PATENT DOCUMENT

Publication Number: US-9054477-B2
Application Number: US-201213875637-A
Country: US
Kind Code: B2

Title: Connectors and methods for manufacturing connectors

Abstract:
Frames for plug connectors capable of being a reduced size may include features to support contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. For example, a frame may include ledges, interlocks and rounded and tapered openings. Methods for manufacturing the frame are also provided.

Claims:
What is claimed is: 
     
       1. A method of manufacturing a metal frame for an electrical plug connector, the method comprising:
 using a metal injection molding process to form a green part from a feedstock comprising metal and thermoplastic polymers, the green part having: 
 (i) a width, height and length dimension; 
 (ii) an insertion end including first and second opposing sides extending in the width and length dimensions, the first side including a first opening and the second side including a second opening registered with and opposite the first opening, and including third and fourth opposing sides extending between the first and second sides in the height and length dimensions; and 
 (iii) a flanged end including a third opening that communicates with a cavity that extends in the length, width and height dimensions from the flanged end into the insertion end past the first and second openings; 
 thereafter, debinding the green part to form a brown part; 
 thereafter, sintering the brown part to form a metal part having the insertion end and flange end; and 
 thereafter, machining the first and second sides of the insertion end of the metal part without machining the third and fourth sides of the insertion end, 
 wherein each of the first, second, third and fourth sides of the insertion end has an outer layer that has a porosity less than a porosity of a remainder of each side, and wherein the outer layer at the first and second sides is thinner than the outer layer at the third and fourth sides. 
 
     
     
       2. The method of  claim 1  further comprising performing finishing operations on the frame after the machining step. 
     
     
       3. The method of  claim 2  wherein the finishing operations include plating the metal frame. 
     
     
       4. The method of  claim 1  wherein the feedstock comprises atomized steel powder, a thermoplastic polymer and wax based plastic. 
     
     
       5. The method of  claim 4  wherein the atomized steel powder comprises atomized stainless steel powder. 
     
     
       6. The method of  claim 4  wherein the thermoplastic polymer comprises polyoxymethylene. 
     
     
       7. The method of  claim 1  further comprising machining a side of the flanged end that includes the third opening. 
     
     
       8. The method of  claim 1  wherein the outer layer has a thickness between 200 and 800 microns at each of the first, second, third and fourth sides. 
     
     
       9. The method of  claim 1  wherein the outer layer is between 20 and 400 microns thinner at the first and second sides than at the third and fourth sides. 
     
     
       10. The method of  claim 1  wherein an outer surface of the first and second sides has a surface roughness that is less than a surface roughness of the third and fourth sides. 
     
     
       11. The method of  claim 1  wherein the flanged end includes an outer surface that joins the first, second, third and fourth sides of the insertion end and an end surface that surrounds the third opening, the outer surface having an outer layer that is thicker than an outer layer of the end surface. 
     
     
       12. The method of  claim 11  further comprising plating a layer of nickel over the outer layer of the first, second, third and fourth sides of the insertion end and the outer and end surfaces of the flanged end.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is the U.S. National Stage entry of PCT/CN2012/081257, filed Sep. 11, 2012 which is herein incorporated by reference for all purposes. 
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to electronic connectors such as audio and data connectors, and in particular ground rings or frames for plug connectors. 
     Many electronic devices mate with electrical connectors that receive and provide power and data. For example, devices, such as tablets, laptops, netbooks, desktops, and all-in-one computers; cell, smart, and media phones; storage devices, portable media players, navigation systems, monitors, and others, use electrical connectors for power and/or data. 
     These electrical connectors are often plug connectors that are designed to mate with corresponding receptacle connectors on an electronic device. Many previously known plug connectors, such as USB connectors, include a plurality of contacts that are surrounded by a metal shell. The metal shell creates a cavity in which debris may collect and adds to the thickness of the connector. As electronic devices continue to become smaller, there is an increasing demand for smaller plug connectors and corresponding receptacle connectors. 
     BRIEF SUMMARY OF THE INVENTION 
     Various embodiments of the invention pertain to a frame (sometimes referred to as a ground ring) that can be used in a plug connector to provide support for a plurality of external contacts on one or more sides of the frame. For example, a plug connector capable being of a reduced size may include a frame having features to support external contacts, house circuitry for coupling with the contacts, facilitate the flow of molten material during the molding of the frame, and allow for ease of insertion and removal of the plug connector to and from a corresponding receptacle connector. 
     Embodiments of the present invention may also provide methods for easily manufacturing the plug connector frames described herein. For example, methods are provided for metal injection molding processes for forming a plug connector frame that includes some or all of the features described above. Some of these methods may result in a plug connector frame having distinctive physical characteristics, including an outer layer with increased density, surface hardness and/or reduced porosity as compared to a remainder of the plug connector frame. 
     According to another embodiment, a frame for an electrical plug connector is provided. The frame can include a width, height and length dimension. The frame can include an insertion end configured to be inserted into an electrical receptacle connector corresponding to the electrical plug connector. The insertion end can include: (i) first and second opposing sides extending in the width and length dimensions where the first side can include a first opening and the second side including a second opening registered with and opposite the first opening, and (ii) third and fourth opposing sides extending between the first and second sides in the height and length dimensions. The frame can include a flanged end that includes a third opening that communicates with a cavity that extends in the length, width and height dimensions from the flanged end toward the insertion end past the first and second openings. The first, second, third and fourth sides of the insertion end each can include an outer layer that has a porosity less than a porosity of a remainder of each side; the outer layer at the first and second sides can be thinner than the outer layer at the third and fourth sides. 
     According to another embodiment, a method of manufacturing a frame for an electrical plug connector is provided. A metal injection molding process can be used to form a green part from a feedstock comprising metal and thermoplastic polymers; the green part can include: (i) a width, height and length dimension; (ii) an insertion end that can include first and second opposing sides extending in the width and length dimensions, the first side can include a first opening and the second side can include a second opening registered with and opposite the first opening, and third and fourth opposing sides extending between the first and second sides in the height and length dimensions; and (iii) a flanged end that can include a third opening that communicates with a cavity that extends in the length, width and height dimensions from the flanged end into the insertion end past the first and second openings. Thereafter, the green part can be debinded to form a brown part. Thereafter, the brown part can be sintered to form a metal part including the insertion end and flange end. Thereafter, the first and second sides of the insertion end of the metal part can be machined without machining the third and fourth sides of the insertion end. 
     Although aspects of the invention are described in relation to a ground ring or plug connector frame for a particular plug connector, it is appreciated that these features, aspects and methods can be used in a variety of different environments, regardless of the corresponding plug connector size or type. 
     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. 1A  illustrates a rendering of one particular electronic media device. 
         FIGS. 1B-1D  depict an eight contact in-line dual orientation plug connector that may include a ground ring or frame according to embodiments of the present invention. 
         FIGS. 2A-2F  depict plug connector  100  at the various stages of manufacture. 
         FIGS. 3A-3F  illustrate an ground ring or frame according to an embodiment of the present invention. 
         FIGS. 4A-4D  are cross sectional views that further illustrate the frame of  FIGS. 3A-3F . 
         FIGS. 5A-5C  illustrate side views of ground rings or frames according to embodiments of the present invention. 
         FIGS. 6A-6F  illustrate another ground ring or frame according to an embodiment of the present invention. 
         FIGS. 7A and 7B  are cross sectional perspective views of two opposing portions of the frame of  FIGS. 6A-6F . 
         FIG. 8A  illustrates an overview of a method of manufacture according to embodiments of the present invention. 
         FIG. 8B  illustrates sub-steps steps for performing each of the steps of the method of  FIG. 8A . 
         FIGS. 9A and 9B  illustrate frames having machined surfaces according to the present invention. 
         FIG. 10A  illustrates a simplified perspective view of a guide rail for routing frames according to embodiments of the present invention into contact with disks of a double-disk grinding machine. 
         FIG. 10B  illustrates a simplified top view of a guide rail routing frames into a double-disk grinding machine. 
     
    
    
     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. Examples of electronic devices that may be used with embodiments of the present invention are shown in the following figure. 
     I. Electronic Devices for Use with the Invention 
       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 a 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 among 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 ground rings or frames of the present invention, further context for the invention is provided in the following section by discussing a one particular plug connector in which the invention may be implemented. 
     II. Plug Connectors that May Include the Invention 
       FIGS. 1B-1D  depict an eight contact in-line dual orientation plug connector  100  that may include a ground ring or frame according to embodiments of the present invention.  FIG. 1B  is a simplified perspective view of plug connector  100  and  FIGS. 1C and 1D  are simplified top and bottom plan views, respectfully, of plug connector  100 . As shown in  FIG. 1B , plug connector  100  includes a body  42  and a tab or insertion end  44  that extends longitudinally away from body  42  in a direction parallel to the length of the connector. A cable  43  is attached to body  42  at an end opposite of Insertion end  44 . 
     Insertion end  44  is sized to be inserted into a corresponding receptacle connector, such as connector  35 , during a mating event and includes a first contact region  46   a  formed on a first major surface  44   a  and a second contact region  46   b  (not shown in  FIG. 1B ) formed at a second major surface  44   b  opposite surface  44   a . Surfaces  44   a ,  44   b  extend from a distal tip or end of the insertion end to a flanged end  109 . When insertion end  44  is inserted into a corresponding receptacle connector, surfaces  44   a ,  44   b  abut a housing of the receptacle connector or host device the receptacle connector is incorporated in. Insertion end  44  also includes a first side surface  44   c  opposite a second side surface (not shown in  FIG. 1B ), which surfaces extend between the first and second major surfaces  44   a ,  44   b . In some embodiments, insertion end  44  is between 4 and 7 mm wide, between 1 and 2 mm thick and has an insertion depth (the distance from the distal tip of insertion end  44  to flanged end  109 ) between 5 and 10 mm. 
     The structure and shape of insertion end  44  and flanged end  109  are defined by a ground ring or frame  105  that can be made from stainless steel or another conductive material. Plug connector  100  includes retention features  102   a ,  102   b  formed as curved recesses in the sides of ground ring  105 . Body  42  is shown in  FIG. 1B  in transparent form (via dotted lines) so that certain components inside the body are visible. As shown, within body  42  is a printed circuit board (PCB)  104  that extends into ground ring  105  between contact regions  46   a  and  46   b  towards the distal tip of plug connector  100 . One or more integrated circuits (ICs), such as Application Specific Integrated Circuit (ASIC) chips  108   a  and  108   b , can be operatively coupled to PCB  104  to provide information regarding plug connector  100  and any accessory or device that plug connector  100  is part of and/or to perform specific functions, such as authentication, identification, contact configuration and current or power regulation. 
     Bonding pads  110  can also be formed within body  42  near the end of PCB  104 . Each bonding pad can be connected to a contact or contact pair within regions  46   a  and  46   b . Wires (not shown) within cable  43  can then be soldered to the bonding pads to provide an electrical connection from the contacts to the accessory or device that plug connector  100  is associated with. Generally, there is one bonding pad and one wire within cable  43  for each set of electrically independent contacts (e.g., a pair of electrically connected contacts, one in region  46   a  and one in region  46   b ) of plug connector  100 . Additionally, one or more ground wires (not shown) from cable  43  can also be soldered or otherwise connected to frame  105  for a ground signal. 
     As shown in  FIGS. 1C and 1D , eight external contacts  106 ( 1 ) . . .  106 ( 8 ) are spaced apart along a single row in each of contact regions  46   a ,  46   b . Each contact in contact region  46   a  is electrically connected to a corresponding contact in contact region  46   b  on the opposite side of the connector. Contacts  106 ( 1 ) . . .  106 ( 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, plug connector  100  can be the plug connector portion of a plug connector/receptacle connector pair that can be the primary physical connector system for an ecosystem of products that includes both host electronic devices and accessory devices. Examples of host devices include smart phones, portable media players, tablet computers, laptop computers, desktop computers and other computing devices. An accessory can be any piece of hardware that connects to and communicates with or otherwise expands the functionality of the host. Many different types of accessory devices can be specifically designed or adapted to communicate with the host device through plug connector  100  to provide additional functionality for the host. Plug connector  100  can be incorporated into each accessory device that is part of the ecosystem to enable the host and accessory to communicate with each other over a physical/electrical channel when plug connector  100  from the accessory is mated with a corresponding receptacle connector in the host device. Examples of accessory devices include docking stations, charge/sync cables and devices, cable adapters, clock radios, game controllers, audio equipment, memory card readers, headsets, video equipment and adapters, keyboards, medical sensors such as heart rate monitors and blood pressure monitors, point of sale (POS) terminals, as well as numerous other hardware devices that can connect to and exchange data with the host device. 
     An example of how the elements of plug connector  100  are manufactured and assembled together is shown in the following figures. 
       FIGS. 2A-2F  depict plug connector  100  at the various stages of manufacture. The manufacture of plug connector  100  can start with the fabrication of ground ring or frame  105 , the construction of printed circuit board  104  and the construction of contact assemblies  116   a ,  116   b  each of which may occur independent of the others in any order. Frame  105  ( FIG. 2A ) may be fabricated using a variety of techniques, which will be discussed in detail below. 
     Printed circuit board  104  ( FIG. 2B ) can be formed with a set of bonding pads  110  formed at one end and a second set of bonding pads  112  formed at the opposing end. Bonding pads  110  can serve as a solder attachment point for wires from cable  43  as discussed above and can be formed on one or both sides of PCB  104  as needed for connections. Eight bonding pads  112  corresponding to the eight contacts  106 ( 1 ) . . . ( 8 ) are formed on each of the opposing top and bottom sides of PCB  104 . Additionally, a third set of bonding pads  114  can be formed on either or both sides of PCB  104  to electrically connector one or more integrated circuits, such as ICs  108   a ,  108   b , to the printed circuit board using a flip-chip or other appropriate connection method. 
     After ICs  108   a ,  108   b  are attached to the printed circuit board, PCB  104  is inserted through a back opening of frame  105  so that bonding pads  112  are positioned within opening  106 . Next, contact assemblies  116   a ,  116   b  ( FIG. 2D ) are positioned within the openings  106  on each side of frame  105 . Each contact assembly includes a frame  115  ( FIG. 2D ) that can be formed from a dielectric material such as polypropylene, and includes eight slots—one for each of contacts  106 ( 1 ) . . . ( 8 ). The contacts can be made from a variety of conductive materials and as examples, can be nickel-plated brass, stainless steel or palladium nickel. The contacts can be cut to size in a stamping or similar process from a metal sheet and placed in respective slots of each frame  115 . 
     The assembled ground ring/PCB/contact assembly structure ( FIG. 2E ) is then placed in a molding tool and a thermoplastic or similar dielectric overmold  118  can be formed around the contacts to provide smooth and substantially flat upper and lower surfaces of the tab or insertion end of plug connector  100  and provide a finished look ( FIG. 2F ). In one embodiment, dielectric overmold  118  is formed with an injection molding process using polyoxymethylene (POM). 
     A cable bundle (e.g., cable  43  shown in  FIG. 1B ) having individual signal wires (not shown), one for each of the functional contacts of plug connector  100  as well as one or more ground wires can be coupled to frame  105 . The individual signal wires are cut and stripped, the jacket of the cable bundle is stripped and the cable shields are folded back over the jacket. The cable bundle can then be attached to the frame/PCB assembly by soldering each of the signal wires to its respective bonding pad  110  and soldering ground wires to frame  105 . The solder joints and exposed wires can be potted with a UV glue to further secure the connections. 
     At this stage of manufacture the end of cable bundle (e.g., cable  43  shown in  FIG. 1B ) is attached to the PCB assembly via the soldered wires and a dielectric strain relief jacket (not shown) can be formed around the attachment point between cable  43  and PCB  104  encasing the portion of PCB  104  that extends out of frame  105  including ICs  108   a ,  108   b . The strain relief jacket can be formed using an injection molding or similar process. The construction of plug connector  100  can then be completed by sliding an outer enclosure around the strain relief jacket. The outer enclosure butts up against and is even with flanged end  109  of frame  105  forming body  42  of plug connector  100 . The outer enclosure can be formed from ABS or a similar dielectric material and adhered to the ground ring and inner jacket using any appropriate adhesive suitable for the particular materials being bonded. 
     As discussed above, although frame  105  is described in relation to one particular plug connector (plug connector  100 ), embodiments of the invention are suitable for a multiplicity of plug connectors that correspond to receptacle connectors for electronic devices, e.g., devices discussed above. 
     Frame  105  may include a number of features to accommodate the elements of plug connector  100  described above. In addition, embodiments of the present invention may include features to aid in manufacturing connectors and/or insertion and removal of a connector from a corresponding receptacle connector. Examples of these features are shown in the following figures. 
     III. Ground Ring Features 
       FIGS. 3A-3F  illustrate an ground ring or frame  300  according to an embodiment of the present invention.  FIGS. 3A-3D  are top, bottom, front and back views, respectively, of ground ring or frame  300  according to an embodiment of the present invention.  FIGS. 3E and 3F  are perspective views of frame  300 . Frame  300  may include a flanged end  305  and an insertion end  310  that extending longitudinally away from flanged end  305  in a direction parallel to the length dimension of frame  300 . 
     Insertion end  310  may be sized to be inserted into a corresponding receptacle connector during a mating invention and includes first and second openings  315   a ,  315   b  on first and second opposing major surfaces  320   a ,  320   b , respectively. In one embodiment, openings  315   a ,  315   b  are identically sized and shaped and directly opposite each other such that insertion end  310  may be a 180 degree symmetrical part. As shown in  FIGS. 3A-3B , openings  315   a ,  315   b  may be rectangular with rounded corners. In other embodiments, opening  315   a ,  315   b  may be otherwise shaped, e.g., the opening may be triangular, circular or irregularly shaped. Insertion end  310  also includes first and opposing side surfaces  325   a ,  325   b . Surfaces  320   a ,  320   b ,  325   a  and  352   b  extend from a distal tip or end  330  of insertion end  310  to flanged end  305 . When insertion end  310  is inserted into a corresponding receptacle connector, surfaces  320   a ,  320   b ,  325   a , and  325   b  may abut inner walls of a housing of a corresponding receptacle connector of a host device. In one particular embodiment, insertion end  310  is 6.6 mm wide in the width dimension, 1.5 mm thick in the height dimension and has an insertion depth (the distance from distal end  330  of insertion end  310  to flanged end  305 ) in the length dimension of 7.1 mm. 
     Frame  300  may include retention features  333   a ,  333   b  that are formed as curved recesses on surfaces  325   a ,  325   b , respectively, proximate distal end  330 . These retention features may engage with corresponding retention features disposed in a receptacle connector of a host device and aid in holding a plug connector that includes frame  300  within the receptacle connector. A flanged end surface  335  of flanged end  305  includes an opening  340  that communicates with a cavity that extends in the length, width and height dimensions. The cavity may be defined in part by inner left and right surfaces  350   a ,  350   b  and inner top and bottom surfaces  350   c ,  350   d . Opening  340  may be sized to receive a PCB (e.g., PCB  104  shown in  FIG. 2B ) that extends towards an inner end surface  345  proximate distal end  330  and between openings  315   a ,  315   b.    
     As shown in  FIGS. 3A and 3B , the widths  355   a ,  355   b  of openings  315   a ,  315   b , respectively, may be greater than the distance  360  between surfaces  350   a ,  350   b  thereby forming ledges  365   a ,  365   b  and  365   c  (shown in  FIGS. 4A and 4B ),  365   d , respectively. Ledges  365   a  and  365   d  may be defined by a first ridge (ridge  370   a  shown in  FIG. 4A ) and ledges  365   b  and  365   c  may be defined by a second ridge (ridge  370   b  shown in  FIG. 4B ). These ledges may be used to support contacts assemblies (e.g., contacts assemblies  116   a ,  116   b  shown in  FIG. 2D ) that are assembled with frame  300 . In some embodiments, ledges of frame  300  may define additional ridges for supporting contact assemblies. As discussed with regards to plug connector  100 , a thermoplastic may be formed around contacts assembled with frame  305 , e.g., by overmolding, such that the contacts assemblies are held in place relative to positioning ledges  365   a - 365   d.    
     Also shown in  FIGS. 3A-3F  are interlocks  375   a ,  375   b , which may further define the cavity of frame  300 . Interlocks  375   a ,  375   b  may be disposed on inner end surface  345 , protrude toward the third opening and have a thickness in the height dimension. Interlocks  375   a ,  375   b  may assist in preventing material overmolded around contacts assemblies assembled with frame  305  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. 
     Frame  300  also includes an outer end surface  380  that extend between surfaces  325   a ,  325   b . As shown in  FIGS. 3E and 3F , outer end surface  350  may be connected to surfaces  325   a  and  325   b  by rounded portions  385   a  and  385   b , respectively. Rounded portions  385   a ,  385   b  may serve to help guide a plug connector including frame  305  into a corresponding receptacle connector. For example, where a plug connector including frame  305  is moved towards a receptacle connector sized to receive the plug connector in a direction that is not aligned with the opening of the receptacle connector, rounded portions  385   a ,  385   b  may allow for a greater margin of error in aligning the plug connector for insertion into the opening of the receptacle connector. That is, rounded portions  385   a ,  385   b  of the plug connector may render the profile of frame  105  at distal end  300  smaller relative to the opening of the receptacle connector and thus easier to insert into the opening. Once frame  105  enters the cavity of the receptacle connector, rounded portion  385   a ,  385   b  may also guide the remainder of frame  105  as the rounded portions  385   a ,  385   b  interface with interior walls of the receptacle connector and cause the plug connector including frame  105  to become aligned with the opening of the receptacle connector. 
       FIGS. 4A-4D  are cross sectional views that further illustrate frame  300 .  FIGS. 4A and 4B  are cross sectional perspective views of two opposing portions of frame  300 .  FIGS. 4C and 4D  are also cross section views and provide side and partial perspective cross sectional views of frame  300 .  FIGS. 4A and 4B  illustrate a portion of the cavity of frame  300  as well as including inner surface  350   c , which was not visible in  FIGS. 3A-3F .  FIGS. 4A and 4B  also show that first and second opening  315   a  and  315   b  may include tapered sidewalls  390   a  and  390   b , respectively. Sidewalls  390   a  and  390   b  may extent into the cavity at a distance  391   a  and  391   b , respectively. Tapered sidewalls  390   a ,  390   b  are drafted at draft angle  392 . For example, draft angle  392  of tapered sidewalls  390   a ,  390   b  may be between 0 and 20 degrees or 5 and 20 degrees. In other embodiments, sidewalls  390   a ,  390   b  may be drafted at different angles, e.g., one may be drafted a 5 degrees and the other at 10 degrees. These tapered opening  315   a ,  315   b  may more readily receive and align contact assemblies, e.g., contacts assemblies  116   a ,  116   b.    
     As shown in  FIGS. 4C and 4D , the inner surfaces connecting insertion end  310  and flanged end  305  may include complex geometry. This may be due in part to the process by which frames according to the present invention may be formed. As discussed in greater detail below, frame  300  may be formed through a metal injection molding process wherein the molten material is injected into a mold through a portion of the mold corresponding to flanged end  305  of frame  300 . As such, this complex geometry may be designed to eliminate sharp corners near the flanged end  305  in order to optimize the flow of material injected into a mold in order to form frame  300 . 
     For example, flat inner surfaces  350   c  and a flat portion  394   a  of flanged end  305  may be connected by rounded portions  395   a  and  396   a . Flat inner surface  350   d  may also be connected to flat portion  394   b  by similar rounded portions (not clearly show in  FIG. 4C-4D ). Additionally, inner surface  350   a  may be connected to inner surfaces  350   c ,  350   d  by rounded portion  398   a  and  398   b , respectively. Similarly, inner surface  350   b  may be connected to inner surfaces  350   c ,  350   d  by rounded portions (only one rounded portion  398   c  is shown in  FIG. 4A-4D ). Rounded sections  397   a  may connected flat portion  394   a  to rounded portion  398   a  and rounded sections  397   b  may connect flat portion  394   b  to rounded portion  398   b . Similar rounded portions may connect flat portions  394   a ,  394   b  to rounded portions connecting surface  350   b  and surfaces  350   c ,  350   d , respectively (e.g., rounded portion  398   a ). 
     Although flanged end  305  is shown in  FIGS. 3A-3F  and  4 A- 4 D as having a particular geometry, other embodiments of the present invention may include a flanged end on a plug connector frame having other geometries. For example, a flanged end having a wider geometry is discussed below. A variety of otherwise shaped flanged ends may also be suitable for the present invention as flanged end  305  may not be intended to be inserted into a receptacle connector such that it would have to conform to any particular geometry of the corresponding receptacle connector. 
     In addition to those features described above in relation to  FIGS. 3A-3F  and  4 A- 4 D, frames according to the present invention may include other features instead of or in addition to those features previously described herein. Examples of these additional features are shown in the following figures. 
       FIGS. 5A-5C  illustrate side views of ground rings or frames according to embodiments of the present invention. As shown in  FIG. 5A , a frame  500  may include a flanged end  505  and an insertion end  510  that extends longitudinally away from flanged end  505  in a direction parallel to the length dimension of frame  500 . Insertion end  510  may include first and second opposing major surfaces  515   a ,  515   b , respectively. Surfaces  515   a ,  515   b  may include curved lead-ins  520   a ,  520   b  proximate the distal end of frame  500 . Curved lead-ins  520   a ,  520   b  may connect an outer end surface  516  with first and second opposing surfaces  515   a ,  515   b , respectively. The curved lean-in feature may render the plug connector in which frame  500  is implemented more readily insertable into a corresponding receptacle connector. In some embodiments, frame  500  may only include curved lead-in  520   a  while others may only include curved lead-in  520   b.    
       FIG. 5B  illustrates an embodiment of a frame  530  that does not include the curved lead-in feature of frame  500 . Instead, frame  530  includes flat first and second opposing major surfaces  545   a ,  545   b  of insertion end  540  that connect with an outer end  546 . This design may be desirable where the curved lean-in describes with reference to  FIG. 5A  is not useful or otherwise not appropriate for a given situation. 
       FIG. 5C  illustrates yet another embodiment of a frame  550  including drafted surfaces. In this embodiment, insertion end  560  includes first and second opposing major surfaces  570   a ,  570   b  that are drafted at draft angle  575 . Draft angle  575  may range between about 0.1 to 1.0 degrees, e.g., 0.5 or 0.25 degrees. In some embodiments only one of surfaces  570   a ,  570   b  may include a draft angle. In other embodiments, other surfaces of frame  530  may be drafted in addition to or instead of surfaces  570   a ,  570   b . Drafted surfaces  570   a ,  570   b  may result from the method of manufacture as described below. 
     As discussed above, the flanged end of frames according to the present invention may vary from those embodiments illustrated in  FIGS. 3A-3F  and  4 A- 4 D. An example of one particular flanged end variation is shown in the following figures. 
       FIGS. 6A-6F  illustrate a ground ring or frame  600  according to an embodiment of the present invention.  FIGS. 6A-6D  are top, bottom, back and front views, respectively, of ground ring or frame  600  according to an embodiment of the present invention.  FIGS. 6E and 6F  are perspective views of frame  600 . Similar to frame  300  discussed above, frame  600  may include a flanged end  605  and an insertion end  610  that extends longitudinally away from flanged end  605  in a direction parallel to the length dimension of frame  600 . Insertion end  610  may include first and opposing major surfaces  620   a ,  620   b . Insertion end  610  may include all the same features and incorporate also the same variations as described above with regards to insertion end  310  (shown in  FIGS. 3A-3F ). However, flanged end  605  may include a number of variations not specifically discussed above with regards to flanged end  305 . 
     As shown in  FIGS. 6A-6F , flanged end  605  may be wider in the width dimension than flanged end  305  and include geometry such as wings  605   a ,  605   b  connected by a base portion  605   c . The wider flanged end  605  may help spread the load when torque is applied to insertion end  610 . Depending on the particular application of a plug connector, frame  600  may help prevent damage to a plug connectors including frame  600  and corresponding receptacles mated with frame  600  when torque is applied to the plug connector. 
       FIGS. 7A and 7B  are cross sectional perspective views of two opposing portions of frame  600 .  FIGS. 7A and 7B  illustrate a portion of the cavity and inner surfaces of frame  600 , some of which may not have been visible in  FIGS. 6A-6F . As shown in  FIGS. 7A and 7B , the inner surfaces of flanged end  605  may be tapered. As with the geometry of the inner surfaces of flanged end  305 , the geometry of the inner surfaces of flanged end  605  may be due in part to the process by which frames according to the present invention may be formed. Frame  600  may also be formed through a metal injection molding process wherein the molten material is injected into a mold through a portion of the mold corresponding to flanged end  605  of frame  600 . As such, this tapered geometry may be designed to eliminate sharp corners near the flanged end  605  in order to optimize the flow of material injected into a mold in order to form frame  600 . 
     For example, as shown in  FIGS. 7A and 7B , flanged end  605  may include tapered first and second opposing surfaces  694   a ,  694   b  and tapered third and fourth opposing surfaces  694   c ,  694   d . The tapered surfaces may connect with corresponding inner surfaces of insertion end  610 , e.g., third and fourth opposing inner surfaces  650   c ,  650   d  (shown in  FIG. 6D ) and first and second opposing inner surfaces  650   a  (shown in  FIG. 6E ),  650   b . Tapered sidewalls  694   a - 694   d  may be drafted at draft angle  695 . For example, draft angle  695  of tapered sidewalls  694   a - 694   d  may be between 5 and 35 degrees or 10 and 30 degrees. In some embodiments, sidewalls  694   a - 694   d  may be drafted at different draft angles, e.g., some may have a draft angle of 17 degrees and the others 10 degrees. 
     Although flanged end  605  is shown in  FIGS. 6A-6F  and  7 A- 7 B as having a particular geometry, other embodiments of the present invention may include a other wider or narrower flanged end geometries. A variety of variable thickness, width and height flanged ends may be included in embodiments of the present invention. 
     Ground rings or frames described herein, e.g., frames  300  and  600 , may be made from a variety materials including metals, dielectrics or a combination thereof. For example frames according to the present invention may be made from stainless steel or conductive polymers. In some embodiments, frames according to the present invention may be may made from a single piece of electrically conductive material, .e.g., stainless steel  630 . 
     As discussed above, frame designs of the present invention may take into account the their method of manufacture. A number of different methods of manufacturing frames of the present invention may be suitable for frames of the invention. Examples of these methods are shown in the following figures. 
     IV. Methods of Manufacture 
     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 of the invention. 
       FIG. 8A  illustrates an overview of a method of manufacture according to embodiments 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 inventions or the claims. 
     As shown in  FIG. 8A , method  800  includes three general steps. At the first step, step  810 , a MIM process is performed in order to form a metal part. At step  820 , select surfaces of the metal part are machined. Lastly, at step  830 , 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 frames  300  and  600  described above. 
       FIG. 8B  illustrates sub-steps steps for performing each of the steps of method  800 . Examples of these sub-steps are discussed below. 
     MIM step  810  includes three sub-steps: steps  812 ,  814  and  816 . At step  812 , 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 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 power may be an atomized steel power, 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 step  814 , 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 step  816 , 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. 
     The MIM process may also result in parts having a number of characteristics typically associated with the MIM process. For example, the outer surfaces of frames, e.g., embodiments of frames  300  and  600  described above, manufactured according to step  810  may include an outer skin layer or outer layer that has different properties than a remainder of the frame. For example, surfaces  320   a ,  320   b ,  325   a ,  325   b  and  340  (shown in  FIGS. 3A-3F ) all may include an outer layer that has different properties than a remainder of material below the outer layer where frame  300  is formed by a MIM process (e.g., step  810 ). The remainder material of a given side may extend between an outer layer on an outer surface or side, e.g.,  320   a , and an outer layer on a corresponding inner surface or side of the frame, e.g., surface  350   c  may correspond to outer surface  320   a . The outer layer may have a thickness of less than around 1000 microns and between 200 and 800 microns in some embodiments. 
     The outer layer of a given side surface may have a porosity less than the porosity of remainder material of the side. Additionally, the outer layer of a given side may also have a greater density and/or greater surface hardness than the remainder of the side. In some embodiments, outer layers of surfaces of frames may possess all three or some combination thereof of the characteristics described above—decreased porosity, increase density, and increased surface hardness—relative to the remainder of each respective surface or side. 
     In some embodiments, implementing a MIM process, e.g., step  810  above, to produce a frame may be desirable because it provides flexibility in achieving a desired geometry and can result in a molded part that is close to the final desired shape, which in turn, may require less machining. Machining may still be required for some features, e.g., retention features, but these may be easily machined into the sides of the ground ring or frame after it is formed and then surfaces of the ground ring or frame can be smoothed using blasting process and then plated, as described above. 
     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. 
     At the conclusion of the MIM process (step  810 ), surfaces of the frame may be machined at step  820 . For example, at step  822 , surfaces of the insertion end (e.g.,  310 ,  610  above) may be machined. And at step  824 , surfaces of the flanged end may be machined. A further discussion regarding which surfaces are machined, why those surfaces are machined, and the resulting characteristics of the machined surfaces with be discussed in detail below with regards to  FIGS. 9A and 9B . The machining of step  820  may be accomplished by a CNC machine, a grinding machine or other suitable machinery. 
     At the conclusion of the machining operation (step  820 ), finishing operation may be performed on the frame at step  830 . For example, at step  832 , the frame may enter a sandblasting machine and/or a tumbling machine. In some embodiments, the media tumbling may be performed before the blasting. These machines may be used to removes burrs from the frame and polish the surface of the frame. At step  834 , a plating operation may be performed on the frame. For example, a nickel plating operation may be implemented. In some embodiments, the plating process may be a nickel electroplating process using nickel sulfate or an electroless nickel plating process, e.g., high phosphorus electroless nickel. For nickel electroplating, the plating process may include a number of steps such as electrolytic degreasing, rinsing with pure water, activating acid, rinsing with pure water, nickel pre-plating, rinsing with pure water, nickel plating, rinsing with pure water, rinsing with hot pure water, cooking in an oven, and drying on a counter. Alternatively, other standard nickel electroplating processes and electroless nickel plating processes may be used at step  834 . 
     As mentioned above, the machining of the frame in method  800  may only pertain to specific surfaces of the insertion and flanged ends of a frame. Examples of machining step  820  are included in the following figures. 
       FIGS. 9A and 9B  illustrate frames  905  and  910  having machined surfaces according to the present invention. Machining surfaces of a frame may serve a number of functions, including reducing or eliminating the draft angle of drafted surfaces (e.g., surfaces  570   a ,  570   b ), providing a cosmetic finish, reducing surface roughness, and/or more precisely controlling tolerances of frames formed in a MIM process. 
       FIG. 9A  illustrates a frame  905  manufactured according to embodiments of step  810  above and having machined surfaces as indicated by hatch patterns. Frame  905  includes first and second major opposing surfaces  915   a  and  915   b  (not shown in  FIG. 9A ) as well as first and second opposing side surfaces  916   a  and  916   b  (not shown in  FIG. 9A ). Frame  905  may also include a flanged end surface  920  surrounding opening  921 . 
     In some embodiments, surfaces  915   a ,  915   b  may be machined according to step  820  (as indicated by a first hatch pattern) while surfaces  916   a ,  916   b  may not be machined. For example, the outer layers (as defined in above with reference to step  816 ) of surfaces  915   a ,  915   b  may be machined to reduce their respective outer layer thicknesses by 10-200 microns. Accordingly, in this embodiment, the outer layers of surfaces  916   a ,  916   b  may be thicker than the outer layers of  915   a ,  915   b . As mentioned above, machining a surface may reduce its surface roughness. Accordingly, surfaces  915   a ,  915   b  may have a surface roughness that is less than the surface roughness of surfaces  916   a ,  916   b . Again, the machining of surfaces  915   a ,  915   b  may also be used to remove the draft on those surfaces. 
     Alternatively, or in addition to the machining of surfaces  915   a  and  915   b , flanged end surface  920  may be machined to reduce its outer layer thickness by 50-300 microns (as indicated by a second hatch pattern). The machining of surface  920  may aid in achieving tighter tolerances for frame  900  such that it may be fitted in custom overmolding tooling for additional assembly steps as described above. In addition, the surface roughness of flanged end surface  320  may be decreased. 
       FIG. 9B  illustrates a frame  910  manufactured according to embodiments of step  810  above and having machined surfaces  925   a ,  930  as denoted by hatch patterns. Similar to frame  905 , frame  910  may include machined surfaces as described with reference to  FIG. 9A . However, a flanged end surface  930  including opening  931  may be machined to reduce its outer layer according to a range of smaller values than that of outer flange surface  920  of  FIG. 9A . For example, flanged end surface  930  may be machined to reduce its outer layer by 10-200 microns, instead of 50-300 microns. 
     Although  FIGS. 9A and 9B  illustrate particular surfaces of frames  905  and  910  are machine and machined to reduce the thickness outer layers of surfaces by particular amounts, other embodiments of the present invention may include frames having different surfaces machined and/or outer layer thicknesses reduced by different amounts. 
     As mentioned above, the machining of step  820  may be accomplished by a number of different machining tools. One particular machining method using a double-disk grinding machine will be described in greater detail in relation to the following figures. 
       FIG. 10A  illustrates a simplified perspective view of a guide rail  1000  for routing frames according to embodiments of the present invention into contact with disks of a double-disk grinding machine. Guide rail  1000  may include supports  1005  for coupling frames  1010  to guide rail  1000 . Retention features  1015   a ,  1015   b  may secure frames  1010  on supports  1005 . Supports  1005  may orient frames  1010  in vertical direction with respect to feed direction  1020  of guide rail  1000 . Supports  1005  may also position frames  1010  relative to a double-disk grinding machine (shown in  FIG. 13 ) such that only the insertion end or portion  1025  of frame  1010  is machined by the double-disk grinding machine during a grinding operation by the double-disk grinding machine. A flanged end or portion  1030  may be positioned by guide rail  1000  such that it does not come into contact with the double-disk grinding machine while the insertion portion is being machined. 
       FIG. 10B  illustrates guide rail  1000  routing frames into a double-disk grinding machine  1040 . Double-disk grinding machine  1040  includes first and second grinding disks  1040   a ,  1040   b . When fed into grinding machine  1040 , front and back sides  1010   a ,  1010   b  of insertion portion  1025  (shown in  FIG. 10A ) of frame  1010  are simultaneously machined by disks  1040   a ,  1040   b , respectively. As discussed above, the flanged end  1030  (as shown in  FIG. 10A ) is positioned by guide rail  1000  such that it is not machined by grinding machine  1040  while the insertion end  1025  (shown in  FIG. 10A ) is being machined. 
     The double disk grinding machine arrangement described above may allow for high-volume production of frames of the present invention that require the machining of their insertion ends. Although  FIGS. 10A-10B  are illustrated and described as only allowing for the machining of the insertion end of a frame according to the present invention, other embodiment may modify this arrangement so as to machine other surfaces of the frames of the invention. 
     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. For example, some specific embodiments of the invention set forth above were illustrated with specific types of frames for plug connectors. A person of skill in the art will readily appreciate that any of the other types of plug connectors described herein may include frames of the invention having the features described herein, and may be manufactured according to the methods of manufacture specifically mentioned herein and various embodiments thereof. 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: 20150609
Grant Date: 20150609
Priority Date: 20120911
Inventors: BRICKNER MICHAEL
COWAN WAYNE
ROSENTHAL BRETT A.
HELEY RICHARD
SCHMIDT MATHIAS W.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/659", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "B22F2998/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F3/225", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "B22F3/162", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F5/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F3/225", "inventive": true, "first": false, "tree": "[]"}, {"code": "B22F3/1021", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F3/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F3/225", "inventive": true, "first": false, "tree": "[]"}, {"code": "B22F5/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "B22F3/225", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": true, "tree": "[]"}, {"code": "B22F2998/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "B22F2998/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/659", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/659", "inventive": false, "first": false, "tree": "[]"}, {"code": "B22F5/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 50277478