PATENT DOCUMENT

Publication Number: US-9935388-B2
Application Number: US-201514617957-A
Country: US
Kind Code: B2

Title: Contact-support mechanism for increased retention force

Abstract:
Circuits, methods, and apparatus that may provide audio jacks capable of providing a sufficient retention force to avoid some inadvertent extractions of an audio plug. Examples may also provide audio jacks that may be readily assembled. Other examples may provide other types of connectors. These audio jacks or other connectors may provide contact structures having one or more contacts, each having a contact support to increase contact retention force. Different materials may be used to form the contacts and the contact supports. In this way, contacts may be formed using a highly conductive material, while the contact supports may be formed of a material having good spring characteristics. While such a contact may not be able to provide an adequate retention force on its own, the use of a contact support may sufficiently increase the retention force to prevent accidental extractions of an audio plug or other connector.

Claims:
What is claimed is: 
     
       1. A first connector comprising:
 a first contact having a first contact portion to mate with a corresponding contact of a second connector when the second connector is mated with the first connector, and a second contact portion to be attached to a circuit board; and 
 a first contact support located such that at least a portion of the first contact is in physical contact with the first contact support and between the first contact support and the corresponding contact in the second connector, 
 wherein the first contact and the first contact support are made of different materials, 
 wherein the first contact has a first side including a surface of the first contact portion to mate with a corresponding contact of a second connector, and a first length extending from the first contact portion to the second contact portion, and 
 wherein the first contact support extends along a second side of the first contact for a majority of the first length, the second side opposite the first side. 
 
     
     
       2. The first connector of  claim 1  wherein the first contact is formed using titanium copper. 
     
     
       3. The first connector of  claim 2  wherein the first contact support is formed using stainless steel. 
     
     
       4. The first connector of  claim 1  wherein the first contact support is formed using a compressible material. 
     
     
       5. The first connector of  claim 4  wherein the compressible material is foam. 
     
     
       6. The first connector of  claim 4  wherein the compressible material is rubber. 
     
     
       7. The first connector of  claim 1  wherein the second contact portion of the first contact is a though-hole contact portion. 
     
     
       8. The first connector of  claim 1  wherein the first contact provides a retention force against the corresponding contact of the second connector when the second connector is mated with the first connector and the retention force is increased by the first contact support. 
     
     
       9. The first connector of  claim 1  wherein the first contact and the first contact support are formed separately. 
     
     
       10. The first connector of  claim 1  wherein the first contact comprises the first contact portion to mate with a corresponding contact of a second connector, the second contact portion to be attached to a circuit board, and a first tab inserted in a housing of the first connector, wherein the second contact portion is to be attached directly to the circuit board, and
 wherein the first contact support comprises a second tab inserted in a housing of the first connector. 
 
     
     
       11. The first connector of  claim 1  wherein the first contact comprises the first contact portion to mate with a corresponding contact of a second connector, the second contact portion to be attached to a circuit board, a tab inserted in a housing of the first connector, and a third contact portion and a fourth contact portion to contact a switch contact, wherein the second contact portion is to be attached directly to the circuit board. 
     
     
       12. A first connector comprising:
 a first contact having a first contact portion to form an electrical connection with a corresponding contact of a second connector when the second connector is mated with the first connector; and 
 a first contact support formed separately from the first contact and located such that at least a portion of the first contact is in physical contact with the first contact support, where the first contact provides a force against the corresponding contact of the second connector when the second connector is mated with the first connector and the force is increased by the first contact support, 
 wherein the first contact has a first side including a surface of the first contact portion to mate with a corresponding contact of a second connector, a second contact portion to be directly attached to a printed circuit board, and a first length extending from the first contact portion to the second contact portion, and 
 wherein the first contact support extends along a second side of the first contact for a majority of the first length, the second side opposite the first side. 
 
     
     
       13. The first connector of  claim 12  wherein the first contact provides a retention force against the corresponding contact of a second connector when the second connector is mated with the first connector. 
     
     
       14. The first connector of  claim 12  wherein the first contact further comprises a second contact portion, where the second contact portion is a though-hole contact portion. 
     
     
       15. The first connector of  claim 12  wherein the first contact and the first contact support are made of different materials. 
     
     
       16. The first connector of  claim 15  wherein the first contact is formed using titanium copper. 
     
     
       17. The first connector of  claim 16  wherein the first contact support is formed using stainless steel. 
     
     
       18. The first connector of  claim 12  wherein the first contact support is formed using a compressible material. 
     
     
       19. The first connector of  claim 18  wherein the compressible material is foam. 
     
     
       20. The first connector of  claim 12  wherein the first contact comprises the first contact portion to mate with a corresponding contact of a second connector, the second contact portion to be directly attached to a circuit board, and a first tab inserted in a housing of the first connector, wherein the first contact support further comprises a second tab inserted into the housing of the first connector. 
     
     
       21. A first connector comprising:
 a first contact having a first contact portion to form an electrical connection with a second contact of a second connector when the second connector is mated with the first connector; 
 a first contact support formed separately from the first contact and located such that at least a portion of the first contact is in physical contact with the first contact support; 
 a third contact having a first contact portion to form an electrical connection with the second contact of the second connector when the second connector is mated with the first connector; and 
 a second contact support located such that at least a portion of the third contact is in physical contact with the second contact support, 
 wherein the first contact comprises the first contact portion to mate with a corresponding contact of a second connector, a second contact portion to be directly attached to a circuit board, and a first tab inserted in a housing of the first connector. 
 
     
     
       22. The first connector of  claim 21  wherein the first contact provides a first force against the second contact of the second connector when the second connector is mated with the first connector and the first force is increased by the first contact support, and
 the third contact provides a second force against the second contact of the second connector when the second connector is mated with the first connector and the second force is increased by the second contact support. 
 
     
     
       23. The first connector of  claim 22  wherein the first contact and the first contact support are made of different materials. 
     
     
       24. The first connector of  claim 21  wherein the third contact and the second contact support are formed separately. 
     
     
       25. The first connector of  claim 21  wherein the first contact has a first side including a surface of the first contact portion to mate with a corresponding contact of a second connector, the second contact portion to be directly attached to a printed circuit board, and a first length extending from the first contact portion to the second contact portion,
 wherein the first contact support extends along a second side of the first contact for a majority of the first length, the second side opposite the first side, and wherein the first contact support comprises a tab inserted in a housing of the first connector.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 13/913,277, filed Jun. 7, 2013, which is a non-provisional of U.S. provisional patent application No. 61/799,119, filed Mar. 15, 2013, which are incorporated by reference. 
    
    
     BACKGROUND 
     Portable electronic devices, such as portable media players, tablet, netbook, and laptop computers, cell, media, and smart phones, have become ubiquitous in recent years. These devices often include an audio jack through which they receive and provide audio information. The audio jacks may include, or be connected to, electronic circuits such as audio drivers for driving headphones or speakers, audio receivers for receiving audio signals from a microphone, and other circuits. These audio jacks may be arranged to receive an audio plug that may be connected to headphones, speakers, microphones, or other equipment. 
     These audio plugs may be electrical audio plugs. Audio jacks may include a number of ring-shaped contacts along their lengths. These contacts may connect to conductors in a cable attached to the audio plug. These contacts may include contacts for left audio, right audio, ground, and microphone. These audio plugs may also be optical audio plugs, that is, they may have an opening at an end to transmit or receive optical signals. In such a situation, the audio plug may be formed of plastic or other nonconductive material. 
     When an audio plug is inserted into an audio jack, it may be desirable that the audio plug remain in a fixed position. Since the audio plug may be connected to headphones or ear buds through a cord, forces may be exerted on the plug in a direction that could inadvertently remove the audio plug from the audio jack. 
     Also, some electronic devices employing audio jacks may achieve great commercial success. As such, millions of these audio jacks may need to be manufactured. Due to the magnitude of this task, any simplification in the assembly process is multiplied the millions of times the audio jacks are assembled. Accordingly, it may be desirable to provide an audio jack that is readily manufactured. 
     Thus, what is needed are circuits, methods, and apparatus that may provide audio jacks capable of providing a sufficient retention force to avoid at least some inadvertent extractions of an audio plug. It may also be desirable that these audio jacks be readily assembled. 
     SUMMARY 
     Accordingly, embodiments of the present invention provide circuits, methods, and apparatus that may provide audio jacks capable of providing a sufficient retention force to avoid at least some inadvertent extractions of an audio plug. Some of these embodiments may also provide audio jacks that may be readily assembled. While embodiments of the present invention are well-suited to audio jacks, other types of connectors may be realized consistent with embodiments of the present invention. 
     An illustrative embodiment of the present invention may provide contact structures having one or more contacts, each having a contact support mechanism to increase contact retention force. In various embodiments of the present invention, different materials may be used to form the contacts than what is used to form the contact support mechanisms. In this way, contacts may be formed using a highly conductive material, while the support mechanism may be formed of a material having good spring characteristics. While a contact formed of a highly conductive material may not be able to provide an adequate retention force on its own, the use of a contact support mechanism having good spring characteristics may sufficiently increase the retention force to prevent accidental extractions of an audio plug or other connector. 
     Again, the contacts may be formed of a material having a low series resistance or impedance. For example, the contacts may be formed using titanium copper, copper, bronze, phosphor bronze or other bronze alloy, or other material. This material may be highly conductive to reduce contact resistance and reduce signal loss through the contact. 
     The contact supports may be formed using a material having good spring characteristics. For example, the contact supports may be formed using stainless steel, such as stainless steel 301, beryllium copper, spring steel, or other such material. The contact supports may be alternatively formed using a compressible material. For example, the compressible material may be rubber, foam, or other such material. These materials may increase the retention force generated by a contact and corresponding contact support such that accidental extractions of a connector plug or other contact are reduced. Also, while one contact support mechanism may be used for each contact, in other embodiments of the present invention, more than one contact support mechanism may be used to increase the retention force of a contact. In still other embodiments, one contact support may be used for more than one contact. The contacts and contact supports may be formed using stamping, machining, metal-injection molding, 3-D printing, or other manufacturing process. 
     An illustrative embedment of the present invention may provide a method whereby audio jacks may readily be assembled. In a specific embodiment of the present invention, a first retention contact may be inserted in an audio jack housing. A first contact support may be inserted behind the first retention contact such that the first retention contact is between the first contact support and a passage in the housing for an audio plug. A plug may be inserted into the passage in the housing. The plug may contact the first retention contact at a first contact portion. 
     The first retention contact may deflect due to this contact. A switch contact may then be inserted. Since the first retention contact is deflected at this point, the switch contact may be readily inserted. The plug may then be withdrawn, and the first retention contact may move towards it original position. A first contact portion of the switch may contact a second contact portion of the first retention contact as the retention contact returns to its original position. 
     In this and various embodiments of the present invention, more than one retention contact and corresponding contact support and switch contacts may be included and inserted into the housing. For example, two retention contacts may be included. These retention contacts may be used as audio contacts, such as left audio contacts. Additional contacts for audio, microphone, and ground (or grounds) may be included and inserted into the housing either before or after the retention contacts and corresponding contact supports and switch contacts are inserted. An optical light-emitting diode module may be included at a rear of the housing passage. 
     While embodiments of the present invention are well-suited to audio jacks having right and left audio, ground, and microphone contacts, embodiments of the present invention may be employed in other types of audio jacks and other types of connectors. For example, embodiments of the present invention may provide audio jacks having right and left audio contacts and one or more ground contacts. In other embodiments of the present invention, one or more contacts may be used for other digital or audio signals, or the one or more contacts may be used for more than one type of signal depending on a configuration of circuitry associated with the audio jack. 
     Still other embodiments of the present invention may be used in other types of connectors. An embodiment of the present invention may provide a first connector having a contact structure. The contact structure may include a first contact having a first contact portion to deflect when the first contact is mated with a corresponding contact in a second connector. The first contact may provide a retention force at the first contact portion, where the retention force maintains a position of the second connector when the second connector is mated with the first connector. The contact structure may include a first contact support located such that at least a portion of the first contact is between the first contact support and the corresponding contact in the second connector. The first contact support may increase the retention force provided at the first contact portion of the first contact. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an audio jack consistent with an embodiment of the present invention; 
         FIG. 2  illustrates a rearview of an audio jack consistent with an embodiment of the present invention; 
         FIG. 3  illustrates an underside view of an audio jack consistent with an embodiment of the present invention; 
         FIG. 4  illustrates a top view of a portion of an audio jack according to an embodiment of the present invention; 
         FIG. 5  illustrates components of an audio jack connector according to an embodiment of the present invention; 
         FIG. 6  illustrates a close-up view of contacts and contact supports according to an embodiment of the present invention; and 
         FIGS. 7-10  illustrate a method of assembling an audio jack according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates an audio jack consistent with an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     Audio jack  100  may include housing  130  covered by shell or shield  140 . Housing  130  may include passage  120  forming an opening  110 . Opening  110  in passage  120  may accept an audio plug (not shown.) Shell  140  may include one or more fingers  142 . Fingers  142  may form electrical connections with a device enclosure or other structure. Shell  140  may further include tabs  144 . Tabs  144  may be inserted into openings in a main-logic board or other appropriate substrate. Tabs  144  may further be soldered to form a connection to a ground plane or trace on the board. 
       FIG. 2  illustrates a rearview of an audio jack consistent with an embodiment of the present invention. Audio jack  100  may include shell  140 , which may include fingers  142  and tabs  144 . Shell  140  may further include a back side  146 . 
       FIG. 3  illustrates an underside view of an audio jack consistent with an embodiment of the present invention. Again, audio jack  100  may include housing  130 , which may be at least partially covered by shell or shield  140 . Housing  130  may include passage  120  forming opening  110 . In this particular example, 11 pins may be brought out for connection to traces or planes on a main logic board. These pins may have the following functionality. Pins  1  and  8  may be insertion-detect pins, pins  2  and  7  may be audio and insert detect pins, pin  3  may be an audio pin, pins  4  and  6  may be ground, pin  5  may be a microphone pin, while pins  9 - 11  may be pins for an optical module, though in other embodiments of the present invention, other pins may be used and they may have different designations. 
     Again, an audio plug may be inserted into opening  110  in housing  130  of audio jack  100 . This plug may be connected through a cable to ear buds, headphones, or other electronic structure. In such a configuration, a force may be applied to the audio plug through the cable. This force may, on occasion, inadvertently cause an extraction of the audio plug. Accordingly, embodiments the present invention provide retention contacts inside audio jack  100  that may be adequate to avoid at least some of these inadvertent extractions. 
     Again, embodiments of the present invention may provide a contact structure having a retention contact and a contact support. The contacts may be arranged to provide a good electronic connection, while the contact support may be arranged to reinforce the contact such that it provides an adequate retention force. An example illustrating various contacts in a specific embodiment of the present invention is shown in the following figure. 
       FIG. 4  illustrates a top view of a portion of an audio jack according to an embodiment of the present invention. In this example, a top cover and shell of the audio jack has been removed thereby exposing the inner contacts. 
     In this example, retention contacts  450  and  480  are provided. Contact support structures  460  and  485  may be located behind the retention contacts  450  and  480 , such that retention contacts  450  and  485  are at least partially between contact support  460  and  465  and passage  120 . 
     Again, by separating the functions of electrical connection and providing retention force, the materials used for contacts  450  and  480  and contact supports  460  and  485  may be chosen independently. Again, the material chosen for contacts  450  and  480  may be highly conductive in order to reduce impedance through the contacts. However highly conductive materials are often too soft and pliable to provide much retention force. Further, they may permanently set in a deflected position after several insertions of an audio plug. Accordingly, contact supports  460  and  485  may be formed using a material with good spring characteristics. 
     In various embodiments of the present invention, contacts  450  and  480  may be formed using titanium copper, bronze, and other materials. In these and other embodiments of the present invention, support contacts  460  and  485  may be formed using stainless steel, such as stainless steel  301 , beryllium copper, spring steel, or other such material. The contact supports may be alternatively formed using a compressible material. For example, the compressible material may be rubber, foam, or other such material. 
     Contact  450  may include notch  452 , which may be used to secure contact  450  in housing  130 . Contact  450  may further include a contacting portion  454  exiting a bottom of the housing as pin  2  where it can be soldered to a main logic board or other appropriate substrate. 
     Contact  450  may further include a first contact portion  456 . Contact portion  456  may engage an audio plug when it is inserted into passage  120  in housing  130 . This engagement may cause contact  450  to deflect downward. Contact  450  may further include a second contacting portion  485 , which may engage contacting portion  472  of switch contact  470 . Switch contact  470  may include notch  474  which may be used to secure switch contact  470  in housing  130 . Switch contact  470  may further include contact portion  476  which may exit through a bottom of housing  130  as pin  1 , where it may be connected to a trace on a main logic board or other appropriate substrate. This audio jack may further include contact  480 , contact support  485 , and contacts switch  490  which may be similarly arranged. 
     In a specific embodiment of the present invention, contacts  450  and  480  may be used as audio contacts. In this specific example, other audio, ground, and microphone contacts may be included. For example, microphone contact  410  may include a contacting portion  412  and a through-hole contact portion  414 , which may exit through a bottom of housing  132  as pin  5  to be connected to a trace on a printed circuit board or other appropriate substrate. Similarly, ground contacts  420  and  430  may include contacting portions  422  and  432 , and contact tail portions  424  and  434 , which are pins  6  and  4 . By using multiple grounds, associated circuitry may detect a short between these contacts to determine that a metal audio plug is inserted into passage  120 . 
     When a non-metallic audio plug is detected, the ground pins are not shorted, and LED module  495  and associated circuitry (not shown) may be activated. This audio jack may further include another audio contact  442 , which may include contacting portions  442  and through-hole contact portion  444 , which may be pin  3 . 
       FIG. 5  illustrates components of an audio jack connector according to an embodiment of the present invention. Again, audio jack  100  may include housing  130  having a passage  120  forming opening  110 . Microphone contact  410  may be included. One or more ground contacts, for example contacts  420  and  430  may be included. A first audio contact, which may be right audio contact  440 , may be included. Retention contacts  450  and  480  and their contact supports  460  and  485  may also be included. Switch contacts  470  and  490 , as well as optical or LED module  495  may also be inserted into housing  130 . Insulative cover  510  may be placed over the top of housing  130 . Shell or shield  140  may at least partially cover housing  130  and cover  510 . 
       FIG. 6  illustrates a close-up view of contacts and contact supports according to an embodiment of the present invention. Specifically, contacts  450  and  480  are shown as are contact supports  460  and  485 . Each of these may include tabs, such as tabs  620  and  462 , which may be used to help keep these contacts and contact supports in a fixed position in housing  130 . These contacts may further include through-hole portions, such as through a portion  610 , which may emerge from a bottom of housing  130  where they may be electrically connected to traces or planes on a main logic board or other appropriate substrate. Contacts  450  may include multiple contacting portions to contact switch contacts  470  and  490 . Specifically, contact  480  may include one or more arms  458  to form electrical connections with switch contact  470 . By including multiple arms, when a piece of debris forces one arm  458  to be electrically isolated, a second arm  458  may still function correctly. 
     Returning to  FIG. 4 , it can be seen that when an audio plug is not inserted into passage  120 , second contact portion  458  of contact  450  remains electrically in contact with contacting portion  472  of switch contact  470 . To maintain this electrical connection, it may be desirable to pre-bias contact  450  such that it applies a force against switch contact  470 . However this force may make it difficult to correctly assemble this audio jack. Accordingly, embodiments of the present invention may provide a method for readily assembling this audio jack. One such method is outlined in the following figures. 
     In  FIG. 7 , contacts  450  and  480  may be inserted into housing  130 . Specifically, tab  452  may be located in a corresponding tab in housing  130  such that contact  450  is secured in place. Through-hole contacting portion  454  may feed through an opening in housing  130 , where it may emerge from a bottom of housing  130 . 
     In  FIG. 8 , contact supports  460  and  485  may be inserted. Specifically, tab  462  may be fit into a corresponding notch in housing  130 . In this way, notches  462  and  452  may fit in corresponding notches in housing  130  to help secure contacts  450  and contacts support  4   60  in place. 
     In  FIG. 9 , audio plug  710  may be inserted into passage  120  in housing  130 . Plug  710  may engage contacts  450  and  480 , for example at first contacting portion  456 , and deflect these contacts. 
     In  FIG. 10 , the deflection of contacts  450  and  480  allows switch contacts  470  and  490  to be inserted without interference from the retention contacts  450  and  480 . Specifically, through-hole portion  476  may be inserted into an opening in housing  130  where it emerge through a bottom of housing  130  to be connected to a trace on a printed circuit board. Notch  474  may be fit into a corresponding notch in housing  130  to secure switch contact  470  in place. 
     Once switch contacts  470  and  490  are in place, audio plug  710  may be removed. At some point in, before, or after, this process, the remaining contacts and LED module may also be inserted. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20150210
Publication Date: 20180403
Grant Date: 20180403
Priority Date: 20130315
Inventors: TZIVISKOS GEORGE
HACK PAUL J.
GAO ZHENG
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7033", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/7175", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7175", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7033", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/15", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 51529111