PATENT DOCUMENT

Publication Number: US-9054478-B2
Application Number: US-201313779433-A
Country: US
Kind Code: B2

Title: Electrical connector having a designed breaking strength

Abstract:
An improved method is employed to produce a plug connector having a defined breaking strength. The plug connector is receivable in a receptacle connector disposed in an electronic device. The plug connector has an inner enclosure bonded to a tab of the connector. The bonds are designed to break at a torque that is less than the breaking strength of the tab of the connector and/or the receptacle connector. The designed breaking strength protects the receptacle connector and/or the electronic device from damage when a force is applied to the plug connector.

Claims:
What is claimed is: 
     
       1. A plug connector comprising:
 a body having a first face and a tab extending from the first face of the body to a distal end of the plug connector; 
 the tab carrying a plurality of contacts and configured to be received in an insertion cavity of a receptacle connector; 
 a metal inner enclosure that at least partially surrounds the body; 
 the inner enclosure welded to at least a portion of the tab with one or more weld locations; 
 wherein the plug connector is designed to break at the one or more weld locations when torque is applied to the plug connector. 
 
     
     
       2. The plug connector set forth in  claim 1 
 wherein a breaking strength of the plug connector is a torque less than 3500 Newton-millimeters. 
 
     
     
       3. The plug connector set forth in  claim 2  wherein the breaking strength is a torque less than 2500 Newton-millimeters. 
     
     
       4. The plug connector set forth in  claim 2  wherein the breaking strength is a torque less than 1500 Newton-millimeters. 
     
     
       5. The plug connector set forth in  claim 2  wherein the breaking strength is a torque less than 500 Newton-millimeters. 
     
     
       6. The plug connector set forth in  claim 1  wherein the plug connector is configured to mate with a corresponding receptacle and the breaking strength of the plug connector is less than a breaking strength of the receptacle. 
     
     
       7. The connector set forth in  claim 1  wherein the one or more weld locations are designed break at a torque that is less than a breaking strength of the tab. 
     
     
       8. The connector set forth in  claim 1  wherein the inner enclosure
 comprises first and second portions. 
 
     
     
       9. The connector set forth in  claim 1  wherein the one or more weld locations include a combination of circular and elongated shapes. 
     
     
       10. The connector set forth in  claim 9  wherein the tab has first and second opposing faces and wherein the one or more weld locations include locations on each of the first and second opposing faces. 
     
     
       11. The connector set forth in  claim 10  wherein the tab further includes first and second opposing sides that extend between the first and second opposing faces and wherein the one or more weld locations include at least one location on each of the first and second opposing sides. 
     
     
       12. A method of making a plug connector comprising:
 forming a body, the body having a first face and a tab extending from the first face of the body to a distal end of the plug connector; 
 disposing a plurality of contacts in the tab, the tab configured to be received in a receptacle; 
 forming an inner enclosure that at least partially surrounds the body; 
 bonding the inner enclosure to at least a portion of the tab; 
 wherein the plug connector is designed to break at the bond when torque is applied to the plug connector. 
 
     
     
       13. The method set forth in  claim 12 , wherein the perimeter of the body is less than or equal to 30 mm. 
     
     
       14. The method set forth in  claim 12 , wherein the inner enclosure comprises a first portion and a second portion. 
     
     
       15. The method set forth in  claim 12 , further comprising:
 forming an outer enclosure disposed at least partially around the inner enclosure. 
 
     
     
       16. The method set forth in  claim 12 , wherein the bond is designed to break at a force that is less than a force required to break the tab. 
     
     
       17. The method set forth in  claim 12 , wherein the bond is designed to break at a force that is less than a force required to break the receptacle. 
     
     
       18. The method set forth in  claim 12 , wherein the plug connector is mounted in an accessory.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to electrical connectors and in particular to connectors having a designed breaking strength. 
     A wide variety of electronic devices are available for consumers today. Many of these devices have connectors that facilitate communication with and/or charging of the corresponding device. These connectors often interface with other connectors through cables that are used to connect devices to one another. Sometimes, connectors are used without a cable to directly connect the device to an accessory, such as a charging station or a sound system. 
     As smart-phones, media players and other electronic devices become more compact and feature intensive, their corresponding cost increases. Thus it is desirable to protect the electronic device from damage. Because connectors are often interfaced with the electronic device, sometimes it may be the connector that causes damage to the electronic device through a drop event or other externally applied force. Thus, connectors that protect the electronic device from damage are desirable. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates to attaching internal enclosures to connector bodies having relatively small geometry such that the connector has a designed breaking strength. By way of example, the connector design may be used on data and/or power connectors, such as USB connectors, Firewire connectors, Thunderbolt connectors and the like. The design enables plug connectors to break at a designed breaking strength before the connector tab and/or the receptacle connector in an electronic device breaks. This design is particularly useful when the plug connector is relatively strong and when it is desirable to protect the electronic device from damage resulting from the plug connector. 
     Some embodiments may comprise a plug connector having an inner enclosure including a first and a second portion. The inner enclosure may at least partially surround the body of the connector. The first and second inner enclosure portions may be bonded to a tab of the connector with one or more bond locations to provide a specific amount of mechanical strength to the body of the connector. In some embodiments the bond locations may be designed such that they will break before the connector tab. In further embodiments the plug connector may be mated with a receptacle connector and the bond locations in the plug connector may be designed such that they break before receptacle connector. In further embodiments the internal enclosure may be a unitary component. Some embodiments may have an outer enclosure that is disposed at least partially around the inner enclosure. 
     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 
         FIG. 1  is a diagram that illustrates an example two devices that can be interconnected with a cable, a plug connector and a connector receptacle. 
         FIG. 2A  is a diagram that illustrates a simplified example of a plug connector received in the receptacle connector of an electronic device. 
         FIG. 2B  is a diagram that illustrates a simplified side view of a plug connector received in the receptacle connector of an electronic device. 
         FIG. 3A  is a diagram that illustrates a plan view of an internal enclosure bonded to a connector tab. 
         FIG. 3B  is a diagram that illustrates a side view of an internal enclosure bonded to a connector tab. 
         FIG. 4A  is a diagram that illustrates a plan view of an internal enclosure bonded to a connector tab. 
         FIG. 4B  is a diagram that illustrates a side view of an internal enclosure bonded to a connector tab. 
         FIG. 5A  is a diagram that illustrates a plan view of an internal enclosure bonded to a connector tab. 
         FIG. 5B  is a diagram that illustrates a side view of an internal enclosure bonded to a connector tab. 
         FIG. 6  is a diagram that illustrates an isometric exploded view of a plug connector. 
         FIG. 7  is a diagram that illustrates an isometric view of an assembled plug connector. 
         FIG. 8  is a diagram that illustrates an isometric view of a cable. 
         FIG. 9A  is a diagram that illustrates an isometric view an electronic device accessory. 
         FIG. 9B  is a diagram that illustrates a simplified side view an electronic device received in an accessory. 
         FIG. 10  is a process by which a connector having an internal enclosure in accordance with an embodiment of the invention can be manufactured. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Many electronic devices such as smart-phones, media players, and tablet computers have connectors that facilitate battery charging and/or communication with other devices. The connectors include a plurality of electrical contacts through which electrical connections are made to another compatible connector to transfer power and/or data signals through the connectors.  FIG. 1  illustrates an example of two such connectors including a plug connector  110  and a receptacle connector  130 . Each of these connectors  110 ,  130  may comply with a well-known standard such as Universal Serial Bus (USB) 2.0, Firewire, Thunderbolt, or the like or may be proprietary connectors, such as the 30-pin and the Lightning connectors used on many Apple products among other types of proprietary connectors. 
     As further shown in  FIG. 1 , plug connector  110  is coupled to a cable  100 , which in turn is coupled to a peripheral device  105  that can be any of many different electronic devices or accessories that operate with such devices. Receptacle connector  130  is incorporated into a computing device  140 . When the plug connector  110  is mated with the receptacle  130 , contacts within each connector (not shown in  FIG. 1 ) are in physical and electrical contact with each other to allow electrical signals to be transferred between computing device  140  and peripheral device  105 . 
     Typically, the plug connector  110  is equipped with an internal enclosure (not shown) that covers the internal body of the connector. Thus, embodiments of the invention may be used in connector  110 . To further illustrate embodiments of the invention, various examples of connectors that include internal enclosures that may be made in accordance with the present invention are discussed below; however these embodiments should in no way limit the applicability of the invention to other connectors. 
     As a first example, reference is made to  FIG. 2A , which depicts a simplified view of a plug connector that can be used as connector  110  shown in  FIG. 1 . Plug connector  200  has a body  210  having a first face  211  and a tab  212  extending from the first face of the body to a distal end  221  of the plug connector. In some embodiments the perimeter of the plug connector is less than 30 mm. Plug connector  200  may further comprise an inner enclosure having a first portion  225   a  and a second portion  225   b . First and second inner enclosure portions  225   a ,  225   b  may be bonded to a portion of tab  212  with one or more bond locations  227 . Myriad methods may be employed to bond first and second inner enclosure portions  225   a ,  225   b  to tab  212 , such as for example, adhesive or fasteners. Tab  212  may be configured to be received in an insertion cavity of a receptacle connector  235  located in an electronic device  205 , and the tab may carry a plurality of contacts  220 . Plug connector  200  may further have one or more electrical cables  230 . 
     Plug connector  200  may be designed to break at bond locations  227  when a force  240  is applied at a distance  250  from receptacle connector  235 . More specifically, when a cantilever force is applied at  240 , a torque on plug connector  200  results and the one or more bonds between the first and second inner enclosure portions  225   a ,  225   b  and tab  212  may be broken. In some embodiments the number, size and configuration of bond locations  227  are specifically designed to break at a force  240  that is less than the breaking force of tab  212  and/or receptacle connector  235 . Thus, by judicious design of bond locations  227 , the plug connector  200  may break before receptacle connector  235 , saving electronic device  205  from damage. 
       FIG. 2B  shows a simplified side view of plug connector  200  engaged with electronic device  205 . In this illustration the location of applied force  240  is more clearly shown as a simple point load at a distance  250  from the entrance of receptacle connector  235 . Force  240  multiplied times distance  250  results in an applied torque exerted on plug connector  200 . However it is understood that the actual force applied may not be a simple one dimensional point load and that other loads may be applied to plug connector  200 . The forces shown here are for illustration only and other mechanical loads are within the scope of this disclosure. For example, in some embodiments plug connector  200  could be subject to a twisting load or an angular load and similar methods may be employed to ensure the plug connector breaks before tab  215  and/or receptacle connector  235 . 
     In some embodiments plug connector  200  is designed to have a breaking strength that is a torque less than 3500 Newton-millimeters. More specifically, bond locations  227  (see  FIG. 2A ) may be designed to break at less than 3500 Newton-millimeters of applied torque, illustrated as force  240  at distance  250  from electronic device  205 . In other embodiments the breaking strength of plug connector  200  is a torque less than 2500 Newton-millimeters. In further embodiments the breaking strength of plug connector  200  is a torque less than 1500 Newton-millimeters. In still further embodiments the breaking strength of plug connector  200  is a torque less than 500 Newton-millimeters. 
       FIGS. 3A-5B  illustrate example embodiments of different bond configurations. Other variants are within the scope of this disclosure.  FIG. 3A  illustrates a plan view of plug connector  300 . Eight circular and staggered bond locations  327  are performed on a top face  350  of first and second internal enclosure portions  325   a ,  325   b . Similar circular bonds may be performed on the opposite face of plug connector  300 .  FIG. 3B  illustrates a view of the right side  355  of plug connector  300  and shows two bond locations  328  on the side of second internal enclosure portion  325   b . Similar welds may be performed on first internal enclosure portion  325   a . The bond locations may bond first and second internal enclosure portions  325   a ,  325   b  to tab  312 . 
       FIG. 4A  illustrates a plan view of connector plug  400 . Two elongated bond locations  427  are performed on a top face  450  of first and second internal enclosure portions  425   a ,  425   b . Similar elongated bonds may be performed on the opposite face of plug connector  400 .  FIG. 4B  illustrates a view of the right side  455  of plug connector  400  and shows one elongated bond location  428  on the side of second internal enclosure portion  425   b . Similar bonds may be performed on first internal enclosure portion  425   a . The bond locations may bond first and second internal enclosure portions  425   a ,  425   b  to tab  412 . 
       FIG. 5A  illustrates a plan view of connector plug  500 . One elongated bond location  527  is performed on a top face  550  of first and second internal enclosure portions  525   a ,  525   b . Similar elongated bonds may be performed on the opposite face of plug connector  500 .  FIG. 5B  illustrates a view of the right side  555  of plug connector  500  and shows one elongated bond location  528  on the side of second internal enclosure portion  525   b . Similar bonds may be performed on first internal enclosure portion  525   a . The bond locations may bond first and second internal enclosure portions  525   a ,  525   b  to tab  512 . 
     It will be appreciated that the plug connector configurations described herein are illustrative that variations and modifications are possible. For instance, in some embodiments bond locations  227  (see  FIG. 2A ) may comprise a combination of circular and elongated shapes. In other embodiments there may be one single bond location while in other embodiments there may be a plurality of bond locations. Further embodiments may have no bond locations on the side faces of the first and second internal enclosure portions. Some embodiments may have metallic internal enclosure portions that are bonded to a metallic tab. Further embodiments may perform bonding using, for example, a laser or spot welder. Other embodiments may use an adhesive or an epoxy to bond the first and second internal enclosure portions to the tab. Further embodiments may comprise first and second internal enclosure portions and the tab made from plastic and the bonding may be performed using an ultrasonic or thermosonic wand. Other embodiments may have a unitary internal enclosure. 
       FIG. 6  shows an example connector plug  600  with the first and second internal enclosure portions  625   a ,  625   b  moved outward for clarity. Internal components  680  may be disposed inside of first and second enclosure portions  625   a ,  625   b . In this illustration it can be seen that in some embodiments, tab  612  is substantially unitary and has a length  640 . In some embodiments there may be an outer enclosure  606  that may be slid over first and second internal enclosure portions  625   a ,  625   b  such that the outer enclosure is disposed at least partially around the inner enclosure.  FIG. 7  shows a one embodiment of a completed plug connector  700  with outer enclosure  706  in its final position over the inner enclosure (not shown). Such embodiments may be used to terminate one or both ends of a cable  800 , as illustrated in  FIG. 8 . 
     Another embodiment that incorporates a plug connector having an internal enclosure is illustrated in  FIG. 9A . In this embodiment, plug connector  900  is installed in accessory  910 .  FIG. 9B  shows a simplified cross sectional view of accessory  910  with electronic device  920  mated with plug connector  900 .  FIG. 9B  also illustrates how a force  940  may be applied to electronic device  920  at a distance  960  from an entrance of receptacle connector  975  in the electronic device. Applied force  940  may, as discussed above, apply a torque force on plug connector  900 . The body of plug connector  900  may be designed as illustrated in  FIGS. 3A-5B  to break at a force that is less than the breaking force of tab  990  and/or receptacle connector  975 . Thus, by judiciously designing the breaking force of the bond locations (see  FIGS. 3A-5B ), plug connector  900  may break before receptacle connector  975 , saving electronic device  920  from damage. 
       FIG. 10  illustrates a process by which a connector having an inner enclosure with a breaking strength less than that of the connector tab and/or the receptacle connector may be made. In step  1005  a partially assembled connector is provided. In step  1010  the inner enclosure is installed at least partially around the connector body. In some embodiments the inner enclosure comprises two portions while in other embodiments it may only comprise one portion. In step  1015  the inner enclosure is bonded to at least a portion of the connector tab. In some embodiments the inner enclosure may be metal and may be welded or glued to a metallic tab. In other embodiments the inner enclosure may be plastic and may be heat welded or glued to the tab. In step  1020  the connector assembly is completed. In some embodiments an outer enclosure is disposed at least partially around the inner enclosure. 
     In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the invention, and what is intended by the applicants to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.

Metadata:
Filing Date: 20130227
Publication Date: 20150609
Grant Date: 20150609
Priority Date: 20130227
Inventors: GOLKO ALBERT J.
KAMEI IBUKI
JONES WARREN Z.
THOMPSON PAUL J.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 51388592