PATENT DOCUMENT

Publication Number: US-9093803-B2
Application Number: US-201213610777-A
Country: US
Kind Code: B2

Title: Plug connector

Abstract:
Disclosed are plug connector assemblies having external contacts formed on only one surface of a connector body of the assembly. In some embodiments, the connector body includes a plastic tip integrally formed within a ground ring that is otherwise made from metal. Additionally, in some embodiments, the plug connector has a base portion with feet on opposing sides of the plug that each includes a hole that can be used to attach the plug connector to an encasing or other structure of a base electronic device it is incorporated into. In some embodiments, the plug connector extends upwardly away from the base at a predetermined angle such that the contacts are located on the side of the plug connector that forms an acute angle with the base.

Claims:
What is claimed is: 
     
       1. A plug connector assembly comprising:
 a base comprising a first foot extending from a first end of the base and a second foot extending from an opposite end of the base; 
 a connector body extending upwardly from the base, the connector body comprising front and rear opposing outside surfaces; and 
 a plurality of external contacts exposed only on the front outside surface of the connector body. 
 
     
     
       2. The plug connector assembly set forth in  claim 1  wherein the plurality of contacts comprises a pair of data contacts. 
     
     
       3. The plug connector assembly set forth in  claim 1  wherein the connector body comprises one or more ground contacts. 
     
     
       4. The plug connector assembly set forth in  claim 1  wherein the structure and shape of the connector body comprises a metal ground ring. 
     
     
       5. The plug connector assembly set forth in  claim 1  further comprising a first side wall extending upwardly from the first end of the base and between the front and rear surfaces and a second side wall extending upwardly from the opposite end of the base and between the front and rear surfaces. 
     
     
       6. The plug connector assembly set forth in  claim 5  further comprising a cutout adapted to engage with a retention feature on a corresponding receptacle connector. 
     
     
       7. The plug connector assembly set forth in  claim 6 , wherein the cutout comprises a first cutout formed on the first side wall and a second cutout formed on the second side wall. 
     
     
       8. The plug connector assembly set forth in  claim 1  wherein the plurality of contacts includes a power contact. 
     
     
       9. The plug connector assembly set forth in  claim 5 , further comprising a first channel in the first side wall and a second channel in the second side wall to facilitate placement in a corresponding receptacle connector. 
     
     
       10. The plug connector assembly set forth in  claim 1 , further comprising a threaded cavity located and passing through each of the first and second feet. 
     
     
       11. The plug connector assembly set forth in  claim 1 , wherein the distal end of the connector body comprises plastic. 
     
     
       12. The plug connector assembly set forth in  claim 11 , wherein the distal end of the connector body comprises a molded plastic leading edge. 
     
     
       13. The plug connector assembly set forth in  claim 1 , wherein the connector body extends upwardly from the base at a predetermined angle between approximately 10 degrees and approximately 25 degrees from vertical. 
     
     
       14. The plug connector assembly set forth in  claim 1 , wherein the connector body extends upwardly from the base at a predetermined angle between approximately 14 degrees and approximately 15 degrees from vertical. 
     
     
       15. The plug connector assembly set forth in  claim 1 , wherein a cavity of the connector body comprises retention ledges. 
     
     
       16. The plug connector assembly set forth in  claim 1 , wherein the rear surface comprises one or more ribs adjacent to a substrate containing the plurality of external contacts. 
     
     
       17. An electrical connector assembly comprising:
 a frame made of a hard conductive material and comprising two major surfaces, two minor surfaces, and a distal end, wherein the frame extends upwardly from a base portion of the assembly at an angle of approximately 10 degrees to approximately 25 degrees from vertical; 
 a plastic tip integrally formed with the frame and that extends at least partially across the distal end of the frame; and 
 a plurality of external contacts formed on one of the two major surfaces of the frame. 
 
     
     
       18. The assembly set forth in  claim 17  wherein the plurality of external contacts are formed on only one of the two major surfaces. 
     
     
       19. The assembly set forth in  claim 17  wherein the base portion further comprises two feet that each extend in opposite directions from a proximal end of the ground ring. 
     
     
       20. The assembly set forth in  claim 17  wherein each of the feet comprises a cavity that extends through each foot. 
     
     
       21. The assembly set forth in  claim 17  wherein the base portion extends upwardly from the base portion at an angle between approximately 14 degrees and approximately 15 degrees from the vertical.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application Ser. No. 61/698,538 filed Sep. 7, 2012 titled “Plug Connector,” the contents of which are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention generally relates to electrical connectors and in particular to connector modules that can be readily incorporated into electronic devices and docking stations. 
     A wide variety of electronic devices are available for consumers today. Many of these devices have connectors that facilitate communication with and/or charging of a corresponding device. Typically these connectors are part of a male plug connector and female receptacle connector system in which the plug connector can be inserted into and mated with the receptacle connector so that digital and analog signals can be transferred between the contacts in each connector. More often than not, the female connector in the connector system is included in a host electronic device such as a portable media player, a smart phone, a tablet computer, a laptop computer, a desktop computer or the like. The plug connector in the connector system is often included in an accessory device such as a charging cable, a docking station, an audio sound system or the like. In some instances, however, devices, for example cable adapters, include both receptacle and plug connectors. Also, in some instances, the plug connector/receptacle connector pairing can be part of a large ecosystem of products that includes both host electronic devices and accessory devices designed to work together. Thus, the same general format plug connector can be incorporated into many different accessories, which in turn can be designed to operate with multiple different host devices that include the corresponding receptacle connector. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention pertain to plug connectors that can function within an ecosystem of products, many of which are adapted to work with dual orientation (also referred to as “reversible”) connectors. Some embodiments of the invention pertain to plug connectors with contacts formed on a single side of the connector that are configured to mate with a receptacle connector in a host device that often mates with a reversible connector. Such a connector may be particularly useful when incorporated into an accessory in which the insertion orientation of the plug connector and the receptacle connector are known. One example of such an accessory is a docking station in which a host electronic device with the receptacle connector is always docked in the same orientation with respect to the docking station. 
     Plug connectors according to certain embodiments of the present invention have a reduced plug length and thickness as compared to currently available electronic connectors, and a smooth consistent feel when inserted and extracted from a corresponding receptacle connector. 
     Other embodiments of the invention pertain to plug connectors with external contacts that include a plastic tip integrally formed within a ground ring that is otherwise made from metal. The plastic tip is positioned at the distal tip of the ground ring and helps ensure that if the plug connector comes in contact with a metal enclosure of a host electronic device, the enclosure is less likely to be scratched or otherwise marred or damaged. As one example, consider a user trying to dock a host tablet computer that is relatively heavy in a docking station having a plug connector extending from a docking bay. The tablet computer has a receptacle connector configured to mate with the plug connector but if in the act of docking the tablet computer, the user “misses” so that the receptacle connector and plug connector are not properly aligned, the enclosure of the tablet computer may contact the plug connector, which partly because of the weight of the tablet computer, may result in a scratch or mark on the enclosure if the plug connector has a metal tip. 
     Still other embodiments of the invention include both a plastic tip and contacts on a single side. Additionally, in some embodiments, the plug connector has a base portion with feet on opposing sides of the plug that each includes a hole that can be used to attach the plug connector to an encasing or other structure of the host electronic device it is incorporated into. The plug connector can extend upwardly away from the base at a predetermined angle such that the contacts are located on the side of the plug connector that forms an acute angle with the base. In one embodiment, the angle of the plug connector with respect to vertical is between 10-25 degrees and in some cases is between 14-15 degrees with respect to vertical. 
     Still another embodiment of the invention pertains to a plug connector that includes a plug connected to a base and extending away from the base. The plug includes first and second major opposing surfaces along with third and fourth minor opposing surfaces that extend between the first and second major surfaces. A contact region that includes eight sequentially numbered external contacts spaced apart along a first row is formed on the first major surface of the plug. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a rendering of one particular electronic media device; 
         FIG. 2  is a simplified perspective view of a plug connector according to one embodiment of the invention that includes contacts on a single side of the connector that can be incorporated into a docking station or similar accessory; 
         FIG. 3  is a simplified bottom plan view of the plug connector in  FIG. 2 ; 
         FIG. 4  is a simplified perspective view of a metal frame that makes up a portion of a plug connector shown in  FIG. 2  without the front side of the frame; and 
         FIGS. 5-6  are various simplified views of a plug connector having a plastic tip according to embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to certain embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known details have not been described in detail in order not to unnecessarily obscure the present invention. 
     As discussed earlier, the invention may apply to a variety of plug connectors which use a variety of different connector technologies. Accordingly, this invention may be used with many electronic devices that mate with a variety of electrical connectors in order to receive and provide power and data. One example of an electronic device that may be used with embodiments of the present invention is shown in  FIG. 1 . 
       FIG. 1  depicts an illustrative rendering of one particular electronic media device  10 . Device  10  includes a multipurpose button  15  as an input component, a touch screen display  20  as both an input and output component, and a speaker  25  as an output component, all of which are housed within a device housing  30 . Device  10  also includes a primary receptacle connector  35  and an audio plug receptacle  40  within device housing  30 . Each of the receptacle connectors  35  and  40  can be positioned within housing  30  such that the cavity of the receptacle connectors into which a corresponding plug connector is inserted is located at an exterior surface of the device housing. In some embodiments, the cavity opens to an exterior side surface of device  10 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 1 . Embodiments of the invention disclosed herein are particularly suitable for use with plug connectors that are configured to mate with primary receptacle connector  35 , but in some embodiments can also be used with audio plug receptacle  40 . Additionally, in some embodiments, electronic media device  10  has only a single receptacle connector  35  that is used to physically interface and connect the device (as opposed to a wireless connection which can also be used) to the other electronic devices. 
     Although device  10  is described as one particular electronic media device, embodiments of the invention are suitable for use with a multiplicity of electronic devices that include a receptacle connector that corresponds to a plug connector including a frame. For example, any device that receives or transmits audio, video or data signals may be used with the invention. In some instances, embodiments of the invention are particularly well suited for use with portable electronic media devices because of their potentially small form factor. As used herein, an electronic media device includes any device with at least one electronic component that may be used to present human-perceivable media. Such devices may include, for example, portable music players (e.g., MP3 devices and Apple&#39;s iPod devices), portable video players (e.g., portable DVD players), cellular telephones (e.g., smart telephones such as Apple&#39;s iPhone devices), video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, PDAs, desktop computers, as well as tablet (e.g., Apple&#39;s iPad devices), laptop or other mobile computers. Some of these devices may be configured to provide audio, video or other data or sensory output. 
     In order to better appreciate the features and aspects of plug connectors according to the present invention, further context for the invention is provided in the following section by discussing one particular implementation of a plug connector according to the present invention. 
       FIG. 2  is a perspective view depicting an eight contact plug connector assembly  100  that may include a ground ring or frame  102  according to embodiments of the present invention. As shown in  FIG. 2 , plug connector assembly  100  includes a connector body  104  that extends longitudinally away from a base portion  106 . Connector body  104  is sized to be inserted into a corresponding receptacle connector, such as connector  35 , during a mating event. Connector body  104  includes a contact region  108  formed on a first major surface  110  that is opposite second major surface  112  of connector body  104 . Surfaces  110 ,  112  extend from the base portion  106  to a distal tip  118  of connector body  104 . When connector body  104  is inserted into a corresponding receptacle connector, major surfaces  110 ,  112  abut a housing of the receptacle connector or host device into which the receptacle connector is incorporated. 
     Connector body  104  includes third and fourth opposing minor surfaces  114 ,  116  that extend between the first and second major surfaces  110 ,  112 . Minor surfaces  114 ,  116  extend from the base portion  106  to distal tip  118 , forming the side walls of connector body  104 . When connector body  104  is inserted into a corresponding receptacle connector, minor surfaces  114 ,  116  may abut inner walls of a housing of a corresponding receptacle connector of a host device. In some embodiments, connector body  104  is between 4 and 7 mm wide, between 1 and 2 mm thick and has an insertion depth (the distance from distal tip  118  to proximal end  120 ) between 5 and 10 mm. In one particular embodiment, connector body  104  is 6.7 mm wide in the width dimension, 1.5 mm thick in the height dimension and has an insertion depth (the distance from distal tip  118  to proximal end  120 ) in the length dimension of 6.6 mm. In other embodiments, body  104  has the same 6.7 mm width and 1.5 mm height but has a length of, for example, between 6.5-8.0 mm. 
     In some embodiments, connector body  104  extends away from base portion  106  at a predetermined angle. In certain embodiments, connector body  104  extends upwardly from base portion  106  at an angle of between approximately 10 and 25 degrees, and in some cases at an angle between approximately 14-15 degrees, with respect to vertical V. In other embodiments, body  104  extends perpendicularly away from base  106 . 
     According to certain embodiments of the invention, the structure and shape of connector body  104  is defined by ground ring  102 , which can be made from stainless steel or another hard conductive material. Connector body  104  includes an opening  136  on first major surface  112  that makes up contact region  108 . As shown in  FIG. 2 , opening  136  may be rectangular with rounded corners. In other embodiments, opening  136  may be otherwise shaped, e.g., the opening may be triangular, circular or irregularly shaped. 
     In some embodiments, base portion  106  of plug connector assembly  100  has a pair of feet, with one foot  130  located on either side of connector body  104 . Each foot  130  has a hole or cavity  132  passing through the foot. Holes  132  may be threaded, which allows the plug connector assembly  100  to be fastened to a device, such as a docking station or some other surface, as desired by using screws or other fastening devices. 
     In certain embodiments, distal tip  118  of connector body  104  may have a curved distal end or leading edge  134 . The leading edge may be rounded for approximately 1 mm of its length at each of its ends, and in some embodiments is rounded for between 0.5 mm and 1.5 mm at each end. Rounded leading edge  134  may make it easier to insert connector body  104  into a corresponding receptacle connector when the connector body is rotated off axis, that is, when the connector body is inserted at an incorrect pitch angle. 
     Contact region  108  includes a plurality of external contacts, such as contacts  126 ( 1 ) . . .  126 ( 8 ) (labeled in  FIG. 2  as  126 ( i )). Contacts  126 ( i ) can be made from copper, nickel, brass, stainless steel, a metal alloy or any other appropriate conductive material or combination of conductive materials. In some embodiments, contacts  126 ( i ) can be printed using techniques similar to those used to print contacts on printed circuit boards. In some other embodiments, contacts  126 ( i ) can be stamped from a lead frame, positioned within contact region  108  and surrounded by dielectric material. 
     As shown in  FIG. 2 , plug connector assembly  100  is particularly well suited for inclusion in a docking station, clock radio, or other device in which a host electronic device having a corresponding plug connector will always connect in a particular orientation. Thus, connector body  104  according to certain embodiments and as shown in  FIG. 2  only includes contacts  126 ( i ) on a single surface of the connector as opposed to both major surfaces. 
     As shown in  FIG. 2 , eight external contacts  126 ( 1 ) . . .  126 ( 8 ) are spaced apart along a single row in contact region  108  of first major surface  110 . Contacts  126 ( 1 ) . . .  126 ( 8 ) can be used to carry a wide variety of signals including digital signals and analog signals as well as power and ground as discussed below. In some embodiments, contact region  108  is located towards distal tip  118  of connector body  104  and/or on the minor surfaces  114 ,  116  of connector body  104 . Embodiments that employ ground contacts at one or more positions along the minor surfaces and/or tip surfaces of connector body  104  instead of within the contact region may enable the overall footprint of connector plug to be smaller than a similar connector that includes ground contacts within the contact region. In other embodiments, contact region  108  may occupy a different location or even the entirety of connector body  104 . 
     The contacts may be spaced apart along a single or multiple rows. Although eight external contacts are shown in  FIG. 2 , contact region  108  may include any number of external contacts, from one to twenty or more arranged in a variety of different patterns. In some embodiments, individual contacts may be sized differently. This may be particularly useful, for example, where one or more contacts are dedicated to carry high power or high current. 
     Contacts  126 ( 1 ) . . .  126 ( 8 ) can be used to carry a wide variety of signals including digital signals and analog signals as well as power and ground as previously discussed. In one embodiment, each contact  126 ( 1 ) . . .  126 ( 8 ) have an elongated contact surface. In one embodiment, the overall width of each contact is less than 1.0 mm at the surface, and in another embodiment the width is between 0.75 mm and 0.25 mm. In one particular embodiment, a length of each contact  126 ( i ) is at least 3 times as long at the surface as its width, and in another embodiment a length of each individual contact  126 ( i ) is at least 5 times as long at the surface as its width. 
     Examples of analog contacts that may be included in contact region  108  include contacts for separate left and right channels for both audio out and audio in signals as well as contacts for video signals, such as RGB video signals, YPbPr component video signals and others. Similarly, many different types of digital signals can be carried by contacts  126 ( i ) in contact region  108  including data signals such as USB signals (including USB 1.0, 2.0 and 3.0), FireWire (also referred to as IEEE 1394) signals, UART signals, Thunderbolt signals, SATA signals and/or any other type of high speed serial interface signal or other type of data signal. Digital signals within contact region  108  may also include signals for digital video such as DVI signals, HDMI signals and Display Port signals, as well as other digital signals that perform functions that enable the detection and identification of devices or accessories to the plug connector. 
     In some embodiments, the sequentially numbered contacts  126 ( 1 ) . . .  126 ( 8 ) include first and second contacts designated for data signals at locations 2 and 3, a power contact designated for power at location 5, third and fourth contacts designated for data signals at locations 6 and 7 and a ground contact at location  126 ( 1 ). In some embodiments connector body  104  further includes an accessory power contact at location 4 and an ID contact at location 8. 
     Power contact  106 ( 5 ) may carry signals of any voltage and, as an example, may carry signals between 2-30 volts. In some embodiments, multiple power contacts are included in contact region  108  to carry power signals of different voltages levels that can be used for different purposes. For example, the accessory power contact may deliver low current power at 3.3 volts that can be used to power accessory devices connected to plug connector assembly  100  can be included in contact region  108 , while power contact  106 ( 5 ) may deliver high current power at 5 volts for charging portable media devices coupled to plug connector assembly  100 . In some embodiments, one or more power contacts within the region can be larger than other contacts to more efficiently enable the larger contacts to carry high power and/or high current. In other embodiments, multiple contacts can be electrically coupled together to provide one or more “larger contacts” for carrying high power and/or high current. 
     Accessory power contact  126 ( 4 ) can be used for an accessory power signal that provides power from the host to an accessory. The accessory power signal is typically a lower voltage signal than the power in signal received over contact  106 ( 5 ), for example, 3.3 volts as compared to 5 volts or higher. The accessory ID contact provides a communication channel that enables the host device to authenticate the accessory and enables the accessory to communicate information to the host device about the accessory&#39;s capabilities such as the communication interface that is used for each of pair of the data contacts. 
     Data contacts  126 ( 2 ),  126 ( 3 ),  126 ( 6 ) and  126 ( 7 ) can be used to enable communication between the host and accessory using one or more of several different communication protocols. In some embodiments, data contacts  126 ( 2 ) and  126 ( 3 ) operate as a first pair of data contacts and data contacts  126 ( 6 ),  126 ( 7 ) operate as a second pair of data contacts allowing two different serial communication interfaces to be implemented over the data contacts as discussed below. In one embodiment, data contacts  126 ( 2 ),  126 ( 3 ) are positioned between the accessory power contact and ground, while data contacts  126 ( 6 ) and  126 ( 7 ) are positioned between the power contact and the accessory ID contact. The data contacts can be high speed data contacts that operate at rate that is at least two orders of magnitude faster than any signals sent over the accessory ID contact which makes the accessory ID signal look essentially like a DC signal to the high speed data lines. The accessory power, ground and charging power contacts are all DC contacts. Thus, positioning the data contacts as just described improves signal integrity by sandwiching the data contacts between contacts designated for either DC signals or essentially DC signals. 
     As shown in  FIGS. 2-3 , a substrate  128 , such as a printed circuit board (PCB), is housed within connector body  104 . As shown in  FIGS. 2-3 , a portion of substrate  128  extends past proximal end  120  of connector body  104 . Substrate  128  includes a plurality of contact bonding pads (not shown) that can correspond in number to the plurality of contacts  126 ( i ) and that are positioned directly beneath contacts  126 ( i ) in contact region  108 . Substrate  128  also includes one or more electronic components, such as integrated circuits, a plurality of conductor bonding pads and ground pads. Each conductor bonding pad can be connected to one or more contact bonding pads by electrical traces that run along substrate  128  (not shown). 
       FIG. 3  is a bottom plan view of plug connector assembly  100  illustrating how the substrate  128  is positioned with respect to connector body  104 . As shown in  FIG. 3 , second major surface  112  of connector body  104  includes internal ribs  124 . Ribs  124  help center substrate  128 , which rests on top of ribs  124 . Specifically, because contacts only exist on one surface of the substrate (such as first major surface  110 ), ribs  124  help bias substrate  124  (and thus the contacts bonding pads included on substrate  124 ) into proper position. 
     As illustrated, minor surfaces  114 ,  116  of connector body  104  may include cutouts  122  that align with a feature on a corresponding receptacle connector. Cutouts  122  may engage with corresponding features disposed in a receptacle connector of a host device and aid in holding connector body within the receptacle connector. Cutouts can also be located at a variety of positions along the connector body  104  including along the minor surfaces  114 ,  116  and/or distal tip  118  and/or bottom surfaces of the connector body. In some embodiments, cutouts  122  are not utilized. 
       FIG. 4  illustrates a ground ring  202  according to an embodiment of the present invention that in some embodiments corresponds to ground ring  102  shown in  FIG. 2 . In some embodiments, ground ring  202  can be made from stainless steel or another hard conductive material. As shown in  FIG. 2 , ground ring  202  comprises a first major surface  210  and a second opposing major surface  212 . Ground ring also includes opposing minor surfaces  214 ,  216 . First major surface  210  includes a cavity  218  that extends generally from a proximal end  220  of ground ring  202  to a distal end  204  in length and the width of cavity  218  is defined by the distance between the two minor surfaces  214 ,  216 . When ground ring  202  is inserted into a corresponding receptacle connector, surfaces  210 ,  212 ,  214 ,  216  may abut inner walls of a housing of a corresponding receptacle connector of a host device. In one particular embodiment, ground ring  202  is 6.7 mm wide in the width dimension, 1.5 mm thick in the height dimension and has an insertion depth (the distance from distal end  204  to proximal end  220 ) in the length dimension of between 6.5-8.0 mm. 
     Ground ring  202  may optionally include cutouts  222  that are formed as curved recesses on surfaces  214 ,  216 , respectively, proximate distal end  204 . If utilized, in some embodiments these cutouts may be retention features (e.g., curved recesses or pockets) that engage with corresponding features disposed in a receptacle connector of a host device and aid in holding connector body within the receptacle connector. In other embodiments, cutouts  222  are elongated slots that extend from distal end  204  along a portion of the length of each side surface  214 ,  216 . The slots may align with retention features in the receptacle connector but not be a retention feature themselves. 
     Cavity  218  includes ledges  224 ,  226  that extend from proximal end  220  toward distal end  204  of ground ring  202 . In some embodiments, ledges  224 ,  226  are undercuts that help retain a plastic cover (not shown) in position. In particular, after metal ground ring  202  has been formed and after the appropriate substrate has been positioned within ground ring  202 , plastic may be introduced by injection molding to form a cover that is flush with first major surface  210  to cover the entire face of cavity  218 . In this way, contacts positioned within ground ring  202  before the plastic is introduced become embedded within the plastic cover after the plastic is introduced. Ledges  224 ,  226  interlock with the injection-molded plastic so that the plastic cover does not detach from metal ground ring  202 . 
     Also shown in  FIG. 4  are interlocks  228 ,  230 , which may further define cavity  218  of ground ring  202 . Interlocks  228 ,  230  may be disposed on inner end surface  232  and may assist in preventing material overmolded around contacts assembled with ground ring  202  from dislodging and moving in the height dimension. Accordingly, interlocks may prevent displacement of the overmolded contact assemblies when forces are applied to the contacts assemblies in the direction of the height dimension. These forces may be caused by users pressing down on the contact assemblies or otherwise subjecting the contact assemblies to forces, e.g., dropping or hitting the contact assemblies of the plug connector. 
       FIG. 4  also illustrates internal ribs  234  that help center substrate (not pictured) within ground ring  202  as explained above. 
       FIGS. 5 and 6  pertain to other embodiments of the invention that include a plastic tip at the distal end of the connector.  FIGS. 5A-5F  illustrates a connector body  304  and a connector body  404 . Connector body  304  has a first major surface  310  and an opposing second major surface  312 . Similarly, connector body  404  has a first major surface  410  and an opposing second major surface  412 . Connector bodies  304  and  404  each include a tip portion  302  that is formed from a plastic material instead of metal This can be done, for example, by forming a ground ring without a metal tip and adding tip portion  302  in an injection molding process that flows injection molding material into the frame using an appropriately shaped mold. In this way, plastic tip portion may be integral with the ground ring. The injection molding process may also fill in spaces between the ground ring and substrate and between individual contacts in contacts  106 ( 1 ) . . .  106 ( 8 ) and the ground ring. 
       FIGS. 5A-5C  disclose various configurations of tip portion  302  disposed along distal tip  318  and, in some embodiments, at least partially along second major surface  312 .  FIG. 5D  illustrates one of many configurations of tip portion  302  as it extends along first major surface  310 . In some embodiments, tip portion  302  does not extend along first major surface  310  or second major surface  312  at all and instead is disposed only along distal tip  318  of connector body  304 . In some variations, connector body  304  also includes metal regions  320  that, while not shown in the figures, can correspond to recesses that engage with retention features of the corresponding receptacle connector and/or provide a side ground contact to help ensure proper functioning of connector body  304 . Although not pictured, first major surface  310  may include contacts, such as contacts  126 ( i ) described above. 
       FIG. 5E  discloses one non-limiting configuration of tip portion  402  along distal tip  418  and second major surface  412  of connector body  404 , while  FIG. 5F  shows first major surface  410  of the embodiment shown in  FIG. 5E . In this particular embodiment, tip portion  402  is disposed along distal tip  418  and extends partially along first major surface  410  and second major surface  412 . Connector body  404  also includes metal regions  420  that are similar to regions  320 . Although not pictured, first major surface  410  may include contacts such as contacts  126 ( i ) described above. 
     Tip portions  302  and  402  may be any size and any configuration and may extend in any direction and distance along distal tip and along one or more of the major surfaces. In some embodiments, the tip portion extends only partially along the one or more major surfaces, while in other embodiments, the tip portion extends further away from the distal tip along the one or more major surfaces. In some embodiments, the tip portion only extends along the distal tip and does not extend along either of the major surfaces. In some embodiments, the tip portion extends at least partially along the minor surfaces as well as the distal tip and/or the major surfaces. 
     Plastic tip portions  302  or  402  may be integrally formed within ground ring, which as described is otherwise made from metal. Because the plastic tip portion is positioned at the distal tip  318 ,  418  of the ground ring, it helps ensure that if the connector body comes in contact with a metal enclosure of a host electronic device, the enclosure is less likely to be scratched or otherwise marred or damaged. 
     In some versions of the embodiments discussed above with respect to  FIGS. 2-6 , the plug connector according to the invention may have a form factor that enables mating with receptacle connector  140  disclosed in concurrently filed U.S. patent application Ser. No. 13/607,366, which is herein incorporated by reference in its entirety, or with a receptacle connector such as receptacle connector  35  in  FIG. 1 . 
     Embodiments of the present invention may provide a plug connector ground ring or frame that may be easily manufactured. For example, techniques such as a metal injection modeling (MIM) in combination with machining and finishing operations may be used to form frames or ground rings of the invention. 
     With one exemplary, non-limiting process, a method of manufacture includes three general steps. At the first step, a MIM process is performed to form a metal part. At the second step, select surfaces of the metal part are machined. Lastly, at the third step, finishing operations are performed on the metal part to complete the manufacture of a ground ring or frame. These steps may be used to form embodiments of connector bodies  104 ,  204 ,  304 , and  404  described above. 
     In some embodiments, sub-steps are performed. At a first sub-step, a green part or green frame is molded. To produce the green part, a MIM feedstock is blended and injected into a molding machine in molten form. Once the liquefied feedstock cools, it may be de-molded in the molding machine. The feedstock may include a variety of elements chosen to produce a metal part with particular characteristics. In one embodiment, a feedstock for use with the invention may include atomized metal powder, a thermoplastic polymer and wax based plastic. The atomized metal powder may be an atomized steel powder, e.g., atomized steel 630 powder. The thermoplastic polymer may provide the plastic binding agent for the MIM process and the wax based plastic may provide the wax binding agent for the MIM process. 
     At a second sub-step, the binders are removed (de-binded) from the green part to produce a brown part or brown frame. The binding material may be removed using heat, solvents (e.g., nitric acid), and/or other methods or a combination thereof. 
     At a third sub-step, the brown part is sintered to produce a MIM part or frame and the MIM process is completed. The sintering process includes subjecting the brown part to temperatures that cause the atomized metal powders to bind together and form the MIM part or frame. 
     Although a particular method of manufacturing a frame according to the invention is discussed above, embodiments of the invention may include manufacturing the frame by other methods, including pressed powder sintering, investment casting, and simply computer numerical control (CNC) machining. 
     As will be understood by those skilled in the art, the present invention may be embodied in many other specific forms without departing from the essential characteristics thereof. Also, while a number of specific embodiments were disclosed with specific features, a person of skill in the art will recognize instances where the features of one embodiment can be combined with the features of another embodiment. Also, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the inventions described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20120911
Publication Date: 20150728
Grant Date: 20150728
Priority Date: 20120907
Inventors: SOOHOO ERIC T.
COLAHAN IAN P.
WEBB MICHAEL J.
JOL ERIC S.
THOMPSON PAUL J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/516", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/516", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/62", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R23/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/516", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 48182816