PATENT DOCUMENT

Publication Number: US-8974126-B2
Application Number: US-201213688727-A
Country: US
Kind Code: B2

Title: Hybrid optical connector

Abstract:
Connector systems that carry electrical signals and optical signals in a single connector are provided. A male electro-optical connector can have an electrical insert portion that fits into a receptacle of a female electro-optical connector to provide a structural connection. The optical interface can be advantageously near a front of the connectors for easy maintenance. Optical connectors with a relatively large diameter for the optical interface are also provided. Optical connectors can include a collector for receiving optical signals at a large opening and providing signals to a photodiode at a small opening of the collector. Such optical connectors with a large diameter for an optical interface can advantageously provide reduced alignment tolerances. Adapters, cable adapters, docking stations, and other apparatus can also be provided.

Claims:
What is claimed is:  
     
       1. A female receptacle connector comprising:
 a front configured to mate with a corresponding connector; 
 an insulator core; 
 a plurality of pins embedded in the insulator core, wherein each pin contains an electrically conductive material, the plurality of pins comprising a first and a second set of pins, wherein front ends of the first set of pins are configured to mate with electrical contacts of the corresponding connector, wherein the insulator core includes an opening for receiving the electrical contacts of the corresponding connector; 
 at least one active optical component for at least one of receiving optical signals from or transmitting optical signals to the corresponding connector, wherein the second set of pins extend to a substrate that is attached to the at least one active optical component; and 
 a lens device extending from the at least one active optical component to the front of the connector, wherein the lens device is configured to carry optical signals to and from an optical device of the corresponding connector, 
 wherein at least a portion of the second set of pins are communicably coupled with the at least one active optical component and are configured to carry electrical signals corresponding to the optical signals. 
 
     
     
       2. The connector of  claim 1 , wherein the front ends of the first set of pins lie on at least two inner surfaces of the opening. 
     
     
       3. The connector of  claim 2 , wherein the opening has a top inner surface, a bottom inner surface, and two side inner surfaces; wherein the first set of pins comprise at least six pins, and wherein at least two pins are located on the top inner surface of the opening, at least two pins are located on the bottom inner surface of the opening, and at least one pin is located on each side inner surface of the opening. 
     
     
       4. The connector of  claim 3 , wherein the pins located on each side inner surface of the opening are configured to provide ground, at least one of the pins on the top inner or bottom inner surface is configured to carry power, and the remaining pins are configured to carry data signals and an identification signal. 
     
     
       5. The connector of  claim 2 , wherein the opening has two side inner surfaces, and wherein each side inner surface comprises a retention mechanism for engaging a side of an insert of the corresponding connector. 
     
     
       6. The connector of  claim 5 , wherein the first set of pins comprise a pin located on each side inner surface of the opening, and wherein the pins located on the side inner surfaces act as the retention mechanism by engaging notches in the sides of the insert of the corresponding connector. 
     
     
       7. The connector of  claim 1 , wherein the first set of pins extend from a circuit board to a front of the connector, and wherein the second set of pins extend from the circuit board to the substrate that is attached to the at least one active optical component. 
     
     
       8. The connector of  claim 1 , wherein the lens device includes aligning elements that receive the optical device of the corresponding connector and aligns the optical device with a lens of the lens device. 
     
     
       9. The connector of  claim 1 , wherein the at least one active optical component includes:
 a laser device that receives electrical signals from a first portion of the second set of pins and that converts the received electrical signals to electromagnetic radiation. 
 
     
     
       10. The connector of  claim 9 , wherein the laser device includes a laser and electrical components, wherein the electrical components receive the electrical signals from the first portion of the second set of pins and generates input signals to the laser. 
     
     
       11. The connector of  claim 9 , wherein the at least one active optical component includes:
 a photodiode device that receives electromagnetic radiation from the corresponding connector and that converts the received electromagnetic radiation to electrical signals on a second portion of the first set of pins. 
 
     
     
       12. The connector of  claim 1 , wherein the second set of pins are attached at a back of the substrate, wherein the at least one active optical component is attached to the back of the substrate, the connector further comprising:
 one or more respective lens devices optically coupled to a respective one of the at least one active optical component, wherein the lens devices are at a front of the substrate, and wherein the substrate has one or more respective holes between each of the least one active optical component and the respective lens devices. 
 
     
     
       13. The connector of  claim 12 , wherein at least two of the pins of the second set are connected together via a plate at the end of the at least two pins, the at least two pins configured to carry ground, wherein the plate is attached to the substrate over the at least one active optical component.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a Continuation of PCT Application No. PCT/US2011/038533, International Filing date May 31, 2011 which claims priority to U.S. Provisional Patent Application Nos: 61/350,430, entitled “Hybrid Optical Connector,” by Jason Sloey, filed Jun. 1, 2010 and 61/379,335, entitled “Hybrid Optical Connector,” by Sloey et al., filed Sep. 1, 2010, the entire contents of which are herein incorporated by reference for all purposes. 
     This application is related to the concurrently filed and commonly owned Continuation Patent Application entitled “Optical Connection of Devices” by Sloey, et al. the entire contents of which is herein incorporated by reference for all purposes. 
    
    
     BACKGROUND 
     The present invention relates generally to connectors and apparatus used to carry optical signals, and more specifically to connectors that can carry both optical and electrical signals and to optical connectors with advantageous properties. 
     Some devices, such as CD players, can output optical signals. Cables with optical connectors (e.g. Toslink) and with optical fiber carry these optical signals to another device (e.g. a stereo receiver). Optical signals have certain advantages, such as no electromagnetic interference. But optical signals also have limitations as to the functionality and support that can be provided. Current optical connectors also have limitations. 
     Therefore, it is desirable to have connectors that can carry optical signals as well as other signals. It is also desirable to have improved optical connectors that can have various advantageous properties, such as easily connected, easily maintained, and supporting high data rates. 
     SUMMARY 
     Accordingly, certain embodiments of the present invention can provide connector systems that carry electrical signals and optical signals in a single connector. An electro-optical connector can be made in a cost effective manner and for easy incorporation into electronic devices and apparatus. A male electro-optical connector can have an electrical insert portion that fits into a receptacle of a female electro-optical connector to provide a structural connection, thereby allowing the optical interface to be advantageously near a front of the connectors for easy maintenance. 
     Also, certain embodiments of the present invention can provide optical connectors with a relatively large diameter for the optical interface, while still providing high data rates (e.g. over 1 Gbps). Optical connectors can include a collector for receiving optical signals at a large opening and providing signals to an optical receiver at a small opening, where the optical receiver converts the optical signals to electrical signals. Optical connectors with a large diameter for an optical interface can also advantageously provide reduced alignment tolerances. 
     According to one embodiment, a female receptacle connector includes an insulator core, electrically conductive pins, and an active optical component. The pins are embedded in the insulator core. There are a first and a second set of pins. The first set of pins are designed to mate with electrical contacts of a corresponding connector. The active optical component is for receiving and/or transmitting optical signals to the corresponding connector. The second set of pins extend to a substrate that is attached to the active optical component. At least a portion of the second set of pins are communicably coupled with the active optical component and are configured to carry electrical signals corresponding to the optical signals. A lens device can extend from the at least one active optical component to a front of the connector, wherein the lens device carries optical signals to or from an optical device of the corresponding connector. 
     According to another embodiment, a method making a connector is provided. A lead frame is formed from a single piece of conductive material. The lead frame includes a carrier piece and a plurality of pins. The plurality of pins extend from the carrier piece, and include a first and a second set of pins. A substrate is attached to the second set of pins. The substrate has at least one active optical component for receiving and/or transmitting optical signals to a corresponding connector. At least a portion of the second set of pins are communicably coupled with the at least one active optical component and are configured to carry electrical signals corresponding to the optical signals. The first set of pins extend past the second set of pins toward a front of the connector for mating with electrical contacts of the corresponding connector. 
     According to another embodiment, a male plug connector includes an insulator core and at least one optical device. The insulator core has an insert portion that extends from a base of the insulator core. The insert portion is configured to fit inside a receptacle portion of a corresponding female connector. The insert portion has a plurality of contact locations. The at least one optical device is for receiving and/or transmitting optical signals to the corresponding female connector. A front end of the at least one optical device is on the base of the insulator core at a location separate from the insert portion. 
     A better understanding of the nature and advantages of the present invention may be gained with reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a block diagram illustrating a connector system for communicating optical and electrical signals according to embodiments of the present invention. 
         FIG. 2A  shows a male plug connector at an end of a cable for communicating optical and electrical signals according to embodiments of the present invention. 
         FIG. 2B  shows a female receptacle connector for communicating optical and electrical signals according to embodiments of the present invention. 
         FIG. 3  shows a lead frame for a female connector that has electrical components for converting between electrical signals and optical signals according to embodiments of the present invention. 
         FIG. 4  shows pins of a lead frame assembly attached to a substrate having at least one active optical component according to embodiments of the present invention. 
         FIG. 5A  shows a cross-sectional side view of substrate at the connection point of an optical transmitter according to embodiments of the present invention. 
         FIG. 5B  shows a cross-sectional side view of substrate at the connection point of an optical receiver according to embodiments of the present invention. 
         FIG. 6A  is a perspective view of a female connector capable of communicating electrical and optical signals according to embodiments of the present invention. 
         FIG. 6B  is a front view of the female connector capable of communicating electrical and optical signals according to embodiments of the present invention. 
         FIG. 7  is a flowchart of a method for making a female connector according to embodiments of the present invention. 
         FIG. 8  shows an adapter for converting optical data signals from a large width fiber to a smaller width fiber according to an embodiment of the present invention. 
         FIG. 9A  illustrates a system with a docking station having at least one active optical component and an electronic device having at least one active optical component according to embodiments of the present invention. 
         FIG. 9B  is a cross-sectional side view of electronic device and docking station according to embodiments of the present invention. 
         FIG. 10  is a cross-sectional view of a male connector having a spring mechanism for an optical element mated with a corresponding female receptacle connector according to embodiments of the present invention. 
         FIG. 11A  is a cross-sectional view of an optical element having a proud surface relative to an external surface of the connector according to embodiments of the present invention. 
         FIG. 11B  is a magnified view of the surface of the optical element and the external surface according to embodiments of the present invention. 
         FIG. 12A  is a top view of a hybrid male plug connector with a central connector according to embodiments of the present invention. 
         FIG. 12B  shows a side view of hybrid male plug connector according to embodiments of the present invention. 
         FIG. 12C  shows a front view of hybrid male plug connector according to embodiments of the present invention. 
         FIG. 12D  is an exploded view of hybrid male plug connector according to embodiments of the present invention. 
         FIG. 13  is a perspective view of a hybrid male plug connector with an active optical component according to embodiments of the present invention. 
         FIG. 14  shows an exploded view of a passive male plug connector according to embodiments of the present invention. 
         FIG. 15  shows an exploded view of an active male plug connector according to embodiments of the present invention. 
       FIGS.  16  and  17 A- 17 C are perspective, front, top, and side views of a female hybrid connector  1500  according to embodiments of the present invention. 
         FIG. 18  shows an exploded view of a female receptacle connector according to embodiments of the present invention. 
         FIGS. 19A and 19B  show various views of a female receptacle connector according to embodiments of the present invention. 
         FIG. 20A  is a simplified perspective view of a connector insert for hybrid male plug connector  50 , while  FIGS. 20B-20D  are simplified bottom, front and side plan views, respectively, according to one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Certain embodiments can provide connector systems that carry electrical signals and optical signals in a single connector. An electro-optical connector can be made in a cost effective manner and for easy incorporation into electronic devices and apparatus. A male electro-optical connector can have an electrical insert portion that fits into a receptacle of a female electro-optical connector to provide a structural connection, thereby allowing the optical interface to be near a front of the connectors for easy maintenance. 
     Also, certain embodiments can provide optical connectors with a relatively large diameter for the optical interface, while still providing high data rates (e.g. over 1 Gbps). Optical connectors can include a collector for receiving optical signals at a large opening and providing signals to an optical receiver at a small opening, where the optical receiver converts the optical signals to electrical signals. Optical connectors with a large diameter for an optical interface can also advantageously provide reduced alignment tolerances. 
     I. Overview 
       FIG. 1  is a block diagram illustrating a connector system  100  for communicating optical and electrical signals according to embodiments of the present invention. Having electrical signals can allow legacy support for older interface standards. Electrical signals can also provide power to electronic devices. Note that  FIG. 1  is not drawn to any particular scale. 
     Electronic device  110  includes an electro-optical connector  120 , which may be any female connector as described herein. Electronic device  110  may be any device that sends or receives data (e.g. audio or video). For example, electronic device  110  may be a media player that sends audio and video signals to another device for displaying the video and playing the audio. Electro-optical connector  120  may be a female or male connector, or have aspects of both. 
     Electro-optical connector  120  includes electrical contacts  122  and an active optical component  124 . Electrical contacts  122  can receive and send electrical signals directly from electrical contacts of a corresponding connector as can occur in a purely electrical connector. Active optical component  124  converts electric signals from the electronic device into optical signals and/or converts optical signals received from another device into electrical signals that are usable by the electronic device. In various embodiments, the active optical component can be an optical transmitter, an optical receiver, or an optical transceiver that includes both an optical transmitter and an optical receiver in a single. Electro-optical connector  120  can have any number of active optical components and may include lens devices for transferring light to active optical component  124  (or active optical component  124  may include such lens devices). In one embodiment, electro-optical connector  120  has two separate active optical components, one for transmitting and one for receiving. 
     Electrically conductive pins  145  can travel from a circuit  140  to connector  120 . A first set of pins  145  can carry electrical signals to be converted by active optical component  124 , or receive electrical signals that result from optical signals being converted to electrical signals. Thus, in once aspect, electronic device  110  (e.g. through circuit board  140 ) can receive electrical signals in a same manner as for a purely electrical connector. Accordingly, electronic device  110  could be built the same for electrical, optical, or electro-optical connectors. A second set of pins  145  can carry electrical signals from circuit board  140  to electrical contacts  122 . In one embodiment, electrical contacts  122  are part (e.g. a front end) of the second set of pins  145 . 
     Electro-optical connector  120  can receive signals from a first connector  160  of cable  150 . First connector  160  may be any male connector as described herein. Cable  150  has optical fibers (e.g. glass or plastic fibers) for carrying optical signals to or from electro-optical connector  120 . A passive optical device  164  of first connector  160  can receive or carry the optical signals to active optical component  124 , or to a lens device of connector  120  that is optically coupled with active optical component  124 . Optical device  164  is passive in that the optical signals are not converted to/from electrical form, but stay in optical form while being carried. In one embodiment, passive optical device  164  can be an extension of an optical fiber or an additional device such as a lens. 
     Cable  150  can also have electrical wires for carrying electrical signals. Electrical contacts  162  connect with electrical contacts  122  when first connector interface  160  is mated with connector  120 . In one embodiment, electrical contacts  162 , and at least part of a housing (an insulator core) in which contacts  162  are embedded, are used to provide alignment for the optical interface. For example, electrical contacts  162  can fit inside connector  120  to provide alignment of active optical component  124  and passive optical device  164 . Such alignment can allow the optical devices to be at a front of the connectors. 
     Having the optical devices at a front of a connector can allow easy cleaning and maintenance of the optical interface. For example, active optical component  124  may be coupled with passive elements (e.g. a lens and/or a collector) that are also part of connector  120 . The passive elements can lie between passive optical device  164  and active optical component  124 . These passive elements can be maintained easier when they lie at a front of connector  120 . 
     In an embodiment with a single active optical component, the component can be a transceiver. In this embodiment, different optical frequencies (e.g. wavelength of 850 nm in one direction and 1350 nm in the other) can be used. Filters or other mechanisms can be used to reduce optical cross talk, e.g., by blocking light from the transmitting part to the receiving part. 
     In some embodiments, cable  150  has two fiber channels, one for each direction of transmission. Each of these channels can be a multi-core fiber, where multiple fibers transmit light in the same direction. For example, the total diameter can be 200-500 microns, with each fiber having a diameter of about 50-100 microns (e.g. 300 total diameter and 100 individual diameters). A multi-core fiber can provide low light loss when bent (e.g. due to the small individual fibers), and the total diameter can provide a large total area for light transmission, which can help with alignment at the connectors. In one embodiment, the total diameter of a multi-core fiber is about the same value as the diameter of receiving lens on connector  120 . 
     In one embodiment, active optical component  124  may work with electromagnetic radiation at a specific wavelength, but any wavelength may be chosen. For example, a wavelength of 650 nm may be used when plastic fibers are to be used in cables, and a wavelength of 850 nm may be used when glass fibers are to be used, as these wavelengths have low loss for these respective materials. But 850 nm may also be used for plastic fibers when cables are not expected to be long (e.g. 5 m or less). 
       FIG. 2A  shows a male plug connector  260  at an end of a cable for communicating optical and electrical signals according to embodiments of the present invention. In one embodiment, male plug connector can correspond to first connector interface  160 . 
     Cable  250  includes male plug connector  260  for sending and receiving optical signals and electrical signals. Housing  270  includes an insert portion  274  and base portion  272 . Electrical signals can be provided with electrical contacts at contact locations in insert portion  274  of housing  270 . The electrical contacts can be embedded in the insert portion, e.g., embedded so that the housing surrounds the contacts or embedded in an inner surface, thereby forming the contacts on the inner surface. Base portion  272  can include a passive optical component  274  for carrying optical signals. In one embodiment, base portion  272  is made integral with insert portion  274 . In another embodiment, base portion  272  is a separate piece from insert portion  274 . 
     In various embodiments, passive optical device  274  can be an extension of an optical fiber in cable  250  or an additional device such as a lens. In one embodiment, male plug connector  260  can also include an active optical component, and thereby can have only electrical wires, and no optical fibers. In one embodiment, the electrical contacts and electrical wires may be omitted when only optical signals are to be carried. In instances where cable  250  is only to transfer electrical signals, passive optical component may be omitted, or just not connected with any optical fibers as the cable would not have any. The other end of such a cable could be any standard electrical connector, e.g., USB. 
       FIG. 2B  shows a female receptacle connector  220  for communicating optical and electrical signals according to embodiments of the present invention. The connection of male plug connector  260  to female connector  220  can provide communication of both electrical and optical signals. The electrical signals can be communicated via electrical contacts in insert portion  274  of male plug connector, which can contact with electrical contacts  222  when the connectors are mated. Electrical contacts  22  (e.g. acting as a front end of a pin) can transmit the electrical signals to pins at a back end of the female connector  220 , and then to a circuit board to which the pins can be electrically connected (e.g. soldered). The optical signals can be communicated via passive optical components  264  to optical links  240 . In various embodiments, the passive optical components  264  can include a lens optically coupled with a fiber or the front end of a fiber, where the front end can be polished. 
     Insert portion  244  of housing  240  can fit (at least partially) inside opening  205  of female connector  220 . The insertion of insert portion  244  can provide a structural connection between male plug connector  260  and female connector  220 . This structural connection can provide alignment of optical links  240  with passive optical components  264 . 
     An optical link of optical links  240  can include an active optical component and passive optical components. In one embodiment, one optical link can include one active optical component (e.g. in the optical link on the left) for transmitting optical signals and the other optical link can include another active optical component (e.g. in the optical link on the right) for receiving optical signals. Passive optical components (e.g. a lens) can carry the light from a front of female connector  220  to the active optical component. 
     In embodiments where the optical links  240  have a lens that is at the front of the connector (e.g., within 1 cm of the front edge or less than ¼ the depth of opening  205 ), optical links  240  can be easily maintained. For example, any debris on the lens can be brushed away. Also, the external surface of the lens can be cleaned and/or polished to provide good transmission of optical signals. In one aspect, the use of insert portion  274  to provide structural connection and broad alignment allows a surface of optical links to be near the front edge of connector  220 . 
     In another embodiment, optical links  240  can be on one side and the electrical pins could be on the other side. In yet another embodiment, electrical contacts  222  can be separated and at the edges, with optical links  240  in the middle. 
     II. Female Hybrid Connector with Centered Optical Elements 
       FIG. 3  shows a lead frame  300  for a female connector that has electrical components for converting between electrical signals and optical signals according to embodiments of the present invention. As shown, lead frame  300  is at an intermediate point of manufacturing. As shown, lead frame has optical elements in the center. Examples of an optical element include a fiber, lens, collector, or active optical component. Other embodiments herein (e.g. female receptacle connector  220  can have the optical elements at the edges). Embodiments with optical elements at the edges can have intermediate stages that are similar to lead frame  300 . 
     Carrier  310  holds the pins  315  and  317 . Carrier  310  and pins  315  and  317  can be made of an electrically conductive material (e.g. copper). Both sets of pins can carry electrical signals, but pins  315  are configured to carry electrical signals to/from electrical contacts of a corresponding connector. Pins  317  are configured to carry electrical signals to/from active optical components on substrate  320 . Substrate  330  includes active optical components and lenses  340  and  345 . Lenses  340  and  345  receive and transmit light to optical devices (e.g. lenses) of the corresponding connector. 
     Although 16 total pins are shown, there can be any number of total pins, which can be split up in any manner between pins  315  and pins  317 . Pins  315  and  317  can correspond to pins  145  of  FIG. 1 . As used herein, the term “pin” is used to refer to a conductive material that can carry electrical signals. Part of the pins can come in contact with pins of another connector, and these pins (e.g. pins  315 ) may also be called contacts. 
     Pins  317  eventually can be connected with a circuit board (e.g. circuit board  140  of  FIG. 1 ) and communicate electrical signals to the circuit board, where the electrical signals correspond to optical signals (i.e. converted from or to be converted into the optical signals). The same circuit board can also be connected with pins  315  and can receive electrical signals on pins  315 , wherein the electrical signals are received from electrical contacts of the corresponding connector. 
     In one embodiment, the back ends of pins  315  and  317  can lie in a single row. After carrier  310  is cut away, a circuit board can be positioned in a similar manner to carrier  310 . Thus, the circuit board can lie behind the connector, thereby allowing the electronic device to be thinner. Also, having the pins in a single row can allow a connection of the pins to an edge of the circuit board, thereby allowing the circuit board to be smaller. 
       FIG. 4  shows pins  417  of a lead frame assembly  400  attached to a substrate  430  having at least one active optical component according to embodiments of the present invention. Lead frame assembly  400  includes active optical components and pins  417  that carry the electrical signals to/from the active optical components. In one embodiment, lead frame assembly  400  corresponds to the substrate  330  and attached components of  FIG. 3 . 
     A substrate  430  is attached to pins  417 . For example, pins  417  can be electrically bonded (e.g. soldered) to a pad on the back of substrate  430 . Pins  417   b  can send signals to substrate  430 . In one embodiment, the signals on pins  417   b  can include power, ground, and two data signals (e.g. data signals). Traces in substrate  430  can send the electrical signals to a laser integrated circuit (IC) and other electrical components  455 . In one embodiment, laser IC and EE components  455  can be put onto one IC as opposed to multiple ICs. 
     Laser IC and EE components  455  can convert the electrical signals to signals that drive an optical transmitter (e.g. a laser). The drive signals can include power, ground, and one data signal. The power signal can be refined, if necessary, to provide a proper power and voltage to the optical transmitter. In one embodiment, the optical transmitter can be behind the transmission lens  445 . The optical transmitter can then provide optical signals to transmission lens  445 , and transmission lens  445  can then provide the converted optical signals to a corresponding lens. 
     A receiving lens  440  can receive optical signals from the corresponding connector. A collector (e.g. parabolic concentrator  460 ) can collect the light and provide the light to an optical receiver (e.g. a photodiode), which converts the optical signals into electrical signals. A photodiode IC and EE components  458  can receive the electrical signals and modify them to conform to specifications of the electronic device in which pins  417   a  are connected. Photodiode IC and EE components  455  can be put onto one IC or onto multiple ICs. 
     In some embodiments, IC and EE components  458  can include a transimpedance amplifier (which converts photocurrent to electrical current) and limiting amplifier. The limiting amplifier can take electrical current and convert it into a voltage signal. The voltage signal can then be provided to a circuit board on pins  417   a  to provide the proper data that was originally conveyed in the received optical signals. 
     In one embodiment, middle pins  417   c  can also provide ground to substrate  430 . The ground can be used for devices on the substrate and/or for shielding of certain devices. For example, ground plate  460  can provide shielding of the active optical components on the back of substrate  430 . Ground plate  460  can be created at the same time that pins  417  are stamped. 
     For DisplayPort or other formats that have multiple signals (channels), the electrical signals on pins  417   a  or  417   b  could be combined and put into a single line before being sent to the substrate assembly (substrate  420  and attached devices). In another embodiment, electronics on the substrate could perform the combining (e.g. in components  455 ). 
     In one embodiment, the substrate assembly is created before being attached to pins  417 . For example, components  455  and  458  can be attached to substrate  430  before it is attached to pins  417 . For example, components  455  and  458  can be bonded (e.g. to pads) on the front of substrate  430 , which can have traces that carry signals between the components. 
     In another embodiment, the substrate is ceramic for providing high insulation between electronic components to keep capacitive coupling low. Ceramic material can be molded, and then components attached. Ceramic molding can reduce capacitive coupling between the differential signals going into laser IC and EE components  455 , or the differential signal coming out of photodiode IC and EE components  458 . Some embodiments can provide up to 10 gigabit/second throughput. There is no electromagnetic interference for optical signals, but after conversion to electrical signals, electromagnetic interference and crosstalk can exist. As the ceramic has a high dielectric constant, the electrical components can be placed closer together and the traces in the ceramic can be placed closer together. 
       FIG. 5A  shows a cross-sectional side view of substrate  530  at the connection point of an optical transmitter  570  according to embodiments of the present invention. In one embodiment, substrate  530  can correspond to substrate  430  of  FIG. 4 . Substrate  530  can be machined to have certain shapes for the attachment of devices to it. 
     In one embodiment, a laser  570  or other optical transmitter is mounted to the back of substrate  530 . A pocket has been cut into the back of substrate  530 . Laser  570  is placed inside the pocket, which allows ground plate  560  (which can correspond to ground plate  460 ) to cover laser  570 . Ground can be received at ground plate  560  from pins  517   c . In one aspect, ground plate  560  can cover laser  570  while remaining flat, thereby providing easy manufacturing. In one embodiment, substrate  530  is ceramic, which can be machined to higher tolerances than plastic (e.g. FR4). 
     A hole  575  formed through substrate  530  can allow light from laser  570  to shine through to transmission lens  545 . For example, laser  570  can shine light through hole  575  to transmission lens  545  when electrical signals are received from other electronics on substrate  530 . In one embodiment, laser  570  is a vertical cavity surface emitting laser (VACSEL). 
     Transmission lens  545  can include a barrel shaped tube with a lens (e.g. a curved lens), which can provide light out in a generally parallel direction. The front of substrate  530  can be machined to receive the back end of transmission lens  545 . For example, the very back end of lens  545  can be made to fit into hole  575 . In one embodiment, an air gap can exist between laser  570  and transmission lens  454 . In another embodiment, the back of transmission lens  545  can be in contact with laser  570 . 
       FIG. 5B  shows a cross-sectional side view of substrate  530  at the connection point of an optical receiver  580  according to embodiments of the present invention. A receiving lens  545  can receive optical signals from an optical device of a corresponding connector. 
     As shown receiving lens  545  is attached to or part of collector  547  (e.g. a parabolic concentrator), which collects light and provides the light to a photodiode  580  or other optical receiver. Substrate  530  can be machine to have pockets on the front and the back in a similar manner as the pockets for laser  570  and transmission lens  545 . The photodiode  580  creates electrical signals from the optical signals. The electrical signals can be modified with other electronics and provided to a circuit board via pins  517   a.    
     Collector  547  has a large opening at receiving lens  545  and a small opening at substrate  530 . Collector  547  can be molded, e.g., from plastic. Light is delivered to an active area of photodiode  580  through the small opening, which can allow photodiode  580  to be small, thus reducing its capacitance. Thus, light is collected at a larger diameter and delivered at a smaller diameter. This collection of light can allow more light to be provided to photodiode  580  than if receiving lens  545  was the same size as photodiode  580 . 
     In one aspect, since receiving lens  545  is relatively large, the alignment between receiving lens  545  and an optical device (e.g. a fiber, lens, or fiber/lens combination) of the corresponding connector is not as crucial. For example, when light leaves the optical device of the corresponding connector, the light diffuses out and might miss the lens. As collector  547  can be made wide (e.g. wider than the optical device), misalignment can still not cause a significant amount of light to be lost. In this manner, some misalignment can be accommodated while still providing a functioning connector. 
     The capacitance of photodiode  580  can increase as the active area of photodiode  580  gets bigger. A photodiode with an active area the same size as receiving lens  545  would have a large capacitance. A high capacitance causes problems at high data rates. Thus, for high data rates, such a large photodiode would be problematic. In one embodiment, photodiode  580  has a capacitance of 0.6 pf or less. 
     Accordingly, collector  547  can allow the use of a smaller photodiode, so that higher data rates can be achieved, while still allowing relatively large alignment tolerances. In one embodiment, the alignment tolerance can be 150 microns. For example, a 150 micron change in alignments off-axis will not result in diminished operation for the transmission of the optical signals. 
     Along with providing larger tolerances for alignment, collector  547  can accommodate cables with larger fibers. For example, a fiber in the connecting cable can have a relatively large diameter (e.g., about 200 to 500 microns), as opposed to smaller standards (e.g. 50-80 microns). This larger diameter can be less susceptible to scratches and debris (such as dust, hair, or lint). Collector  547  can be designed specifically for a particular sized fiber. The shape of collector  547  can be dependent on the size (e.g. width and shape) of the large opening, the size of the small opening (which may correspond to the size of photodiode  580 ), and the wavelength of the light being used. 
     To provide fine alignment of the optical interface, receiving lens  545  and/or transmission lens  545  can include an aligning element  548 . Aligning element  548  can be angled so that front edges of the fiber (or lens over the fiber) of the corresponding connector are moved toward the center of receiving lens  545 . Other alignment features, such as the shape of the plug (see  FIG. 2 ), can help to provide initial alignment to get the front of the fiber (e.g. passive optical component  264 ) close to receiving lens  545 . Thus, aligning element  548  can provide lateral alignment of the optical interface. 
     To ensure that the corresponding fiber or other optical element makes contact with aligning elements  548 , the corresponding connector (e.g. male plug connector  260 ) can have a spring (e.g. a coil spring) that pushes the optical element forward to make contact with aligning element  548 . The lens device may have angled aligning elements that engage aligning element  548 . A combination of the spring and the aligning element  658  can control the gap between the fiber and receiving lens  545  to be within a tolerance. 
     In one embodiment, receiving lens  545  can have a rounded shape to provide some focusing of the light from the fiber toward the lens so that the light does not escape. In another embodiment, receiving lens  545  and collector  547  may be a single piece (e.g. an integral piece of glass). In yet another embodiment, receiving lens  545  may be a separate piece from collector  547 . For example, receiving lens  545  could be made of sapphire, glass, clear ceramics, or harder material to prevent scratching, where as collector  547  could be made of plastic. In another aspect, a coating could be applied to receiving lens  545 . Receiving lens  545  can be close to the end of the connector to allow for easy replacement. 
       FIG. 6A  is a perspective view of a female connector  600  capable of communicating electrical and optical signals according to embodiments of the present invention.  FIG. 6B  is a front view of the female connector  600  capable of communicating electrical and optical signals according to embodiments of the present invention. Female connector  600  may be a finished connector that can be put into an electronic device, docking station, or other device. 
     In one embodiment, female connector  600  has an insulator core  610 . Insulator core  610  may be created by applying an overmold to a lead frame assembly (e.g. as shown in  FIG. 3  without carrier  310 ). For example, a plastic housing could be molded over pins  617 , a substrate with active optical components, and pins that connect with the substrate. Insulator core  610  can cover the electronics (e.g. electrical components  455  and  458 ) on the front of the substrate, and cover part of lenses  640  while still leaving the front of lenses  640  exposed. 
     Pins  617  and pins that service the active optical components of the substrate may be exposed in the back female connector  600 , prior to incorporation into a device. A shell  650  can be placed around insulator core  610 , or at least a front part of insulator core  610 . Shell  650  can be made of metal in order to shield pins  617  from electromagnetic interference. In one embodiment, a front edge of female connector  600  can be the front edge of insulator core  610 , which may coincide with a front edge of shell  650 . 
     In one embodiment, lenses  640  could be added in after insulator core  610  is over molded. For example, insulator core  640  could be drilled to form holes where lenses  640  are to be placed. In one aspect, the substrate would already have the holes in the proper place, and thus just the overmold may need to be drilled. In another embodiment, insulator core  610  could be formed with a space for the lenses to be fit. As lenses  640  can have their front surface at a front of the connector, lenses  640  can be cleaned easily to ensure continued operation. 
     Female connector  600  can have alignment features of an opening  605  for an insert portion of a male plug connector (e.g. insert portion  274 ). Fine alignment of the optical interface can be provided by aligning elements of lenses  640  (e.g. aligning element  548 ). Thus, alignment features of female connector  600  can be sufficient to provide proper alignment of the optical interface. In some embodiments, the height and width of shell  650  is consistent with connectors that are purely electrical. 
     III. Manufacturing of Female Hybrid Connector 
       FIG. 7  is a flowchart of a method  700  for making a female connector according to embodiments of the present invention. Method  700  can be used to create various intermediate assemblies and connectors as shown in  FIGS. 3-6 . 
     In block  710 , a lead frame having pins is formed. Lead frame can be made from a single piece of conductive material. For example, a strip of conductive material can be stamped into a shape that has a carrier piece (e.g. carrier  310 ) and a plurality of pins (e.g. pins  315  and  317 ). The plurality of pins can include a first electrical set (e.g.,  315 ) and a second optical set (e.g.  317 ) of pins. The different sets may be designated for different types of electrical signals (e.g. one set may be for electrical signals that are communicated via an optical interface). The pins may be of varying length and shape. 
     The plurality of pins can extend from the carrier piece in the same plane as the carrier piece. In one aspect, there may be gaps between certain pins. For example, the gaps may be the same as the gaps between pins  417   a  or  417   b  and pins  417   c . In one embodiment, one or more of the optical pins may have a plate at the end of them, e.g. ground plate  460 . The ground plate can be created at the same time that pins  417  are stamped. 
     In block  720 , the pins are bent. In one aspect, the pins are bent to allow connection to a circuit board once they are cut from the carrier piece, and to allow additional steps to be performed. The different sets of pins can be bent into different shapes. For example, the electric pins can be longer and be bent down at the front tips, whereas the optical pins can be bent up for later attachment to a substrate (e.g. substrate  430 ). Also, the different pins within a set can bent differently. For example, pins for carrying ground can be bent differently than the pins for carrying data signals. 
     In block  730 , a substrate (e.g. substrate  430 ) is attached to the optical set of pins. The substrate can have at least one active optical component for receiving and/or transmitting optical signals to a corresponding connector. At least a portion of the optical set of pins are communicably coupled with the at least one active optical component and are configured to carry electrical signals corresponding to the optical signals. 
     In one embodiment, the substrate has been previously machined to have pockets on the front and back for accommodating active optical components and for accommodating a transmission lens and a receiving lens apparatus, which can include a light collector. Holes may be formed between corresponding pairs of pockets on the front and back end for light to pass through. 
     In block  740 , an insulator core (e.g. insulator core  610 ) is molded onto the pins. In one aspect, the insulator core can be molded over only a portion of each pin (e.g. a front portion). The insulator core can also be molded over the substrate. In one embodiment, the insulator core covers the electrical pins up to and potentially past their front tips. The electrical set of pins can extend past the optical set of pins toward a front of the connector for mating with electrical contacts of the corresponding connector. 
     In block  750 , lenses may be inserted into the insulator core. In one embodiment, the insulator core can be drilled to form holes for the lenses. The holes may be drilled where pockets have already been formed into the substrate. In another embodiment, the insulator core can be molded with the holes already in place. In yet another embodiment, the lenses may be attached to the substrate before the insulator core is molded. 
     In block  760 , a back end of the pins are cut. The back end of the pins can then later be electrically connected (e.g. soldered) to a circuit board. 
     In block  770 , a shell is placed around the insulator core. The shell (e.g. shell  650 ) can be placed around all of the insulator core or only part of it (e.g. a front portion). The shell may provide shielding from electromagnetic interference, and it also may act as alignment feature for a male plug that is inserted into an opening in the female connector. 
     IV. Adapter Using Collector 
       FIG. 8  shows an adapter  800  for converting optical data signals from a large width fiber to a smaller width fiber according to an embodiment of the present invention. As mentioned above, connectors consistent with embodiments of the present invention can receive optical signals from optical cables that have relatively large optical fibers. However, it may be desirable to provide a connection to an interface that uses a fiber with a relatively small width. In one aspect, collector  810  (e.g. collector  547 ) can provide such conversion in adapter  800 . As used herein, an optical data signal carries bits of data in pulses of light. 
     Optical cable  850  can have a first connector (not explicitly shown) that connects with an electronic device  810  having an optical or electro-optical connector  820 , e.g. a connector interface described in  FIGS. 1-6 . For example, the first connector can be the male plug connector  260  of  FIG. 2 . Optical cable  850  can carry optical signals using an optical fiber  855  (which may include a multi-core fiber) that has a relatively large diameter. In one embodiment, optical cable  850  can correspond to cable  150  of  FIG. 1 . 
     In one embodiment, if the electronic device (e.g. device  110 ) needs to connect to another electronic device  880  that has an interface that uses a smaller fiber, adapter  850  can provide the conversion of the optical signals from a large diameter fiber to a small diameter fiber. Adapter  800  can have one end that receives optical data signals with a first fiber  858  having the large width. Collector  810  (e.g. a parabolic concentrator) can collect the light at the large width and provide the light to a small width fiber  820 . In another embodiment, collector  810  may receive the light directly from fiber  855 , and thus adapter  800  would not have fiber  858 . 
     Adapter  800  can then provide optical signals using small fiber  820  to a connector  830  of a receiving device  880 . As connector  830  requires a smaller fiber at its interface, adapter  800  is used. Typically, connector  830  will have a smaller tolerance for alignment than other connectors mentioned herein. 
     In another embodiment, cable  850  can include adapter  800  that reduces the width of the connector down to the smaller fiber. In this embodiment, cable  850  would include collector  810  coupled with fiber  855 , thereby making cable  850  into an adapter. Cable  850  can also include smaller-width fiber  820 , which can then be connected with connector  830 . If such an optical cable  850  is only to convey optical signals to connectors of the type of connector  830  (or other optical only connectors), then optical cable  850  may not have electrical contacts or electrical wires. 
     In yet another embodiment, adapter  800  (or cable  850  constructed as an adapter) can have two collectors in opposite directions. Once collector could be used for transmission to another electronic device  880  and the other collector could be used for transmission from another electronic device  880 . 
     V. Docking Station with Optical Element 
       FIG. 9A  illustrates a system with a docking station  960  having at least one active optical component and an electronic device  952  having at least one active optical component according to embodiments of the present invention.  FIG. 9B  is a cross-sectional side view of electronic device  952  and docking station  960  according to embodiments of the present invention. In one embodiment, electronic device  952  and docking station  960  have connectors that include a collector, which allows a high tolerance for misalignment. Thus, only a coarse alignment features are used, which can provide optical communication with no structural connection. In one aspect, such a connection does not use electrical contacts. 
     Docking station  950  can allow an electronic device  952  or other electronic device to communicate with other media devices (not shown). As shown, docking station  950  includes a housing  954  that encloses internally various electrical and structural components and that defines the shape or form of docking station  950 . The shape of housing  954  may be widely varied. For example, it may be rectangular, circular, triangular, cubical, and the like. In the illustrated embodiment, housing  954  has a rectangular shape. Housing  954  may be formed by one or more housing components. For example, as shown, housing  954  may be made up of a top member  956  and a base member  958 . The manner in which members  956  and  958  are connected may be widely varied (e.g., screws, bolts, snaps, latch, etc.). 
     Within a top surface  960  of housing  954 , there is provided a media bay opening  962  for physically receiving a bottom portion  964  of the electronic device  952 . As shown, the media bay opening  962  has shape that coincides with the shape of electronic device  952 , i.e., bottom portion  964  of electronic device  952  may be inserted within media bay opening  962 . The depth of opening  962  can generally configured to keep the user interface of the electronic device  952  exposed to the user. Opening  962  may be vertical or sloped. As shown in  FIG. 9B , opening  962  is sloped so that electronic device  952  rests in a tilted position within the docking station  950 . As should be appreciated, a tilted electronic device  952  is easier to use (e.g., more ergonomic). The slope may be widely varied. For example, it may tilt electronic device  952  about 5 to about 25 degrees and more particularly about 15 degrees. 
     Beneath a bottom surface of opening  962 , there is provided a first optical connector  966  for engaging a corresponding optical connector disposed on the bottom surface of electronic device  952 . By way of example, first optical connector  966  may include lenses and a collector  968  as described in  FIGS. 4 ,  5 A, and  5 B. However, in one embodiment, there are no electrical contacts. 
     One or more active optical component s  969  can optically coupled with a small opening of the collector, e.g., a photodiode can receive light at the small opening of collector  968 . The electrical signals from the photodiode can be modified or sent directly to a circuit board  970 . As should be appreciated, the sides of the opening  962  can serve as alignment elements for placing the connectors in the correct position. As the alignment is not too sensitive, other general alignment features besides the sides of the bay opening can also serve as the alignment features. 
     The corresponding optical connector of electronic device  952  can have a transmitting lens that has a similar dimension as the large opening of collector  968  of first optical connector  966 . Thus, as both connectors have similar and relatively large dimension, the alignment between the connectors is not as critical. The connectors do not have to be perfectly aligned in order to still communicate optical signals. Thus, a structural connection, as provided with an insert portion described for  FIG. 2  is not needed. Note that as the active optical components in both connectors can be kept small, high data rates can be achieved. 
     Accordingly, the bottom surface of opening  962  can be flat. Also, the bottom surface of opening  962  can be made of material that is opaque to visible light, but which transmits light in the wavelength (which is not in the visible spectrum) that is used to communicate the optical signals between electronic device  952  and docking station  950 . Thus, docking station  950  can communicate data without a need for a physical connection to electronic device  952 . In fact, docking station  950  may appear as if there is no connector at all. 
     In one embodiment, docking station  960  can also include inductive charging mechanism. For example, a vertical wall can extend from surface  960  to engage a back of electronic device  952 . The vertical wall can have inductive coils that can charge electronic device  952 , which also has inductive coils. 
     V. Male Plug with Spring for Optical Elements 
     As mentioned above, embodiments of connectors with optical elements can have a spring that pushes an optical element toward an optical element of the corresponding connector. This movement can provide alignment of the corresponding optical elements and can provide a smaller distance between the optical elements, which can reduce signal loss and interference. One or more of the mating optical elements (e.g. lens or fiber) of the male plug connector and/or the female receptacle connector can have a spring mechanism, as opposed to having a fixed fiber and ferrule as may occur in other embodiments. 
       FIG. 10  is a cross-sectional view of a male connector  1000  having a spring mechanism for an optical element mated with a corresponding female receptacle  1050  connector according to embodiments of the present invention. Male plug connector  1000  can include an enclosure  1020 , a connector housing  1030 , and a fiber  1005  with a sleeve  1007 , which may provide protection and may be reflective. Near the interface with female connector  1050 , fiber  1005  can have a ferrule  1010  surrounding it. In one embodiment, ferrule  1010  is made of metallic material. 
     In various embodiments, ferrule  1010  can provide strength to fiber  1005  and can provide alignment. In one embodiment, ferrule  1010  has an aligning element  1012  (e.g. a chamfer) that helps to provide alignment. In another embodiment, a spring  1017  pushes ferrule  1010 , along with fiber  1005 , forward toward the female connector  1050 . The forward force can cause ferrule  1010  to engage aligning elements  1062  (e.g. aligning elements  548  from  FIG. 5 ) of female connector  1050 . The aligning elements  1062  (e.g. a chamfer) can cause fiber  1005  to move up or down to being fiber  1005  more in alignment with lens  1060  (or other optical element). 
     The ferrule and fiber combination of male connector  1000  can have a freedom of movement at least in an up and down direction (as shown). For example a space can exist between ferrule  1010  and housing  1030 . This freedom of movement along with a force from the engagement of the aligning elements can provide the relative movement of fiber  1005  and lens  1060  to bring them into alignment. 
     As one can see, fiber  1010  can be aligned with a center of lens  1060 . Fiber  1010  can also be aligned with collector  1065  and active optical component  1075 . With better alignment, more light from fiber  1005  can reach the active optical component  1075 , thereby providing a stronger signal. In one embodiment, the aligning elements  1012 / 1062  can ensures fiber X/Y alignment to ±0.07 mm, where X/Y is vertical and in/out of the paper, as shown. 
     In some embodiments, a surface of lens  1060  is only slightly below an enclosure surface  1070 . Having distance  1080  between these two surface be small (e.g. 15 mm) can help to prevent debris from being trapped and can allow for cleaning of lens  1060 . Distance  1080  being small can also help provide a small gap between the optical elements of the two connectors. 
     In other embodiments, aligning elements  1012 / 1062  can maintain a gap between lens (e.g. a transmission or a receiving lens) and fiber  1005  to prevent or reduce abrasion. The width of the distance between the upper and lower aligning elements  1062  can be smaller than a width of ferrule  1010  to provide gap  1080 . Spring  1017  can keep ferrule  1010  seated against aligning elements  1062 , which can keep end gap to a maximum of 0.15 mm. In one embodiment to reduce abrasions, lens  1060  may be made of a hard material, such as hardened glass (e.g. aluminosilicate glass), sapphire, clear ceramics, spinel (e.g., Magnesium Aluminum Oxide), and aluminum oxynitride (e.g. ALON™), which can be transparent in the wavelength of the transmitted light. With a durable lens, it may be acceptable, and even desirable, to have the two optical elements to actually touch, thereby providing better transmission of light from one connector to another. The lens can cause a reduction in total light transmitted under perfect conditions, but the lens can provide durability (e.g. less scratches) so that the total light that can be transmitted does not severely diminish over time, e.g. due to scratches. 
     VI. Proud Lens on Female Connector 
     In some embodiments, it may be desirable to have optical elements of the female connector protrude to engage optical elements of the female connector. Such a protruding construction can provide for cheaper manufacturing, and allow the optical elements on the male connector to be flush or recessed with an enclosure surface. Having a front edge of an optical element of the male plug connector being flush or recessed can provide for a more durable male plug connector. As the make plug connector may be used for many devices, often shove in a drawer or other space with other objects, and other such hard use, it may be desirable for the optical element of the male plug connector to not protrude as in  FIG. 10 . Such a protruding construction for the female connector can also provide contact between two surfaces of optical elements of the connectors, which can provide better transmission of light. 
       FIG. 11A  is a cross-sectional view of an optical element having a proud surface relative to an external (outer) surface of the connector according to embodiments of the present invention. Connector  1110  is shown having an external surface  1105 . In the embodiment shown, connector  1110  includes a lens  1115 , optically clear adhesive  1120 , collector  1125 , optical fiber  1130 , and an active optical component  1140 . In various other embodiments, optical fiber may be omitted such that collector  1125  transmits light directly to active optical component  1140 ; collector  1125  and lens  1115  may be an integral piece (thus obviating a need for an adhesive); and lens  1115  may be made of a hard material such as sapphire. 
     In one embodiment, the optical clear adhesive can be a liquid. In one embodiment, the adhesive is a pressure sensitive adhesive. In another embodiment, the front surface of collector  1125  can be non-flat (e.g. concave) and the liquid adhesive can flow to fill in the uneven surface of the connector. The corresponding male plug connector can also have a sapphire lens, which can be attached to the fiber with an optically clear adhesive. In another embodiment, air gaps do not occur between the collector  1125  and lens  1115 . 
       FIG. 11B  is a magnified view of the surface of the optical element and the external surface according to embodiments of the present invention. Lens  1115  has a surface that protrudes from (is proud of) outer surface  1105 . In one embodiment, an edge of a surface of lens  1115  is angled, e.g. to provide an aligning element such as a chamfer. The aligning element can be used in a similar manner as described for  FIG. 10 , but with the male plug connector having a recess for receiving the proud surface of lens  1115 . In one embodiment, connector  1110  can also have a spring mechanism to move lens  1115  closer to the surface of the corresponding optical element of the male connector. 
     In one embodiment, lens  1115  and a corresponding optical element (e.g. another lens) of the male plug connector both protrude from respective outer surfaces. In another embodiment, both or just one of the surfaces are flush, as opposed to protruding. The protrusion from a surface can provide easier access to the lens in order to remove dirt. In yet another embodiment, lens  1115  (and other lenses mentioned herein) can be rounded, which can cause debris on the lens may naturally fall to the edges. The lens and collector could be a single integral part, which could be made of sapphire or other suitably hard and optically clear material. As an example, lens  1115  can be about 1.5 mm to 2 mm in diameter, with a thickness of about 0.5 mm. 
     VII. Male Hybrid Connector with Small Insert 
     In some embodiments having connectors with an electrical and optical interface, it can be desirable to have the insert for the electrical interface be small while still providing a sufficient number of contacts. Having the insert be small can reduce the size of the female connector, thereby allowing the electronic device to be smaller or to free up space for additional circuitry in the electronic device. 
     As an example, the male plug connector  260  can be reduced in size. The male plug connector  260  of  FIG. 2A  has an insert  274  that fits around the tongue in which electrical contacts  22  reside. In one embodiment, insert portion  274  can be made smaller by removing the top surface of the insert so that the contacts are exposed on one side. The sidewalls can still provide alignment features so that the insert portion is not inserted incorrectly. With a top surface removed, electrical contacts  222  can be placed on a bottom surface of opening  205  instead of being on a tongue that sticks into the middle of opening  205 . Thus, receptacle connector  220  can be made smaller. 
     However, even with such changes, it may be desirable to have an even smaller insert. The sidewalls of insert portion  274  can also be removed, thereby having the contacts be on an outmost surface of the insert. Such an embodiment could lead to users plugging in the insert with an incorrect orientation, which could be ameliorated with other alignment devices, such as notches and keys. Even with the contacts an outer surface, the insert may still have a large width to accommodate all of the contacts in a row (horizontal as shown). To provide enough contacts while still limiting size, some embodiments can have inserts with contacts on more than one surface and/or have contacts that are dependent on depth of insertion. 
     Regarding one embodiment, contacts can be on a top and bottom surface of the insert. For example, four contacts can be on top and four different contacts can be on the bottom. Thus, eight contacts can be obtained with the same amount of width. In one aspect, the corresponding receptacle would also have mating contacts on a top and bottom interior surface of opening  205 , thereby possible causing receptacle connector  220  to have greater height. But, the overall size including width and height can be made smaller. In this manner, more contacts can be fit into a smaller space. However, such an embodiment may still not provide the desired number of contacts within the desired space. 
     Accordingly, one embodiment has different contacts at different depths. For example, an insert could have a first contact near a front (distal) tip of the insert, and a second contact at the same horizontal location but behind the first contact. The corresponding receptacle connector would have corresponding contacts at different depths within the opening. In this manner, many contacts can be fit onto a small insert. The provisional applications referenced above contain various inserts, which may be used with embodiments of the present invention. 
       FIG. 12A  is a top view of a hybrid male plug connector  1200  with a central connector according to embodiments of the present invention. Connector  1200  has an insert  1210  with two contacts  1215  on a top surface and one or more contacts  1217  on the sides of insert  1210 . Contact  1217  may be a ring that extends from one side over the front of insert  1210  to the other side. In one embodiment, contact  1217  is a ground contact and contacts  1215  can include a power contacts or be contacts for data signals. In one embodiment, insert  1210  is symmetric with regards to the top and bottom. For example, the bottom surface can have two contacts in a same position as contacts  1215 . Other embodiments can have more than two contacts (e.g., 4 or 6) on the top surface and/or the bottom surface. Yet other embodiments can have a contact on a front face of insert  1210 . 
     In the embodiment shown, optical links  1219  are shown on either side of insert  1210 . In one implementation, one optical link is a transmission link and the other is a receiving link. Interior cable  1215  can be an electrical cable for transmitting electrical signals to/from the electrical contacts of insert  1210 . In one embodiment, interior cable  1208  is an optical fiber for communicating optical signals to and/or from an optical link  1219 . 
       FIG. 12B  shows a side view of hybrid male plug connector  1200  according to embodiments of the present invention. A recess  1220  (e.g. a notch) is on a side edge. Recess  1220  can be used to secure connector  1200  into the corresponding receptacle connector using a retention mechanism in the corresponding female connector, e.g., with a cantilevers spring or a detent. The top surface with contacts  1215  can be considered a major surface as it is larger than the edge surfaces. Thus, insert  1210  has five contacts in a relatively small space. 
       FIG. 12C  shows a front view of hybrid male plug connector  1200  according to embodiments of the present invention. In one embodiment, optical elements  1230  of optical links  1219  can provide transmission and/or reception of optical signals. Optical elements  1230  can correspond to lenses, active optical elements, collectors, and fibers as described herein. 
       FIG. 12D  is a perspective view of a hybrid male plug connector  1200  according to embodiments of the present invention. In the embodiment shown, optical signals can be passively sent through an optical fiber  1208 , which is optically coupled with a lens  1232 . Fiber  1208  can be covered with a ferrule  1234 . The optical signals can then be sent from lens  1232  to a corresponding optical element of a female connector. In one embodiment, lens  1232  can be a sapphire lens. In another embodiment, ferrule  1234  can be a fixed fiber ferrule, as can be other ferrules mentioned herein. 
       FIG. 13  shows an exploded view of a passive male plug connector  1300  according to embodiments of the present invention. The male plug  1300  is passive in that internal fiber  1308  transmit optical signal to optical link  1319  for sending to the corresponding female connector. Ferrule  1334  can cover fiber  1308  at the end. Optical elements  1330  can be of various shapes, materials, forms, and functions as described herein. Contacts  1315  can lie on top of a pad  1316 . Internal cables  1305  can carry power, ground, and/or data signals for contacts  1315 , and other contacts. 
       FIG. 14  is a perspective view of a hybrid male plug connector  1400  with an active optical component according to embodiments of the present invention. In one embodiment, plug connector  1400  has a same connector insert  1410  as plug connector  1200 . But, the optical aspects of plug connector  1400  can differ from passive plug connector  1200 . For example, plug connector  1400  can convert electrical signals to optical signals, and vice versa, such that only electrical signals are carried through cable  1470 . For example, a lens  1432  can receive an optical signal, which can be collected by a parabolic concentrator  1455  (or other collector) and sent to an active optical component  1460  for conversion to an electrical signal. 
       FIG. 15  shows an exploded view of an active male plug connector  1500  according to embodiments of the present invention. In the embodiment shown, a circuit board  1590  is coupled with optical modules  1560  and  1565 . Electrical signals from wires (not shown) inside a cable  1570  can be attached to circuit board  1590  and transmitted to optical module  1565  for conversion into optical signals. Optical module  1560  can receive optical signals and convert the optical signals to electrical signals transmitted to the wires via circuit board  1590 . 
     VIII. Female Hybrid Connector for Receiving a Small Insert 
       FIG. 16  is a perspective view of a female hybrid connector  1600  according to embodiments of the present invention. Female connector  1600  has a lens  1623 , collector  1655 , and active optical component  1660  as described herein. An opening  1605  can receive an insert, e.g., insert  1210  of male connector  1200 . Contacts  1622  on the top and bottom surfaces of opening  1605  can provide an electric connection with contacts  1215  of male connector  1200 . Contacts  1627  on the sides of opening  1605  can make an electrical connection with contact  1217  on the edges of insert  1210 . In one embodiment, contacts  1627  engage recesses  1220  in contacts  1217 , thereby providing a retention mechanism and an electrical connection. The contacts  1627  can be part of a cantilever spring or a detent. In another embodiment, recesses  1220  engage a retention mechanism that is separate from contacts  1627 . 
       FIG. 17A  is a front view of a female hybrid connector  1700  according to embodiments of the present invention. An opening  1705  can receive an insert of a corresponding male connector, e.g. connector  1200  or  1400 . Opening  1705  has a top inner surface  1780 , a bottom inner surface  1782 , and two side inner surfaces  1784 . In one embodiment, four contacts  1722  on the top and bottom inner surfaces can receive electrical signal from an insert. In one embodiment, there is one power contact, one identification contact, and two data contacts, which can provide a differential signal. Two contacts  1727  can receive two signals or the same signal from side contacts on an insert. In one embodiment, contacts  1727  both receive ground. 
     In various embodiments, contacts  1722  can receive power, data, or an identification signal, or any combination thereof. The identification signal can be used to determine the type of device that the male plug connector is part of, and thus which type of data signals are to be sent (e.g. audio, video, etc.). The type of signals to be sent can also be determined based on a program that is being run on a processor of the electronic device to which the female connector is part of. Female connector  1700  also has two lenses  1732  for receiving optical signals from the corresponding male connector. 
       FIG. 17B  is a top view of a female hybrid connector  1700  according to embodiments of the present invention.  FIG. 17B  shows different sets of pins  1722   a ,  1772   a , and  1770 . In one embodiment, pins  1722   a  are a tail end of contacts  1722 , and thus contacts  1722  can be considered front ends of pins  1722   a . In another embodiment, pins  1727   a  are a tail end of contacts  1727 , and thus contacts  1727  can be considered front ends of pins  1727   a . Any of the pins may be electrically connected (e.g. soldered) to a circuit board. In one embodiment, pins  1722   a  can provide power and/or data to the circuit board, and pins  1727   a  can provide ground. In another embodiment, pins  1770  can provide power, ground, and other signals to an active optical component, such as  1660 . Pins  1770  can also carry the data signal that was converted from optical to electrical, or vice versa. 
       FIG. 17C  is a side view of a female hybrid connector  1700  according to embodiments of the present invention. As shown, pins  1772  are at an end of the connector  1700  and flatten out for connection to a circuit board. Pins  1722   a  are shown coming from two locations within the connector, at a top and a bottom of the opening  1705 . 
     As an example, suppose data signals are sent over the two contacts  1722  on top inner surface  1780 , or over one contact on top inner surface  1780  and one contact on bottom inner surface  1722 . In one implementation, the signal can be a differential signal. In another implementation, a signal can be sent over just one contact. In one embodiment, various signals can be sent through these data contacts at different times. This multiplexing/demultiplexing can be achieved with a circuit in the connector or on a circuit of an electronic device. The circuit can send certain signals at one point in time and then send other signals at a different point in time. Thus, instead of having certain contacts dedicated to a particular type of signal (e.g. audio or video), one contacts or pair of contacts can transmit any type of signal. 
     In one embodiment, both the male plug connector and the female plug connector can multiplex many signals onto one data path (connection between one or a pair of data contacts). In another embodiment, both the male plug connector and the female plug connector can demultiplex many signals from the one data path to many paths. For example, on the female connector, two contacts  1722  can receive the multiplexed data signals, and a circuit in the connector can separate the incoming signal (e.g. 1 signal demultiplexed to N signals) and provide the demultiplexed signals on pins at the back of the connector. But, this may cause the connector to still be large. Thus, the demultiplexing may occur on the circuit board that pins  1722   a  are connected. The optical signals may also be multiplexed in a similar fashion, for example, either with a circuit on a substrate that the active optical component is part of or by a circuit on the circuit board. 
     The male plug connector can also perform the demultiplexing on signals from the female connector. In one embodiment, the multiplexed N signals can be provided each over N or 2N wires in a cable to which the male plug connector is part of. For example, multiple channels of a display port signal can be sent along a single data path, either electrical or optical. The multiplexing/demultiplexing can be synchronized between the circuits of the connectors. As examples, this synchronization can occur according to a protocol (which dictates a specific timing, including a specific order, of the signals) or according to control signals which specify which data signals are following a control signal. 
     In one embodiment, a subassembly of pins  1770  and  1772  for one active optical component can be manufactured as a single piece. The two pieces for the active optical components can then be assembled together with an overmold. The electrical contacts could then be added into (e.g. pressed into) the overmolded insulator core. In another embodiment, each of the pins  1722 ,  1770 , and  1772  can initially be one lead frame (e.g. attached to a carrier) to control spacing. The housing  1790  (insulator core) can be overmolded over all pins at the same time. 
       FIG. 18  shows an exploded view of a female receptacle connector according to embodiments of the present invention. Contact/pins  1822  are shown on the top and bottom inner surface of opening  1805  of housing  1890 . Contacts/pins  1827  are shown on side inn surfaces of opening  1805 . In one embodiment, contacts  1827  can be part of a retention mechanism, and can provide ground or other signal to pins  1827   a  at a tail end of the contact/pin. In another embodiment, pins  1870  are electrically coupled with the active optical component  1860  and any collector/lens combination  1855 . 
       FIGS. 19A and 19B  shows various views of a female receptacle connector according to embodiments of the present invention. As shown, the pins  1927  lie in a different plane than at least some of the pins  1922  and the pins  1970 . In one embodiment, pins in different planes can be attached to different sides of a same circuit board. 
     Other examples of a connector insert for a hybrid male plug connector can be found in  FIGS. 20A-20D .  FIG. 20A  is a simplified perspective view of a connector insert for hybrid male plug connector  50 , while  FIGS. 20B-20D  are simplified bottom, front and side plan views, respectively, according to one embodiment of the present invention. As mentioned above, any number of contacts can be one a top surface and a bottom surface, and these embodiments show six on top and six on the bottom. 
     As shown, connector  50  includes a tab  52  that extends from an outer shell  54  that can be made from a dielectric material such as a thermoplastic polymer and formed in an injection molding process. Tab  52  has a front major surface  56   a  upon which six contacts  58   (1)  and  58   (6)  are positioned and a back major surface  56   b  upon which an additional six contacts  58   (7)  and  58   (12)  are located. In one embodiment, spacing is consistent between each of the contacts on the front and back sides and between the contacts and the edges of the connector providing 180 degree symmetry so that plug connector  50  can be inserted into a corresponding receptacle connector in either of two orientations as discussed below. 
     In one aspect, a significant portion of tab  52  can be part of a ground ring  55  that extends from a distal tip of the connector towards the outer shell and partially surrounds contacts  58   (1) - 58   (12)  along an outer periphery of tab  52 . Ground ring  55  can be made from any appropriate metal or other conductive material and in one embodiment is stainless steel plated with copper and nickel. Two indentations or pockets  60   a  and  60   b  can be formed in ground ring  55  and located on opposing sides  56   c  and  56   d  of the tab near its distal end. In operation, tab  52  can be inserted into a receptacle connector until pockets  60   a  and  60   b  operatively engage with a retention mechanism, such as a cantilevered spring or detent. The retention mechanism fits within pockets  108  and provides a retention force that secures connector  50  to the matching receptacle connector. In order for the connectors to be separated, a force greater than the retention force can be supplied in a direction that pulls the mated connectors away from each other. In other embodiments, other retention mechanisms can be used such as mechanical or magnetic latches or orthogonal insertion mechanisms. 
     As shown in  FIGS. 20A-20D , contacts  58   (1) - 58   (12)  are external contacts that are positioned along an outer surface of tab  52  and connector  50  does not include an exposed cavity in which particles and debris may collect. To improve robustness and reliability, connector  50  can be fully sealed and includes no moving parts. Furthermore, connector  50  has a considerably reduced insertion depth and insertion width as compared to commonly available TRS and TRRS connectors described above. In one particular embodiment, tab  52  of connector  50  has a width, X, of 4.0 mm; a thickness, Y, of 1.5 mm; and a insertion depth, Z, of 5.0 mm. It is understood that the dimensions of connector  50  as well as the number of contacts may vary in different embodiments. 
     When connector  50  is properly engaged with a receptacle connector, each of contacts  58   (1) - 58   (12)  is in electrical contact with a corresponding contact in the receptacle connector. In one embodiment, tab  52  has a 180 degree symmetrical, double orientation design which enables the connector to be inserted into a connector jack in both a first orientation where surface  56   a  is facing up or a second orientation where surface  56   b  is facing up. Thus, connector  50  can be said to be orientation agnostic. In one embodiment, the contact order on the bottom side of the connector, from left to right, can be as follows: the first two contacts are designated for a pair of differential data signals, the third contact is designated for a power contact, the fourth contact is designated for an audio contact and the fifth and sixth contacts are designated for another pair of differential data signals. Similarly, the contact order on the bottom side of the connector, from left to right, can be as follows: the first two contacts are designated for a pair of differential data signals, the third contact is designated for an audio contact, the fourth contact is designated for a power contact and the fifth and sixth contacts are designated for another pair of differential data signals. 
     The specific details of particular embodiments may be combined in any suitable manner or varied from those shown and described herein without departing from the spirit and scope of embodiments of the invention. 
     The above description of exemplary 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.

Metadata:
Filing Date: 20121129
Publication Date: 20150310
Grant Date: 20150310
Priority Date: 20100601
Inventors: SLOEY JASON S.
GOLKO ALBERT J.
JOL ERIC S.
SPRAGGS IAN
Assignee: APPLE INC
CPC Classifications: [{"code": "H10F77/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/262", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4292", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L31/0232", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4246", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/3817", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4204", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/389", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/262", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/38", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/4246", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/3817", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4204", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/4292", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4246", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/3817", "inventive": true, "first": true, "tree": "[]"}, {"code": "G02B6/389", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B6/4292", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 44279865