PATENT DOCUMENT

Publication Number: US-7743496-B2
Application Number: US-453907-A
Country: US
Kind Code: B2

Title: Cable termination methods

Abstract:
A termination for a multi-conductor cable is made by providing a metal structure that includes a plurality of parallel but spaced apart fingers that are joined together by a connecting member adjacent at least one end of each finger. Each of the conductors in the cable is connected to a respective one of the fingers at a location that is spaced from the connecting member. The cable and the fingers are then over-molded with an insulating material where the conductors are connected to the fingers. This over-molding leaves a portion of the length of each finger exposed. The connecting member is then severed and removed.

Claims:
1. A method of terminating a multi-conductor cable comprising:
 providing a metal structure that includes a plurality of substantially parallel, spaced apart, metal fingers that are joined together adjacent at least one end of each finger by a metal connecting member that is part of the metal structure, the metal structure by itself maintaining the fingers in parallel, spaced apart relationship to one another; 
 mechanically and electrically connecting each one of the conductors to a respective one of the fingers at a location along the finger that is spaced from the connecting member, said connecting being performed prior to over-molding any insulating material onto the metal structure; 
 over-molding with an insulating material the cable and the fingers where the conductors have been connected to the fingers, said over-molding leaving a portion of the length of each finger exposed; and 
 severing the connecting member from the fingers. 
 
   
   
     2. The method defined in  claim 1  wherein after the severing, a portion of the length of each finger is still exposed. 
   
   
     3. The method defined in  claim 2  further comprising:
 inserting the portion of the length of each finger that is still exposed into an aperture in an electrical circuit. 
 
   
   
     4. The method defined in  claim 3  further comprising:
 connecting the portion of each finger that has been inserted into the electrical circuit to electrical circuitry of the electrical circuit. 
 
   
   
     5. The method defined in  claim 4  wherein the connecting the portion of each finger to electrical circuitry comprises:
 soldering the portion of each finger to the electrical circuitry. 
 
   
   
     6. The method defined in  claim 1  wherein the connecting comprises:
 soldering each of the conductors to a respective one of the fingers. 
 
   
   
     7. The method defined in  claim 1  further comprising:
 providing each of the fingers with a through aperture at the location where the connecting will be performed. 
 
   
   
     8. The method defined in  claim 1  further comprising:
 providing each of the fingers with a through aperture where the over-moldering will cover the finger and will therefore enter the aperture. 
 
   
   
     9. The method defined in  claim 1  wherein the cable includes an outer cover around the conductors adjacent to, but spaced from, where the connecting is performed, and wherein the over-molding covers and bonds with the outer cover adjacent to where the connecting is performed. 
   
   
     10. The method defined in  claim 9  wherein the over-molding also forms a shape separate from the fingers that can be used to provide a mechanical connection to other structure that the cable is to be connected to. 
   
   
     11. The method defined in  claim 1  wherein the over-molding also leaves the connecting member exposed.

Description:
BACKGROUND OF THE INVENTION 
   This invention relates to electrical connectors for use in electronic circuitry for making electrical and mechanical connections of multi-conductor cables to other circuit structures and components. 
   Connecting the wires of a multi-conductor cable to another electronic circuit component such as a printed circuit board (“PCB”) should be done in a way that is rapid and efficient and produces strong and reliable electrical and mechanical connection of the cable and its conductors to the other component. Especially for products where the cable may be subject to on-going stress during use of the finished product, it is desirable for the connection of the cable to the other component to be able to resist such stress and not fail to maintain secure and reliable connection of the cable. Improvements to cable termination technology are therefore always being sought. 
   SUMMARY OF THE INVENTION 
   In accordance with certain aspects of the present invention, a termination or connector for a multi-conductor cable is made using a substantially flat piece of metal that has a plurality of substantially parallel, laterally-spaced-apart fingers that are initially connected together by at least one transverse member joining at least one end of the fingers. Each of the conductors (wires) of the multi-conductor cable is electrically and mechanically connected to a respective one of the fingers. The end of the cable adjacent the metal component and at least the portion of the fingers to which the wires have been attached are then enclosed in an insulating material (e.g., by molding the insulating material around the structure to be enclosed). Another portion of each finger is not so enclosed, and the transverse member is preferably also not so enclosed. The transverse member is then removed from the fingers, which leaves the fingers electrically isolated from one another, but still mechanically stable relative to one another by being partly embedded in the insulating material. The portion of the fingers that are not embedded in the insulating material project from the insulating material and can be used as exposed electrical contacts for electrically and mechanically connecting the structure described above to other circuitry requiring connection to the cable. 
   Further features of the invention, its nature and various advantages, will be more apparent from the accompanying drawings and the following detailed description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a simplified perspective or isometric view of an illustrative embodiment of a component that can be provided and used in accordance with the invention. 
       FIG. 2  is a simplified perspective or isometric view of an illustrative embodiment of use of the  FIG. 1  component in accordance with the invention. 
       FIG. 3  is a simplified perspective or isometric view of an illustrative embodiment of further use of what is shown in  FIG. 2  in accordance with the invention. 
       FIG. 4  is a simplified perspective or isometric view of an illustrative embodiment of still further use of what is shown in  FIG. 3  in accordance with the invention. 
       FIG. 5  is a simplified perspective or isometric view of an illustrative embodiment of yet further use of what is shown in  FIG. 4  in accordance with the invention. 
   

   DETAILED DESCRIPTION 
   An illustrative embodiment of a component  10  that can be used in accordance with the invention is shown in  FIG. 1 . In this embodiment, component  10  is a substantially flat piece of metal that includes four, substantially parallel, but laterally spaced-apart parts that may be referred to as tines or fingers  20   a - d . The use of four such fingers  20  is only illustrative, and it will be understood that smaller or larger numbers of fingers  20  can be used (as long as there is a plurality of such fingers). At their upper ends (as viewed in  FIG. 1 ), fingers  20  are all connected together by a transverse part  30   a  of component  10 . Similarly, at their lower ends, fingers  20  are again all connected together by another transverse part  30   b  of component  10 . 
   Each of fingers  20  is axially divided into two different regions: an upper region  22   a  and a lower regions  22   b  (as viewed in  FIG. 1 ). The upper region  22   a  of each finger  20  is preferably somewhat wider than the lower region  22   b . In addition, the upper region  22   a  of each finger  20  preferably includes one or more apertures  24  through that finger (from one of the major planar surfaces of component  10  to the other of the major planar surfaces of that component). Although three holes  24  are shown through the region  22   a  of each finger  20  in the illustrative embodiment shown in  FIG. 1 , it will be understood that any number of such holes (or alternatively no holes) can be provided in each finger  20 . 
     FIG. 2  shows an illustrative embodiment of a next step in the formation of a connector in accordance with this invention. As shown in  FIG. 2 , the end of each of four wires  42   a - d  in four-conductor cable  40  is exposed from overall cable jacket or insulation  41  and from that conductor&#39;s individual conductor insulation  43   a - d , and that wire is soldered to a respective one of fingers  20   a - d  as shown at  44   a - d . This soldering is preferably done to the region  22   a  of each finger  20 , and still more preferably at an aperture  24  through each finger. For example, the exposed end of a wire  42  may be passed through an aperture  24 , and then the aperture may be filled in around the wire with solder  44  to make a secure mechanical and electrical connection between the wire and the now-connected finger  20 . 
   An illustrative embodiment of a next step in the formation of a connector in accordance with the invention is shown in  FIG. 3 . In this step an insulating material  50  is formed around the end portion of cable  40 , the wires  42  that were exposed from the wire and cable insulation and soldered to metal component  10 , and a substantial part of the length of fingers  20   a - d . In particular, the portions of the lengths of fingers  20  that are covered by insulating material  50  preferably include all of the length of upper regions  22   a  (with the exception of a small amount immediately adjacent to upper transverse member  30   a ), and a small amount of lower regions  22   b  immediately adjacent to upper regions  22   a . A substantial lower portion of regions  22   b  is not covered by material  50 . Transverse members  30   a  and  30   b  are also not covered by insulating material  50 . A preferred technique for forming material  50  as shown in  FIG. 3  and described above is insert molding (the “insert” in the mold being everything shown in  FIG. 2  that is described above as becoming covered by material  50 ). This step may also be referred to as over-molding. 
   Note that several features of metal component  10  help to ensure that, after material  50  has been molded around it as described above and that material has cured (hardened to what is effectively a solid), fingers  20  maintain their relative positions in material  50 . Some of these features are extra apertures  24 , through which material  50  passes to help anchor fingers  20  in material  50 . Material  50  also passes through the spaces between laterally adjacent fingers  20 . This also helps to keep fingers  20  in place, aligned with one another, and spaced apart from one another in material  50 . The fact that the finger-width transitions (from regions  22   a  to regions  22   b ) are embedded in material  50  also helps to resist any tendency of fingers  20  to pull out of material  50  in the downward direction. Molding of material  50  around individual wires  42 / 43 , solder regions  44 , and cable insulation  41  (to which material  50  preferably forms a mechanical bond) also helps to stabilize metal component  10  in material  50 , and to enable material  50  to greatly increase the strength of the mechanical connection between cable  40  and its individual wires  42 , on the one hand, and metal component  10 , on the other hand. The portion  52  of material  50  that extends upstream along cable  40  may also help to distribute the effects of lateral flexure of the cable along some length of the cable, thereby helping to reduce the risk of cable breakage due to sharp or concentrated lateral flexure of the cable at one location. For this purpose, portion  52  of material  50 , which extends annularly around cable  40 , may be relatively thin to give portion  52  some lateral flexibility. 
   If desired, material  50  may be formed with additional external features that can help anchor the connector to a housing of electronic circuitry with which the connector will be used. In the illustrative embodiment shown in  FIG. 3  these external features include two flanges  54   a  and  54   b  that extend annularly around the longitudinal axis of cable  40  at respective different locations along that axis. The wall of the above-mentioned circuitry housing can fit into the channel  56  between the two flanges to help prevent cable  40  and its connector from being pulled away from the housing or being forced farther into the housing. Channel  56  can also be non-circular (e.g., as a result of the provision of a key  58  extending into the channel at one or more locations around the channel) to additionally prevent rotation of cable  40  and its connector about the longitudinal axis of the cable relative to the above-mentioned circuitry housing. 
   An illustrative embodiment of a next step in forming a connector  60  in accordance with the invention is shown illustratively in  FIG. 4 . This step involves trimming off and removing the transverse members  30   a  and  30   b  of metal component  10 . This leaves fingers  20  electrically isolated (insulated) from one another. A portion of the region  22   b  of each finger  20  projects from the lower portion of material  50  as is clearly visible in  FIG. 4 . The thus-projecting portions of fingers  20  constitute the exposed metal contacts of connector  60 . These exposed metal contacts can be used for electrically (and mechanically) connecting connector  60  to other circuitry with which the connector will be used. 
     FIG. 5  shows an illustrative embodiment of use of connector  60  from  FIG. 4  in accordance with possible further aspects of the invention. As shown in  FIG. 5 , exposed metal contacts  20   a - d  of connector  60  are pushed through respective apertures in printed circuit board (“PCB”)  70 . Each of contacts  20   a - d  is then soldered at  72   a - d  to electrically connect that contact to a respect circuit trace on PCB  70 . Note that solder  72  also helps to permanently mechanically secure connector  60  to PCB  70 . 
   Although the following geometric considerations are not necessarily present in all embodiments of the invention, they can constitute preferred features. It will be noted that in the embodiments that have been shown and described, the principal plane of metal component  10  is substantially perpendicular to the longitudinal axis of cable  40 . This results in contacts  20   a - d  in finished connector  60  being transverse to (not parallel to or aligned with) the longitudinal axis of cable  40 . Contacts  20   a - d  are therefore pushed into the apertures in PCB  70  along an axis that is substantially perpendicular to the longitudinal axis of cable  40 . This means that any subsequent axial pulling (or pushing) on cable  40  is not aligned with the axis along which connector  60  goes into apertures in PCB  70 , and so such pulling or pushing on cable  40  does not work (at least not directly) to pull contacts  20  out of the PCB apertures. This can be desirable to provide more secure attachment of cable  40  to PCB  70 . 
   It will be understood that the foregoing is only illustrative of the principles of the invention, and that various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention. For example, although connectors with four contacts  20   a - d  are shown and described for the most part herein, it will be understood that the invention can be used to make connectors having any plural number of contacts. As another example of modifications within the scope of the invention, it may be possible in some embodiments to eliminate one of the two transverse members  30  that are generally shown and described elsewhere in this specification. Metal component  10  would then be more like a fork, and it would only be necessary to cut off the one transverse member  30   a  or  30   b  to produce a result like that shown in  FIG. 4 .

Metadata:
Filing Date: 20071220
Publication Date: 20100629
Grant Date: 20100629
Priority Date: 20071220
Inventors: PREST CHRISTOPHER D.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49179", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10356", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/0263", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K3/3447", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/3447", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49117", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49174", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R4/023", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49174", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10424", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10356", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10962", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R4/023", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10424", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49123", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10924", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49123", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10962", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10924", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49179", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/0263", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 40786928