PATENT DOCUMENT

Publication Number: US-9899757-B2
Application Number: US-201514845084-A
Country: US
Kind Code: B2

Title: Surface connector with silicone spring member

Abstract:
Contact structures for devices, where contacts in the contact structures provide a proper normal force while consuming a minimal amount of surface area, depth, and volume in a device and where the contact structures prevent or limit the ingress of fluid or debris into the device. On example may provide a contact structure having a frame. The frame may be arranged to be placed in an opening in a device enclosure for an electronic device or the frame may be part of the electronic device. The frame may include a number of passages, each passage for a contact of the contact structure. Each contact may be held to the frame by a pliable membrane. Each contact may connect to a board in the electronic device via a compliant conductive path.

Claims:
What is claimed is: 
     
       1. A contact structure comprising:
 a frame having a plurality of passages from a top of the frame to a bottom of the frame, each passage having an inside edge, wherein the frame is nonconductive; 
 a plurality of contacts, each contact having a top surface, a bottom surface, and an outside edge-and located in one of the plurality of passages; and 
 a plurality of pliant membranes, each between the outside edge of one of the plurality of contacts and the inside edge of a passage such that at least a portion of a top surface and at least a portion of a bottom surface of the contact are exposed. 
 
     
     
       2. The contact structure of  claim 1  wherein a top surface of each of the plurality of contacts is circular. 
     
     
       3. The contact structure of  claim 1  wherein the outside edge of each of the plurality of contacts and an adjacent inside edge of each of the plurality of pliant membranes each comprise first interlocking features that interlock to secure the plurality of contacts in place in the plurality of pliant membranes. 
     
     
       4. The contact structure of  claim 3  wherein an outside edge of each of the plurality of pliant membranes and the inside edge of each of the plurality of passages each comprise second interlocking features. 
     
     
       5. The contact structure of  claim 4  wherein the first interlocking features include a first notch located circumferentially around the outside edge of each of the plurality of contacts and a first tab on the adjacent inside edge of each of the plurality of pliant membranes. 
     
     
       6. The contact structure of  claim 5  wherein the second interlocking features include a second notch located circumferentially around the inside edge of each passage and a second tab on the outside edge of each of the plurality of pliant membranes. 
     
     
       7. The contact structure of  claim 6  wherein the frame is formed using one of a liquid crystal polymer (LCP), glass-filled nylon, aluminum, or ceramic. 
     
     
       8. The contact structure of  claim 6  wherein the plurality of pliant membranes are formed of silicone or rubber. 
     
     
       9. The contact structure of  claim 6  wherein the plurality of pliant membranes are nonconductive. 
     
     
       10. The contact structure of  claim 6  wherein the contacts are formed of copper, a copper-nickel alloy, or stainless steel. 
     
     
       11. The contact structure of  claim 6  wherein the top surfaces of the contacts are circular, oval, or square. 
     
     
       12. The contact structure of  claim 1  further comprising a plurality of compliant conductive paths, each from one of the plurality of contacts to a board. 
     
     
       13. The contact structure of  claim 12  wherein each of the plurality of compliant conductive paths are a wire, spring, or spring-loaded contact. 
     
     
       14. The contact structure of  claim 1  wherein the frame is part of a device enclosure for an electronic device housing the contact structure. 
     
     
       15. An electronic device comprising:
 a housing, the housing having an opening, the opening having an inside edge; and 
 a contact structure located in the opening in the housing and comprising:
 a frame having an outside edge and further having a plurality of passages from a top of the frame to a bottom of the frame, each passage having an inside edge; 
 a plurality of contacts, each contact having a top surface, a bottom surface, and an outside edge, and located in one or the plurality of passages; and 
 a plurality of first pliant membranes, each between an outside edge of one of the plurality of contacts and an inside edge of a passage such that at least a portion of a top surface and at least a portion of a bottom surface of the contact are exposed, 
 wherein the outside edge of each of the plurality of contacts and adjacent inside edges of the plurality of first pliant membranes each comprise interlocking features that interlock to secure the plurality of contacts in place in the plurality of first pliant membranes. 
 
 
     
     
       16. The electronic device of  claim 15  wherein the frame is nonconductive. 
     
     
       17. The electronic device of  claim 15  further comprising an insert molded membrane between the inside edge of the opening in the housing and the outside edge of the frame. 
     
     
       18. The electronic device of  claim 15  further comprising a second pliant membrane between the inside edge of the opening in the housing and the outside edge of the frame. 
     
     
       19. The electronic device of  claim 15  wherein the interlocking feature on the outside edge of each of the plurality of contacts comprises a first notch located circumferentially around the contact. 
     
     
       20. The electronic device of  claim 19  wherein the interlocking feature on the adjacent inside edge of each of the plurality of first pliant membranes includes a first tab to fit in the first notch in the outside edge of each contact. 
     
     
       21. The electronic device of  claim 20  wherein the inside edge of each passage includes a second notch and each first pliant membrane has a second tab to fit in the second notch in the inside edge of each passage. 
     
     
       22. The electronic device of  claim 21  wherein the inside edge of the opening in the housing and the outside edge of the frame include interlocking features to secure the frame in place in the housing. 
     
     
       23. A contact structure comprising:
 a frame having a plurality of passages from a top of the frame to a bottom of the frame, each passage having an inside edge; 
 a plurality of contacts, each contact having a top surface, a bottom surface, and an outside edge and located in one or the plurality of passages; and 
 a plurality of pliant membranes, each between an outside edge of one of the plurality of contacts and an inside edge of a passage such that at least a portion of a top surface and at least a portion of a bottom surface of the contact are exposed, 
 wherein the outside edge of each of the plurality of contacts and adjacent inside edges of the plurality of pliant membranes comprise interlocking features that interlock to prevent the plurality of contacts from being pushed out of the plurality of pliant membranes. 
 
     
     
       24. The contact structure of  claim 23  wherein a top surface of each of the plurality of contacts is circular. 
     
     
       25. The contact structure of  claim 23  wherein the frame is nonconductive. 
     
     
       26. The contact structure of  claim 23  wherein the interlocking feature on the outside edge of each of the plurality of contacts comprises a first notch located circumferentially around the contact. 
     
     
       27. The contact structure of  claim 26  wherein the interlocking feature on the adjacent inside edge of each of the plurality of pliant membranes includes a first tab to fit in the first notch in the outside edge of each contact.

Description:
BACKGROUND 
     The number of types of electronic devices that are commercially available has increased tremendously the past few years and the rate of introduction of new devices shows no signs of abating. Devices, such as tablet, laptop, netbook, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors, and others, have become ubiquitous. 
     Power and data may be provided from one device to another over cables that may include one or more wire conductors, fiber optic cables, or other conductor. Connector inserts may be located at each end of these cables and may be inserted into connector receptacles in the communicating or power transferring devices. In other systems, contacts on the devices may come into direct contact with each other without the need for intervening cables. 
     In systems where contacts on two electronic devices come into contact with each other, it may be difficult to generate enough normal force to ensure a good electrical connections between contacts in the two devices. To provide a sufficient normal force, contacts may often have a substantial depth and consume a relatively large volume of space in the electronic device. The loss of this space may mean that the electronic device is either larger or only includes a reduced set of functionality. 
     Connector systems in general may inadvertently provide paths for the ingress of moisture, liquids, or other fluids. These connector systems may also provide pathways whereby external dust or particulate matter may reach an interior of an electronic device. 
     Thus, what is needed are contact structures for devices, where contacts in the contact structures provide a proper normal force while consuming a minimal amount of surface area, depth, and volume in a device and where the contact structures prevent or limit the ingress of fluid or debris into the device. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide contact structures for devices, where contacts in the contact structures provide a proper normal force while consuming a minimal amount of surface area, depth, and volume in a device and where the contact structures prevent or limit the ingress of fluid or debris into the device. 
     An illustrative embodiment of the present invention may provide a contact structure having a frame. The frame may be arranged to be placed in an opening in a device enclosure for an electronic device or the frame may be part of the electronic device. The frame may include a number of passages, each passage for a contact of the contact structure. Each contact may be held to the frame by a pliable membrane. Each contact may connect to a board in the electronic device via a compliant conductive path. 
     In these and other embodiments of the present invention, the frame may be formed of a liquid crystal polymer (LCP), glass-filled nylon, aluminum, ceramic, or other material. The pliable membrane may be formed of silicone, rubber, or other pliable material. The pliable membrane may be formed by insert molding or other appropriate method. At least one of the frame or pliable membrane may be nonconductive. The contacts may be copper, stainless steel, or other conductive material. The contacts may be circular, oval, square, or they may have another shape. The contacts may be formed by machining, stamping, or other appropriate method. The compliant conductive path may be a wire, spring, spring-loaded contact, and may be formed using copper, a copper-nickel alloy such as NKC388, or other material. 
     The contacts may be fixed in position in passages in the frames in various ways. In an illustrative embodiment of the present invention, a contact may be formed as a disk, where a circular outside edge of the disk is supported by a pliant membrane. The disk may have a notch in the circular edge. The pliant membrane may have a corresponding tab that fits into the notch in the side of the disk. In these and other embodiments of the present invention, the frame may have a similar notch in each passage and the pliant membrane may have a second tab fit into the frame notch. This arrangement may secure the contact to the frame and prevent the contact from being pushed out of the frame when contact is made with a second contact on a second electronic device. This arrangement may provide contacts having a minimal depth. These contacts may also consume a limited amount of surface area. The volume in a device that is consumed by these contacts may thus be limited. 
     The contacts may be fixed in position in passages in the frames in other ways as well. For example, a contact may have a wider top and a narrower lower or base portion. This may simplify manufacturing of the contact. The contact may then be held in place with a pliant membrane that has a narrower top portion and a wider base. The wider base may secure the contact to the frame and prevent the contact from being pushed out of the frame when contact is made with a second contact on a second electronic device. 
     In various embodiments of the present invention, the contact frames may be attached to a device enclosure for an electronic device in various ways. In an embodiment of the present invention, a frame may be attached to a device enclosure using an insert molded membrane. This insert molded membrane may hold the frame rigidly relative to the device enclosure. In another embodiment of the present invention, a frame may be attached to a device enclosure using a second pliable membrane. This may allow the contact structure to move relative device enclosure. Either the frame or the device enclosure, or both, may have a notch in a face at the frame-to-device interface. The insert molded membrane may have a tab in either or both of these notches. These tabs and notches may secure the frame to the device enclosure such that the frame is not pushed out of the device enclosure when contact is made with a second contact on a second electronic device. In other embodiments of the present invention, the frame may be formed as part of a device enclosure for an electronic device. 
     Embodiments of the present invention may provide contact structures that may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These contact structures may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system according to an embodiment of the present invention; 
         FIG. 2  illustrates a contact structure according to an embodiment of the present invention; 
         FIG. 3  illustrates an example of interlocking features that may be used to secure a contact in a frame of a contact structure according to embodiment of the present invention; 
         FIG. 4  illustrates a side view of a contact structure according to an embodiment of the present invention; 
         FIG. 5  illustrates a side view of a contact structure according to an embodiment of the present invention; 
         FIG. 6  illustrates a side view of a contact structure in a portion of a device housing according to an embodiment of the present invention; 
         FIG. 7  illustrates a side view of a contact structure and a portion of a device housing according to an embodiment of the present invention; and 
         FIG. 8  illustrates a side view of a contact structure in a portion of a device housing according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates an electronic system according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, the host device  110  may be connected to accessory device  120  in order to share data, power, or both. Specifically, contacts  112  on host device  110  may be electrically connected to contacts  122  on accessory device  120 . Contacts  112  on host device  110  may be electrically connected to contacts  122  on accessory device  120  via cable  130 . In other embodiments of the present invention, contacts  112  on host device  110  may be directly and electrically connected to contacts  122  on accessory device  120 . 
     To facilitate a direction connection between contacts  112  on host device  110  and contacts  122  on accessory device  120 , contacts  112  may be part of a surface mount contact structure. An example of a surface mount contact structure that may include contacts  112  is shown in the following figure. 
       FIG. 2  illustrates a contact structure according to an embodiment of the present invention. This contact structure may include a frame  210  having an outside edge  213 . Contacts  112  may be placed in passages in frame  210 . Membranes  220  may hold contacts  112  in place in frame  210 . Contacts  112  may electrically connect to traces (not shown) on a board  250  via compliant conductive paths  240 . 
     In these and other embodiments of the present invention, frame  210  may be formed of a liquid crystal polymer (LCP), glass-filled nylon, aluminum, ceramic, or other material. Pliable membrane  220  may be formed of silicone, rubber, or other pliable material. Pliable membrane  220  may be formed by insert molding or other appropriate method. At least one of the frame  210  or pliable membrane  220  may be nonconductive. Contacts  112  may be copper, stainless steel, or other conductive material. Contacts  112  may be circular, oval, square, or they may have another shape. Contacts  112  may be formed by machining, stamping, or other appropriate method. The compliant conductive paths  240  may be wires, springs, spring-loaded contacts, and may be formed using copper, a copper-nickel alloy such as NKC388, or other material. 
     In this example, three contacts  112  are shown in a contact structure. In various embodiments the present invention, one contact may be used to convey a signal, one may be used to convey power, while another may be used for ground. Signals on a signal contact may be provided or received by an electronic device housing this contact structure. Power on a power contact may be provided or received by the electronic device housing this contact structure. 
     When corresponding contacts are brought into physical and electrical contact with contacts  112 , pliable membrane  220  may deflect in response to an applied force, represented here as corresponding contact  230 . This deflection may create a normal force in response to the force applied by corresponding contact  230 . 
     As a force is applied by contacts  230 , it may be desirable that contacts  112  are not pushed through frame  210 . Accordingly, various features, such as interlocking features, may be used to hold contacts  112  in place in frame  210 . An example is shown in the following figure. 
       FIG. 3  illustrates an example of interlocking features that may be used to secure a contact in a frame of a contact structure according to embodiment of the present invention. Again, contacts  112  may be located in passages  211  in frame  210 . The passages  211  may be formed as openings from a top side of frame  210  to a bottom side of frame  210 . Contacts  112  may include notches  302 . Pliable membrane  220  may include tabs  222  that fit in notches  302 . These interlocking features may help to secure contacts  112  in place in pliable membrane  220 . Notch  302  may be formed in an outside edge of contact  112 . Notch  302  may be formed completely around contacts  112 , or it may be limited to certain locations along an outside edge of contact  112 . 
     Similarly, an inside edge of passage  211  may include notch  212 . Pliable membrane  220  may include tabs  224  that fit in notches  212 . Again, these interlocking features may help secure pliable membrane  220  in place in passages  211  of frame  210 . Taken together, interlocking features including notches  302  and  212 , and tabs  222  and  224 , may secure contacts  112  in place in frame  210 . Also, this configuration may help to prevent or reduce liquid or debris ingress into the electronic device housing this contact structure. As with notch  302 , notch  212  may be located all the way around and inside edge of passage  211 , or it may be limited to certain locations along the inside edge of passages  211  in frame  210 . 
     This contact structure may be formed in various ways. For example, frame  210  may be formed. Contacts  112  may be formed, for example, by machining or stamping. Contacts  112  may be held in place in passages of frame  210  while silicone or other material is insert molded between contacts  112  and sidewalls of passages in frame  210 . This arrangement may provide a contact having a limited footprint or surface area, as well as a limited depth. This combination may help to reduce a volume of a device consumed by this contact structure. 
       FIG. 4  illustrates a side view of a contact structure according to an embodiment of the present invention. Contacts  112  may include notches  302 . Similarly, frame  210  may include notches  212 . Pliable membranes  220  may be formed using insert molding or similar technique to fill notches  302  and  212  with tabs  222  and  224 . As before, contact  112  may be electrically connected to traces on board  250  using compliant conductive paths  240 . 
     In various embodiments of the present invention, other interlocking features may be used to secure contacts  112  in place in frame  210 . An example is shown in the following figure. 
       FIG. 5  illustrates a side view of a contact structure according to an embodiment of the present invention. In this example, contacts  112  may have a wide upper portion  512  and a narrower lower portion  514 . Pliable membrane  220  may include a narrow upper portion  522  and a wider lower portion  524 . In this way, as a downward force is applied to contact  112 , contact  112  is held in place relative to pliable membrane  220 . 
     Frame  210  of the contact structures in these in other embodiments of the present invention may be formed as part of a device enclosure housing an electronic device. In other embodiments the present invention, the device enclosure may have an opening and frame  210  of the contact structure may be placed in that opening. Frame  210  may be secured in the opening in the device housing in various ways. Examples are shown in the following figure. 
       FIG. 6  illustrates a side view of a contact structure in a portion of a device housing according to an embodiment of the present invention. In this example, contact  112  may be secured to frame  210  by pliable membrane  220 . Frame  210  may be secured to housing  610  by membrane  620 . Membrane  620  may be rigid or pliable. Membrane  620  may be formed by insert molding or other techniques. Membrane  620 , as with membrane  220 , may help to prevent the ingress of moisture, debris, or other matter into an electronic device housing this contact structure. 
     As with contacts  112  in frame  210 , interlocking features may be used to secure frame  210  to device housing  610 . This may prevent frame  210  from being pushed into the electronic device when contact is made with a second electronic device. An example is shown in the following figure. 
       FIG. 7  illustrates a side view of a contact structure and a portion of a device housing according to an embodiment of the present invention. In this example, frame  210  may include notch  218  in an outside wall. Similarly, device housing  610  may include notch  612  in an inside wall of an opening. Tabs  622  and  624  of membrane  620  may be located in notches  612  and  218 . These interlocking features may help to secure frame  210  to device housing  610 . As before, contacts  112  may be electrically connected to traces on board  250  through compliant conductive paths  240 . 
     Again, in the above examples, membranes  620  and  220  may be used to provide protection from moisture and particulate or debris ingress into an electronic device. In other embodiments of the present invention, other structures may be used to prevent such ingress. An example is shown in the following figure. 
       FIG. 8  illustrates a side view of a contact structure in a portion of a device housing according to an embodiment of the present invention. In this example, frame  210  and device housing  610  may have a gasket or O-ring  810  placed between them. This gasket or O-ring  810  may be secured in place using a glue, silicone, or other adhesive. Gasket or O-ring  810  may provide protection against moisture or debris ingress into an electronic device incorporating this contact structure. As before, contacts  112  may be secured to frame  210  using pliable membranes  220 . Contacts  112  may be electrically connected to traces on board  250  using compliant conductive paths  240 . 
     Embodiments of the present invention may provide contact structures that may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These devices may include contact structures that may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, HDMI, DVI, Ethernet, DisplayPort, Thunderbolt, Lightning, JTAG, TAP, DART, UARTs, clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20150903
Publication Date: 20180220
Grant Date: 20180220
Priority Date: 20150903
Inventors: DO TRENT K.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/42", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/08", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/08", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2428", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/521", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2428", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/42", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 58191151