and insulate components, e.g., contacts  214   a - 214   c  (shown in  FIGS. 5A and 5B ). In these embodiments, as well as previously mentioned embodiments employing injection molding, vacuum injection molding may be used and may minimize trapped air or gases that may lead to defective connectors. 
     In some embodiments, when connector plug  210  is engaged with a corresponding receptacle connector (shown in  FIG. 7B ) and extracted at an angle to the insertion axis, more force is applied to the base of the connector than at its tip. To address this discrepancy, in some embodiments the flexibility of flexible inner member  225  varies along the length of the member so that, for example, it is more flexible near the base portion or proximal end of the connector and less flexible near the distal end of the connector. Flexibility can be varied in this manner by, among other techniques, varying the materials along the length of the connector, varying the thickness of flexible inner member  225  along its length or varying the shape of flexible inner member  225  along its length or any combination of these approaches. For example, in one embodiment flexible inner member  225  may include a superelastic sheet near its base and a polyurethane sheet near its distal end. The superelastic and polyurethane sheets may overlap and be adhered together in an area between the proximal and distal ends. In one particular embodiment, flexible inner member  225  includes two sheets of polyurethane near the distal end of connector  210  and a single sheet of nitinol near the base of connector  210 . At a point approximately one third of the length of the connector from the distal end, the nitinol sheet is sandwiched between the two polyurethane sheets for a portion of the length. 
     In other embodiments, connector  210  may not only have variable flexibility about its length, but it may also alternate between rigid and flexible throughout its length in a myriad of combinations. For example, a hybrid rigid-flexible connector may be implemented in some circumstances. 
     In some embodiments, connector  210  is designed to break when side-loaded at a certain tension after it is inserted into a matching connector jack (shown in  FIGS. 7A and 7B ). It is preferable that connector  210  breaks as opposed to the connector jack because if the connector jack breaks, the electronic device in which it is housed may no longer be usable. To this end, in some embodiments, plug connectors according to the present invention are made from flexible materials such as elastomers or polymide dielectric materials to reduce strain when side-loaded under high levels of force and the like. As an example, when fully inserted, a rigid portion and a portion of a flexible portion of connector  210  may be inserted within a matching connector jack (shown in  FIGS. 7A and 7B ). When connector  210  is extracted from a matching connector jack (shown in  FIGS. 7A and 7B ) with a force that intersects its insertion axis, connector  210  bends or deforms the flexible portion which reduces the risk the connector will bind within or break the connector jack (shown in  FIGS. 7A and 7B ). 
       FIG. 7A  is a simplified perspective view of a matching connector jack (connector receptacle)  400  according to embodiments of the invention.  FIG. 7A  illustrates connector jack  400  according to the present invention including a housing  402  that defines an interior cavity  404  into which a plug connector, such as connector  210 , can be inserted. Also shown in  FIG. 7A  are contacts  414   c  and  414   a  that may be electrically coupled to corresponding contacts  214   c  and  214   b  (shown in  FIGS. 5A-5C ). Connector jack  400  aligns axial contact  214   c  with overhead contact  414   c  as illustrated in  FIG. 7A , allowing connector  210  to be operatively coupled to connector jack  400 . Similar connector jack contacts may be implemented for the other contacts of connector  210 , e.g., contact  214   b  may have a corresponding contact on connector jack  400 —similar to the contact  414   a.    
       FIG. 7B  is a cross-sectional view of the jack connector of  FIG. 7A  and a side view of a complementary plug to mate with jack connector  400 .  FIG. 7B  illustrates connector  210  inserted in connector jack  400  according to one embodiment of the present invention. Also shown are contact  414   c  and contact portion  412   a  of movable ground contact  412   b  which engage corresponding contact  214   c  and ground contact  212 . Similar corresponding contacts may exist for contacts  214   a  and  214   b . The rear element  416   a  forms an angled face  416   b  at an angle corresponding to that of the oblique face of ground contact  212  so that when the connector  210  is fully inserted into the jack connector  400 , the oblique face of ground contact  212  is flush with angled face  416   b.    
     In some embodiments, connector  210  may have a retention feature that holds it firmly in place when fully inserted within corresponding connector jack  400 . The retention feature may be mechanical or magnetic. 
     In an example of a mechanical embodiment, movable ground contact  412   b  may initially be held by stopping element  418  in a position wherein spring element  412   c  of movable ground contact  412   b  only is partially compressed. When connector  210  is inserted with sufficient force to further compress spring element  412   c , it may further compress movable ground contact  412   b  into the position shown in  FIG. 7B ; this allows full insertion of connector  210  and provides a retention force as connector  210  is pressed against angled face  416   b  by the spring portion  412   c  of movable ground contact  412   b . This retention force provides the retention feature. Connector  210  may be extracted from connect jack  400  when sufficient extraction force is applied to connector  210  to compress spring element  412   c.    
     In one example of a magnetic connector system, each of the plug connector and receptacle connector have a magnetic element. A magnetic element in the plug connector may be attracted to a magnetic element in the receptacle connector such that the plug connector may be magnetically held in place when mated with the receptacle. In a specific example, magnets in the receptacle may be arranged in proximity to each other with opposing polarities. With this arrangement, field lines originating in one magnet in the receptacle connector may pass through the ferromagnetic element in the plug connector and terminate in another magnet in the receptacle. Mechanical retention systems may also be used which may implement a cantilevered spring or detent to hold the connector plug in place. 
       FIGS. 7A and 7B  also illustrate the space saving feature of the D-shaped connector implementation, wherein an electronic device may be made slimmer or have additional internal components by virtue of the D-shaped connector&#39;s smaller thickness. 
     In other embodiments of the invention, the connector plug may have a differently shaped cross-section.  FIGS. 8A-8C  are simplified cross-sectional views of connector plugs according to embodiments of the invention. The cross-section of the connector plug may be shaped like a non-regular polygon (non-equilateral and non-equiangular polygon), including a non-equilateral triangle (shown in  FIG. 8A ), a non-regular octagon (shown in  FIG. 8B ), a non-regular hexagon (shown in  FIG. 8C ) or other shapes wherein a plurality of axial contacts and a plurality of axial insulation strips may be integrated. An inherent feature of a connector plug with a non-regular polygon cross section is that it will have a single insertion orientation when mated with a receptacle connector having a matching cavity. In other words, these embodiments may be described in terms of whether the cross-section of the connector plug has rotational symmetry—a cross section that looks the same after rotating the orientation of the cross-section less than 360 degrees in any direction. In embodiments of the invention, the cross-section of the connector plug does not have rotational symmetry. Connector plug with axial contacts have a required insertion orientation that may be dependent on the positions of the contacts. Thus, the connector plug (specifically its cross section) may be designed to only have one insertion rotation compatible with the shape of the connector receptacle in order for the contacts to be able to mate properly without additional design modifications. 
     As will be understood by those skilled in the art, the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. For example, while embodiments of the invention were discussed above with respect to audio plugs having four contacts, the invention is not limited to any particular number of contacts. Some embodiments of the invention may have as few as two contacts while other embodiments can have thirty or even more contacts. As one example of a variation with additional contacts, an additional insulation ring may be implemented so as to split each of the contacts  214   a ,  214   b  and  214   c  into halves, thereby doubling the number of contacts. In other embodiments, the location of the contacts, insulation strips, insulation rings, and grounds may be interchangeable—creating additional variations of the present invention. 
     Additionally, while the invention was described with respect to an audio connector, it is not limited to any particular type of signal and can be used to carry video and/or other signals instead of audio-related signals or in addition to audio-related signals. Also, in some embodiments, connectors according to the present invention can carry both analog and digital signals. As an example, connector  210  and its flexible version can be modified to include one or more fiber optic cables that extend through the connector and can be operatively coupled to receive or transmit optical signals between a mating connector jack. Those skilled in the art will recognize, or be able to ascertain, using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20110527
Publication Date: 20150922
Grant Date: 20150922
Priority Date: 20100528
Inventors: GOLKO ALBERT J.
SCHMIDT MATHIAS W.
JOL ERIC S.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/05", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/642", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/562", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/642", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/642", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/562", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/05", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/05", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/562", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 45004439