PATENT DOCUMENT

Publication Number: US-8845363-B2
Application Number: US-201213607528-A
Country: US
Kind Code: B2

Title: Reinforcing bars in I/O connectors

Abstract:
Reinforcing bars or a reinforcing element with holes can be embedded within the shell of a receptacle connector to strengthen the shell, and potentially provide shielding. For example, a receptacle connector having a plurality of contacts configured to mate with corresponding contacts of a corresponding plug connector can include a shell having an opening for receiving the corresponding plug connector. The shell can include an upper portion and reinforcing bars embedded within the upper portion. The shell can include an upper portion and a reinforcing element with holes embedded within the upper portion. Methods for manufacturing the shell are also provided.

Claims:
What is claimed is: 
     
       1. A receptacle connector for an electronic device, the receptacle connector for receiving a corresponding plug connector, the receptacle connector comprising:
 a plurality of contacts configured to mate with corresponding contacts of the corresponding plug connector; and 
 a shell having an opening for receiving the corresponding plug connector, the shell comprising:
 an upper portion having an electromagnetic shielding portion adjacent to each of the plurality of contacts; and 
 reinforcing bars embedded within and spanning a substantial portion of the electromagnetic shielding portion, the reinforcing bars configured to provide electromagnetic shielding. 
 
 
     
     
       2. The receptacle connector of  claim 1 , wherein the upper portion is adjacent to the corresponding plug connector when the plug connector is inserted into the receptacle connector. 
     
     
       3. The receptacle connector of  claim 1 , wherein the shell further comprises:
 a lower portion; 
 a back portion; 
 a right portion; and 
 a left portion; 
 wherein reinforcing bars are embedded within more than one portion of the shell. 
 
     
     
       4. The receptacle connector of  claim 3 , wherein reinforcing bars are also embedded within the lower portion. 
     
     
       5. The receptacle connector of  claim 3 , wherein reinforcing bars are also embedded within one or more of the left, right and back portions. 
     
     
       6. The receptacle connector of  claim 1 , wherein the reinforcing bars are in a grid configuration. 
     
     
       7. The receptacle connector of  claim 1 , wherein the reinforcing bars are in a diagonal grid configuration. 
     
     
       8. The receptacle connector of  claim 1 , wherein the shell is an injection molded part. 
     
     
       9. The receptacle connector of  claim 1 , wherein the electronic device is a mobile phone, tablet, or portable media player. 
     
     
       10. The receptacle connector of  claim 1 , wherein the reinforcing bars are made from carbon steel, nickel, or titanium. 
     
     
       11. The receptacle connector of  claim 1 , wherein the upper portion is adjacent to an antenna of the electronic device. 
     
     
       12. The receptacle connector of  claim 1 , wherein the upper portion is made of an insulator material. 
     
     
       13. A receptacle connector for an electronic device, the receptacle connector for receiving a corresponding plug connector, the receptacle connector comprising:
 a plurality of contacts configured to mate with corresponding contacts of the corresponding plug connector; and 
 a shell having an opening for receiving the corresponding plug connector, the shell comprising: 
 an upper portion having an electromagnetic shielding portion adjacent to each of the plurality of contacts; and 
 a reinforcing element having holes and embedded within and spanning a substantial portion of the electromagnetic shielding portion, the reinforcing element configured to provide electromagnetic shielding. 
 
     
     
       14. The receptacle connector of  claim 13 , wherein the reinforcing element is formed by bar elements configured in a mesh pattern that includes the holes. 
     
     
       15. The receptacle connector of  claim 13 , wherein the reinforcing element is formed by a sheet of material having the holes. 
     
     
       16. The receptacle connector of  claim 13 , wherein the upper portion is adjacent to an antenna of the electronic device. 
     
     
       17. The receptacle connector of  claim 13 , wherein the shell further comprises:
 a lower portion; 
 a back portion; 
 a right portion; and 
 a left portion; 
 wherein the reinforcing element is embedded within more than one portion of the shell. 
 
     
     
       18. The receptacle connector of  claim 13 , wherein the reinforcing element is made from carbon steel, nickel, or titanium. 
     
     
       19. A method of manufacturing a receptacle connector for an electronic device, the receptacle connector for receiving a corresponding plug connector, the method comprising:
 suspending a plurality of contacts within a die, the die for forming a shell of the receptacle connector, the plurality of contacts suspended in a first region of the die; 
 suspending a reinforcing element within the die, the reinforcing element suspended in a second region of the die that corresponds to an electromagnetic shielding portion of the shell formed by the die, the second region adjacent to each of the plurality of contacts suspended in the first region, the reinforcing element spanning a substantial portion of the second region, the reinforcing element configured to provide electromagnetic shielding; 
 injecting material into the die to form at least part of the shell; and 
 removing the shell from the die. 
 
     
     
       20. The method of  claim 19 , wherein the reinforcing element is suspended using supports disposed in one or more recesses of the die into which ends of the reinforcing element may be inserted. 
     
     
       21. The method of  claim 19 , wherein the reinforcing element comprises reinforcing bars in a grid configuration. 
     
     
       22. The method of  claim 19 , wherein the reinforcing element is formed by a sheet of material having holes. 
     
     
       23. The method of  claim 19 , wherein the reinforcing element is suspended in regions of the die corresponding to more than one portion of the shell, and wherein the shell further comprises:
 an upper portion, the upper portion including the shielding portion; 
 a lower portion; 
 a back portion; 
 a right portion; and 
 a left portion. 
 
     
     
       24. The method of  claim 19  further comprising:
 machining one or more portions of the reinforcing element that protrude from the shell.

Description:
BACKGROUND 
     The present invention relates generally to input/output electrical connectors, and in particular shells for receptacle connectors. 
     Many electronic devices include electrical connectors that receive and provide power and data. These electrical connectors are typically receptacle connectors and are designed to receive a male plug connector. The male plug connector may be on the end of a cable. The plug connector may plug into the receptacle connector of an electronic device, thereby forming one or more conductive paths for signals and power. 
     The receptacle connector often has a shell that surrounds and provides mechanical support for contacts. Receptacle connector shells are typically made from plastics. These contacts may be arranged to mate with corresponding contacts on the plug connector to form portions of electrical path between devices. 
     These receptacle connectors may be attached or otherwise fixed to device enclosures that surround an electronic device. As electronic devices continue to become smaller, these enclosures have increasingly limited internal space while still including a large number of internal components. Limited space within the enclosures of devices creates a number of challenges. For example, the limited internal space of these enclosures drives the demand for smaller internal components such as smaller receptacle connector shells. However, smaller receptacle connector shells may be prone to breaking due to thinner shell walls, particularly when made of plastic. As another example, a metallic shell may couple with an antenna and cause interference as the dimensions of the device become smaller. 
     A plastic shell may include glass in a polymer resin, but while this may be used to strengthen the shell, it may also make the shell more brittle and more prone to breaking. 
     Many devices suffer from all or some of these deficiencies or from similar deficiencies. Accordingly, it is desirable to provide small devices with connectors that are strong and reduce interference. 
     BRIEF SUMMARY 
     Various embodiments of the invention pertain to receptacle connector shells for electrical connectors that improve upon some or all of the above described deficiencies. For example, reinforcing bars can be embedded within the shell of a connector receptacle to strengthen the shell and potentially reduce breakage. Reinforcing bars embedded within a shell of a receptacle connector may also serve as shielding for the connector receptacle. Accordingly, some embodiments relate to improved receptacle connector shells that can provide for a smaller, stronger receptacle connector shell, increased Electromagnetic Interference and Electromagnetic Compatibility performance (“EMI/EMC performance”), and increased flexibility in the positioning of an antenna within the enclosure of an electronic device. Other embodiments of the invention pertain to methods of manufacturing receptacle connector shells of the present invention. Although aspects of the invention are described in relation to environments where space within the enclosure of an electronic device is limited, it is appreciated that these features and aspects can be used in a variety of different environments, regardless of space constraints. 
     According to one embodiment, a receptacle connector for an electronic device is provided. The receptacle connector can include a plurality of contacts configured to mate with corresponding contacts of a corresponding plug connector and a shell having an opening for receiving the corresponding plug connector. The shell can include an upper portion and reinforcing bars embedded within the upper portion. 
     According to another embodiment, a receptacle connector for an electronic device is provided. The receptacle connector can include a plurality of contacts configured to mate with corresponding contacts of a corresponding plug connector and a shell having an opening for receiving the corresponding plug connector. The shell can include an upper portion and a reinforcing element having holes embedded within the upper portion. 
     Another exemplary embodiment of the present invention may provide a receptacle connector that may be easily manufactured. A method of manufacturing a receptacle connector is provided. A reinforcing element can be suspended within a die for forming a shell of the receptacle connector. The reinforcing element can be suspended in a region of the die that corresponds to an upper portion of the shell formed by the die. Material can be injected into the die to form at least part of the shell. The shell can be removed from the die. 
     The receptacle connector shell described herein can be used in a variety of different electronic devices, which may use a variety of different connector technologies. The invention may apply to many commonly used data connectors including standard USB and mini USB connectors, FireWire connectors, as well as many of the proprietary connectors, e.g., Apple&#39;s proprietary 30-pin connector, used with common portable electronics. The invention may also apply to internal connectors or other connections between components within the enclosure of an electronic device. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a simplified perspective drawing of a host device having a receptacle connector according to embodiments of the present invention. 
         FIG. 2  illustrates a receptacle connector having a plug connector proximate thereto and inserted therein. 
         FIG. 3  illustrates a partially transparent perspective view of a receptacle connector shell including a reinforcing element according to embodiments of the present invention. 
         FIG. 4  illustrates a cross sectional view of an electronic device including a receptacle connector according to the embodiment of the present invention as shown in  FIG. 3 . 
         FIG. 5  illustrates a partially transparent perspective view of a receptacle connector according to an embodiment of the present invention. 
         FIG. 6  illustrates a cross sectional view of a plug connector being extracted from a receptacle connector according to an embodiment of the present invention. 
         FIG. 7  illustrates a cross sectional view of a plug connector inserted into a receptacle connector according to an embodiment of the present invention. 
         FIGS. 8A-8B  illustrate additional embodiments of reinforcing elements according to the present invention. 
         FIGS. 8C-8E  illustrate additional embodiments of receptacle connector reinforcing elements according to the present invention. 
         FIGS. 9A-9B  illustrate an exemplary die for use in methods of manufacturing according to the present invention. 
         FIG. 10  illustrates a method of manufacture according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments can provide a connector receptacle for an electronic device having a reinforced shell. The shell can be reinforced with reinforcing elements such as reinforcing bars or rebars. The reinforcing elements can be embedded in a portion of the connector receptacle shell to strengthen the shell. The reinforcing element can be configured in a mesh pattern, thereby allowing the reinforcing elements to provide EMI shielding for the receptacle connector to improve EMI/EMC performance of the electronic device. The shell of the reinforced connector receptacle can be made in an effective manufacturing process. 
     I. Device and Connector Configuration 
       FIG. 1  is a simplified perspective drawing of a host device  100  having a receptacle connector  110  according to embodiments of the present invention. Host device  100  includes a receptacle connector  110  that may receive a corresponding plug connector  120  via an opening (shown in  FIG. 2 ). The plug connector includes external contacts  130  that can accommodate some or all of video, audio, data and control signals along with power and ground. 
     Corresponding electrical contacts (shown in  FIG. 3 ) may be located in receptacle connector  110 . Plug connector  120  is compatible with receptacle connector  110  of host device  100  that can be, as shown in  FIG. 1 , a mobile phone. Host device  100  may be a portable computing device; a tablet; a desktop; an all-in-one computer; a cell, smart or media phone; a storage device; a portable media player; a navigation system; a monitor or other electronic device. 
     As discussed above, electronic devices may include components that are susceptible to EMI. For example, host device  100  may include an antenna. Receptacle connector  110  and plug connector  120 , when mated with receptacle connector  110 , may each create EMI for an antenna of host device  100  if not properly shielded. In some cases, it may possible to position a device&#39;s antenna to avoid EMI. However, as electronic devices continue to become smaller, there is increasingly limited internal space within devices and thus reduced flexibility in positioning internal components such, e.g., an antenna, to avoid EMI. Additionally, this demand for smaller devices requires internal components, e.g., receptacle connector  110 , to be smaller. Smaller receptacle connectors may necessarily have thinner shell walls that may not be thick enough to shield EMI originating from the receptacle connector. Additionally, a smaller receptacle connector may also be prone to breaking due to the thinner shell walls. Accordingly, some embodiments discussed below relate to improved receptacle connector shells that can provide for a smaller, stronger receptacle connector shell, increased EMI/EMC performance, and increased flexibility in the positioning of an antenna within the enclosure of an electronic device, e.g., host device  100 . 
       FIG. 2  illustrates a receptacle connector  210  having a plug connector  120  proximate thereto and inserted therein. As shown in  FIG. 2 , plug connector  120  includes a tab  122  having an electrical contact region  124  with a plurality of electrical contacts  130  for electrically coupling to corresponding electrical contacts (shown in  FIG. 3 ) disposed inside receptacle connector  210 . Receptacle connector  210  is generally defined by a housing including a shell  240 , one or more brackets  245  and  250 , and contacts (shown in  FIG. 3 ). Shell  240  is attached to a surface or components on the interior of device  100  (shown in  FIG. 1 ), typically by use of the brackets  245 ,  250 . Shell  240  may be coupled within a device using an upper bracket  245  that extends over the upper portion of the shell  240  and a lower bracket  250  that extends underneath shell  240 . The end portions of each bracket  245  and  250  include holes for receiving a screw to facilitate mechanically coupling the shell  240  within a device enclosure, e.g., enclosure  105  (shown in  FIG. 1 ) of device  100  (shown in  FIG. 1 ). Shell  240  may also include additional brackets and/or coupling elements for coupling shell  240  within device  100  (shown in  FIG. 1 ). Plug connector  120  and connector receptacle  110  are connected by inserting tab  122  along insertion axis until the tab  122  is fully inserted into a mated configuration in which electrical contacts  130  and corresponding contacts (not shown in  FIG. 2 ) in receptacle  210  are electrically coupled, as shown in  FIG. 2 . 
     II. Connector Shell Including Reinforcement Bars 
     Reinforcing elements, e.g., rebars, can be embedded within the shell of a connector receptacle to strengthen the shell and increase EMI/EMC performance. Similar to how concrete walls are reinforced by rebars, shells may also be reinforced by rebars. When arranged in a mesh configuration, these rebars may also serve as shielding for the connector receptacle by means of an effect similar to that of a Faraday cage or shield. Hence, a mesh of embedded rebars may block electrical fields like the ones that may cause a device&#39;s antenna to couple with a receptacle connector or a mated plug connector. A sheet of metal embedded in a receptacle connector may provide similar shielding, but the sheet metal itself may couple with the device&#39;s antenna and create EMI. However, a mesh of rebars may require less metal than a solid structure like sheet metal such that it would be less prone to antenna coupling while still providing similar levels of shielding via an effect similar to that of a Faraday cage. Accordingly, embodiments of reinforcing elements, e.g., rebars, described herein may allow for improvements in both the mechanical domain, e.g., structural strength, and the electrical domain, e.g., EMI/EMC performance. 
       FIG. 3  illustrates a partially transparent perspective view of a receptacle connector shell including a reinforcing element according to embodiments of the present invention. As shown in  FIG. 2 , a reinforcing element  360  may include a number of reinforcing bars or rebars. Reinforcing element  360  may be made from a variety of materials including metals, dielectrics, polymers or a combination thereof. Reinforcing element  360  may be made primarily or exclusively from a metal, such as carbon steel. While reinforcing element  360  is shown as including one or more straight rebars in  FIG. 3  and other included examples, rebars may have other shapes. For example, rebars may be rectangular, circular, curved, triangular, L-shaped, Z-shaped, U-shaped or otherwise shaped, including other shapes described herein. Additionally, the cross section of the rebars of reinforcing elements discussed herein may be non-circular, e.g., triangular, rectangular, asymmetrically shaped or otherwise shaped. Rebars may have a non-constant cross section where the shape and/or thickness of the rebars may vary about the length of the one or more rebars. Reinforcing element  360  may include more than one rebar, e.g., a mesh of rebars, as discussed below. 
     A. Parallel Rebars Configuration 
     As shown in  FIG. 3 , reinforcing element  360  may be embedded within an upper portion of shell  340 . Shell  340  may be made from an insulator material, e.g., polymeric materials such as thermoplastics, thermosets, and/or elastomers, with or without embedded particles such as glass. As shown in  FIG. 3 , reinforcing element  360  may be in a grid or mesh configuration including parallel bars and overlapping perpendicular bars. These bars may have a circular cross-section and include ridges or other encircling protrusions for better anchoring within shell  340  and ties or welds may be implemented at joints  365  where bars overlap to strengthen the frame of reinforcing element  360 . Ties may be implemented using steel wire that is twisted about the intersection point of two or more rebars, e.g., a snap or single tie. Also shown in  FIG. 3  are contacts  330  positioned within the lower portion of shell  340  and extending into the opening  315  (shown in  FIG. 4 ) of receptacle connector  310 . Contacts  330  may connect to one or more flexible circuit boards, printed circuit boards or other substrates within the host device, e.g., device  100  as shown in  FIG. 1 . 
     While reinforcing element  360  of  FIG. 3  includes 14 rebars that extend a full or substantial width or length of the upper portion of shell  340 , some embodiments of the present invention may include more or less rebars aligned in the width and/or length direction. Furthermore, in other embodiments, the rebars do not extend a full or substantial length or width of the upper portion of shell  340 , but rather extend a shorter length or even a longer length. 
       FIG. 4  illustrates a cross sectional view of an electronic device including a receptacle connector according to the embodiment of the present invention as shown in  FIG. 3 . As shown in  FIG. 4 , reinforcing element  360  may be embedded within an upper portion of shell  340  adjacent to antenna  380  of device  300 . Antenna  380  may serve as the exclusive radio frequency (RF) antenna or may be one of many antennas within device  300 . Antenna  380  may be any number of antennas used in electronic devices, including a WiFi antenna, a CDMA or GMS antenna, a Global Positioning System (GPS) antenna, or any other antenna implemented in electronic devices. As the position of antenna  380  may vary among electronic devices, so may the position of reinforcing element  360  vary to be adjacent to antenna  380  and embedded in shell  340 . The configuration and/or position of reinforcing element  360  may also vary in order to accommodate receptacle connector contacts  330  (shown in  FIG. 3 ), which also may be embedded within shell  340 . For example, a reinforcing element may include gaps in its rebar pattern to allow for receptacle connector contacts to protrude through the shell and the reinforcing element unobstructed and make contact with corresponding contacts on a mated plug connector. 
     As will be discussed in greater detail below, embedded reinforcing elements as discussed herein may provide shielding for a receptacle connector so as to prevent or reduce coupling between an antenna of an electronic device, e.g., antenna  380 , and the connector receptacle as well as a mated plug connector. This shielding may be similar to a Faraday cage or shield and may lead to improved EMI/EMC performance of the electronic device. 
     B. Diagonal Rebar Configuration 
       FIG. 5  illustrates a partially transparent perspective view of a receptacle connector according to an embodiment of the present invention. As shown in  FIG. 5 , reinforcing element  560  may be configured in a diagonal grid or mesh formation having parallel bars and overlapping perpendicular bars that extend diagonally within an upper portion of shell  540 . Reinforcing element  560  of receptacle connector  510  may include ridges, have a circular cross section, and implement ties or welds at joints  565 . Reinforcing element  560  includes twenty rebars that are equally spaced and aligned in two different directions, the two directions being perpendicular to one another. Alternatively, the rebars may be aligned in two different directions that are not perpendicular to one another. As another example, more or less rebars may be included in order to create a more or less dense mesh of rebars. As yet another example, the rebars may not be equally spaced and/or may be aligned in more than two different directions. 
     In some embodiments of reinforcing element  560 , the rebars may not extend a full or substantial distance across the upper portion of shell  540 , but rather extend a shorter length or even a longer length. Alternatively, some rebars may extend a full or substantial distance across the upper portion of shell  540  while others rebars only extend a partial distance across the upper portion of shell  540 . 
     Similar to the embodiment shown in  FIG. 4 , reinforcing element  560  may be embedded within an upper portion of shell  540  or another portion of shell  540  adjacent to the antenna of an electronic device. Some embodiments of the invention may include more or less rebars. In other embodiments, the rebars may not extend a full or substantial diagonal length of shell  540 , but rather extend a shorter length or even a longer length. 
     III. Prevention of Damage 
       FIG. 6  illustrates a cross sectional view of a plug connector being extracted from a receptacle connector according to an embodiment of the present invention. During the use and operation of host device  600 , plug connector  620  may be inserted into and extracted from receptacle connector  610  on a regular basis. Each insertion and extraction event may apply forces to the shell  640  that can potentially cause damage to shell  640 . While  FIG. 6  illustrates a specific force vector, vector F 1 , applied by a user on plug connector  620  during an extraction event, many different forces may be applied in a number of different ways during extraction events and in yet additional ways during insertion events. For example, as is commonly recommended for extracting connectors from devices, a force may be applied away from host device  600  and in the same direction as the axis of opening  615  of receptacle connector  610 . Device  600  may also be dropped or otherwise acted upon so as to apply an unintentional force to plug connector  620 , which may be contrary to recommended force applications for the insertion or extraction of plug connector  620 . 
     As shown in  FIG. 6 , force vector F 1 —a common, but non-recommended application of force for plug connector extraction—may translate via plug connector  620  and result in other forces being applied to shell  640 , e.g., resultant force vectors F 2  and F 3 . For example, force vector F 1  may result when a user retracts plug connector  620  from receptacle connector  610  by holding the electronic device with one hand and pulling on the plug connector in the direction of the insertion axis with the other hand, but also applies some incidental torque to plug connector  620  during the retracting process. Force vector F 3  may result in the wall of the shell  640  opposite to the wall embedded with reinforcing element  650  experiencing a load at a front edge near opening  615 . Force vector F 2  may result at the wall of shell  640  embedded with reinforcing element  660  experiencing load at point between a back wall of shell  640  and opening  615 . Depending on the magnitude of force vector F 1 , force vectors F 2  and F 3  may apply a significant load to shell  640 . The application of these significant forces or the continued application of similar less significant forces to shell  640  could potentially cause a catastrophic failure of shell  640 . 
     As discussed earlier, many receptacle connector shells are made from glass filled material, e.g., glass resin, for rigidity and strength. However, glass filled materials may be brittle and lead to catastrophic brittle failures under loads as opposed to slow yielding ductile failures associated with non-filled polymers. By placing rebars, e.g., embodiments of reinforcing element  360  and  560 , inside receptacle connectors shells, other non-filled materials may be used that may allow for higher elongation to break and more desirable failure modes. For example, by removing glass particles from a polymer resin, the polymer may retain its elastic properties. These elastic properties may allow shells, e.g., shells  340  and  540 , to flex when a load is applied rather than resulting in material failures. The flex or elongation before failure provided by polymers in combination with rebars that help in managing flex may result in a more robust design. As a result of this combination, embodiments of receptacle connector shells discussed herein may have more give and may potentially be less prone to breakage. By increasing the overall strength of connector receptacle shells with rebars, it may be possible for connector receptacle shells to have thinner walls without increasing the risk of material failures. 
     As discussed earlier, reducing the size of internal components, e.g., reducing wall thickness, may be beneficial in meeting the demand for increasingly smaller device enclosures. Thus, even though increasingly wall thickness is effective in increasing the overall strength of connector receptacle shells, size constraints may prevent thicker walls from being a desirable option or even an option at all. Alternatively, embedded sheet metal in a shell could be used instead of increasing wall thickness to increase strength, but this may result in issues in the electrical domain as discussed below. 
     IV. Shielding 
       FIG. 7  illustrates a cross sectional view of a plug connector inserted into a receptacle connector according to an embodiment of the present invention. As discussed above, electrical connectors can reduce the EMI/EMC performance of a device if not properly shielded. For example, receptacle connector  710  either alone or in combination with plug connector  720  may interfere with antenna  780  if not properly shielded. This interference may result from antenna coupling wherein one or more electrically conductive objects, e.g., receptacle connector  710  and/or plug connector  720 , interact with radiated electromagnetic waves, e.g., RF waves  785  radiated from antenna  780 , and transform the radiated energy into energy conducted by the conductive objectives. In this manner, metal components, wires and other electrically conductive elements of receptacle connector  710  and plug connector  720  may act as unwanted antennas and interfere with the efforts by antenna  780  to send and receive RF waves  785 . In  FIG. 7 , double-headed arrows represent antenna coupling. Antenna coupling  790  represents antenna coupling between antenna  780  and connector  710  and/or plug connector  720 . Antenna coupling  795  represents antenna coupling between antenna  780  and the upper portion of shell  740 , which includes embedded reinforcing element  760 , adjacent to antenna  780  and/or any reinforcing elements embedded within shell  740 . 
     As discussed above, many receptacle connector shells are made from glass resin to provide structural rigidity and strength. However, in some cases, glass resin may not be able to provide sufficient shielding to prevent coupling  790 . Inserting molding sheet metal in a receptacle connector shell was discussed above as an alternative means of reinforcing and shielding the receptacle connector. In contrast with glass resin, sheet metal may have the ability to provide sufficient shielding to prevent unacceptable levels of antenna coupling  205 . However, while sheet metal may shield antenna coupling  790 , the sheet metal may also cause unacceptable levels of antenna coupling  795  and reduce EMI/EMC performance of device  700 . As such, sheet metal may not be an appropriate solution in all cases. 
     As also discussed above, a mesh of rebars, e.g., embodiments of reinforcing elements  360  and  560  (shown in  FIGS. 3 and 5 , respectively), may provide similar structural advantages to that of embedded sheet metal. However, as shown in  FIG. 7 , reinforcing element  760  would require much less metal to be embedded in shell  740  because it is not a solid sheet of metal. Hence, using rebar in shell  740  may allow for strategic placement of less metal inside shell  740  such that antenna coupling  195  may be reduced to acceptable levels. In addition, the mesh configuration of embodiments of reinforcing elements still may provide sufficient shielding to prevent unacceptable levels of antenna coupling  790  by means of an effect similar to that of a Faraday cage or shield. A Faradays cage is an enclosure formed by a mesh of conductive material, e.g., reinforcing element  760 , that blocks electrical fields like the ones that cause antenna coupling. As such, embodiments of reinforcing elements described herein may allow for improvements in both the mechanical domain, e.g., structural strength, and the electrical domain, e.g., EMI/EMC performance. 
     In some situations, simply moving the antenna of an electronic device away from the receptacle connector of electronic device may also help to prevent antenna coupling, e.g., antenna coupling  790  and/or  795 . However, as discussed above, other design constraints may make moving antennas not always possible or may result in other challenges. Hence, the use of reinforcing elements as described may allow for greater flexibility in designing an electronic device by not necessitating that the device&#39;s antenna be located away from the receptacle connector in order to achieve acceptable EMI/EMC performance. 
     V. Additional Variations 
       FIGS. 8A-8B  illustrate additional embodiments of reinforcing elements according to the present invention. Reinforcing elements may be varied in a number of ways other than those discussed above. For example,  FIG. 8A  shows reinforcing element  860  of receptacle connector  810  embedded in at least three portions of shell  840 , including an upper, lower and back portion as shown in  FIG. 8A . Alternatively, reinforcing elements may be embedded throughout shell  840 , including the upper, lower, right (not shown), left (not shown) and back portions or combinations thereof. Again, shell  860  may be made from plastic or other nonconductive materials while rebars may be made from metals such as steel. 
     As shown in  FIG. 8B , reinforcing element  861  may include undulate rebars  863 . The undulating section of the undulate rebar may be limited to of a select number rebars and may be further limited to only a portion of the select number of rebars as shown in  FIG. 8B . However, the undulated rebars and the undulated portions of the undulated rebars may be varied. For example, all the rebars of a reinforcing element may be partially undulated or only two rebars may be undulated, but the entire length of the rebar may be undulated. The undulated design may be used because finite element analysis (FEA) of the undulated design establishes advantages in load distribution across a reinforcing element and a shell or may also be used to match the shape of shell  841  or otherwise shaped receptacle connector shells. The use of undulate rebars may be implemented with any of the embodiments of reinforcing elements discussed herein. Thus, while the discussion of patterns of rebars of reinforcing elements discussed was primarily focused on variance in a first and a second dimension, reinforcing elements of the present invention are not limited to a two-dimensional pattern. For example, the rebars of some reinforcing elements may be bent at the ends of the rebars to secure the rebars&#39; embedded position within a receptacle connector shell, e.g., shell  841 . 
       FIGS. 8C-8E  illustrate additional embodiments of receptacle connector reinforcing elements according to the present invention. As shown in  FIG. 8C , instead of parallel and overlapping perpendicular rebars, reinforcing element  864  includes a number of interlocked rings of rebar. The rings of reinforcing element  864  are arranged in a straight line where each ring is interlocked with the ring immediately adjacent to it. Once interlocked, the rings of reinforcing element  864  could be arranged in a number of different configurations, e.g., a straight line of interlocked rings as shown in  FIG. 8C  or a series of interlocked rings arranged in a rectangular pattern. Ties or welds, as discussed earlier, may be used in some embodiments to hold the rings of embodiments of reinforcing element  866  in a particular arraignment. Alternatively, one or more rings in a series of rings may be interlocked with more than one ring in the series of rings, e.g., one ring may be interlocked with 2 or 8 rings and another ring may be interlocked with 3 or 10 rings. 
     In some embodiments, the thickness of the rebars of a reinforcing element may be varied. For example, a dense mesh of relatively thin bars that are easily bendable could be implemented as shown by reinforcing element  866  in  FIG. 8D . Flexible reinforcing element  866  made be made from metal, e.g., titanium, nickel or other alloy, such that a single unit of mesh could be bent to be embedded in multiple portions of a connector receptacle shell. These variations and other similar variations may serve to optimize the distribution of loads applied to connector receptacle shells as well as the overall strength of connector receptacle shells. 
     In other embodiments, a connector receptacle reinforcing element may be a solid structure that includes holes. For example,  FIG. 8E  shows a reinforcing element  867  including holes  868 . Reinforcing element  867  may be a sheet of metal and holes  868  may be formed through a stamping process performed on the sheet metal. Alternatively, reinforcing element  867  may be a molded sheet of metal formed through a casting process to include holes  868 . Reinforcing element  867  may also be formed by arranging rebars in a mesh configuration that includes holes. While holes  868  of  FIG. 8E  are shown as being rectangular shaped holes, holes  868  may also be otherwise shaped. For example, holes  868  may be circular, triangular, or irregularly shaped. When embedded in a receptacle connector shell of a device, reinforcing element  867  may improve the EMI/EMC performance of the device. 
     As with other examples provided herein, reinforcing element  867  may be made from a variety of materials including metals, but also dielectrics and polymers or a combination thereof. In some embodiments, reinforcing element  867  may be made primarily or exclusively from a metal, such as carbon steel. 
     In some embodiments, more than one embodiment of a reinforcing element according to the present invention may be implemented within a single receptacle connector shell. For example, one wall of a receptacle connector shell may be embedded with one embodiment of a reinforcing element while another wall of the shell may implement another embodiment of a reinforcing element. As another example, more than one reinforcing element may be embedded within a single portion or wall of a receptacle connector shell; the reinforcing elements may be stacked on top of each other or adjacent to each other in this example. Additionally, as discussed above, embodiments of the present invention may provide receptacle connectors that are configured to accept various different plug connectors implementing a variety of different connector technologies. 
     In embodiments of the present invention the design variables discussed above, e.g., rebar types, patterns, positioning and others, may be varied to achieve the appropriate balance of receptacle connector shell strength and EMI/EMC performance desired for a particular application. Generally speaking, as the density of a rebar pattern and/or the thickness of the rebars of an embedded reinforcing element increases, so does the strength of the receptacle connector shell and the strength of the shielding provided by the reinforcing element. However, as the density of a rebar pattern and/or the thickness of the rebar of an embedded reinforcing element increases, so does the potential for antenna coupling between the reinforcing element and an antenna of the electronic device. However, for each embodiment discussed herein, an increase in rebar pattern density and/or rebar thickness will yield a different resultant strength, shielding and antenna coupling balance. Accordingly, a suitable embodiment for a particular application will depend on the desired balance of receptacle connector shell strength, connector receptacle shielding and antenna coupling. 
     VI. Method of Manufacture 
     It may be desirable to provide an effective manufacturing process for the receptacle connectors discussed above. Accordingly, embodiments of the present invention provide for a method of manufacture for the embedding of reinforcing elements within a receptacle connector shell. For example, reinforcing elements may be embedded in a receptacle connector shell through injection molding, machining, and/or press fitting. 
     A. Injection Molding 
       FIGS. 9A-9B  illustrate an exemplary die for use in methods of manufacturing according to the present invention. Receptacle connector shells as discussed above may be manufactured as one piece using a die or mold, e.g., die  900  as shown in  FIGS. 9A-9B . Die  900  includes a first die portion  910  and a second die portion  920 . First and second die portions  910  and  920  may each include a recess, e.g., recesses  930  and  940 , such that when die portions  910  and  920  are brought together a composite recess or cavity is formed that is capable of receiving molten resin to form a receptacle connector shell via an injection molding process. Die portions  910  and  920  may also include supports, e.g., supports  950  as shown in  FIG. 9A , for suspending reinforcing elements, e.g., reinforcing element  960 , within a die recess, e.g., recess  930 , during the injection molding process. 
     While  FIG. 9A  shows a support  950  for each end of the rebars of reinforcing element  960  provided within recess  930 , the number of supports  950  may only be proportional to the number of reinforcing bars included on a reinforcing element, e.g., a support may be included for each end of every other rebar. Supports  950  may also be included within recess  940 . Thus, the position of supports  950  may vary so as to facilitate the embedding of a reinforcing element in one or more portions of receptacle connector shells as described above. In some embodiments, supports  950  may be slots into which ends of rebars of reinforcing elements may be inserted. Accordingly, the position and types of supports  950  may vary in order to accommodate the different embodiments of the receptacle connector as discussed herein. Die  900  may also include various other features to assist in the injection molding process, e.g., a spruce, a runner, gates, alignment pins, and/or other features. 
       FIG. 10  illustrates a method of manufacture 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 inventions or the claims. 
     At step  1010 , a reinforcing element is positioned or suspended within a die cavity. For example, supports  950  (shown in  FIG. 9 ) may be used to position or suspend a reinforcing element, e.g., reinforcing element  960  (shown in  FIG. 9 ), within a die cavity, e.g., the composite recess formed by recesses  930  and  940  of die  900  (shown in  FIG. 9 ). The positioning of a reinforcing element within a recess of a die may be done manually or may be automated. For example, in embodiments where supports  950  are slots, the ends of the rebars of a reinforcing element may be manually inserted into supports  950 . At this point, the die portion, e.g., first die portion  910  and a second die portion  920 , may be brought together to form the die cavity with a reinforcing element suspended within the die cavity. 
     At step  920 , material is injected in the die cavity. The material, e.g., thermoplastics, thermosets, and/or elastomers, may be injected by means of an injection molding machine that mixes, heats, and forces the material into a die, e.g., die  900 . As discussed earlier, the injection molding process may be aided by a spruce, a runner, gates, and/or other features to assist the flow of the injected material. At the conclusion of this step, the die cavity may be completely filled with the injected material and the injected material may now be in the shape of a connector receptacle shell. 
     At step  930 , the injected molded part is removed from the die. Once the injected material cools, the die may be opened and the part, a receptacle connector shell such as shell  240  as shown in  FIG. 2 , may be removed or ejected from the die, e.g., by means of ejector pins. The cooling process may accomplish via a coolant being passed through the die to absorb the heat from the die, which was heated by the injected material. At the conclusion of the cooling process the molded part, e.g., the receptacle connector shell, may be in the form of a solid as shaped by the die. The die may be opened by separating the portions of the die leaving the molded part in the recess of one of the die portions, e.g., recess  930  of first die portion  910 . In some embodiments, ejector pins, which may be placed in the portion of a die that contains the molded part after the die is opened, may be used to push the molded part out of the recess of a die portion, e.g., die portion  910 . 
     At step  940 , the injection molded part may be machined as necessary. This machining step may be used to remove any portion of a reinforcing element that protrudes from the injection molded receptacle connector shell. For example, the ends of the rebar of a reinforcing element that were placed in suspension supports, e.g., supports  950 , may protrude from the outer surface of the injection molded receptacle connector shell. For a number of reasons, aesthetic or otherwise, the protruding ends of rebar may be removed at step  940  via machining. As another example, machining may be used to remove any excess material, e.g., flash, on the injection molded receptacle connector shell. 
     In some embodiments, method  900  may include fewer or additional steps. For example, contacts or other elements of receptacle connectors may be suspended within the die cavity prior to injecting material into the die. As another example, other machining steps may be implemented after step  940  to form features on a receptacle connector shell. 
     B. Other Methods of Manufacture 
     In other embodiments portions of receptacle connector shells may be press fit together after placing a reinforcing element between them in order to embed the reinforcing element within the shell. In yet additional embodiments, holes are machined into a receptacle connector shell into which rebars may be inserted and held in place with an adhesive. In other embodiments, metal particles may be mixed in with a material before the material is injection molded into a receptacle connector shell die so as to provide structural and/or EMI/EMC performance advantages. 
     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 as including only one type of rebar in a reinforcing element. A person of skill in the art will readily appreciate that one or more of any of the other types of rebars discussed herein, as well as others not specifically mentioned, may be used instead of or in combination with any of the rebars shown in embodiments of the reinforcing element discussed herein. 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: 20120907
Publication Date: 20140930
Grant Date: 20140930
Priority Date: 20120907
Inventors: ARDISANA, II JOHN B.
JOL ERIC S.
SLOEY JASON S.
SHAH DHAVAL N.
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C45/14631", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/14122", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6599", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/36", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14065", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6599", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/648", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C45/14639", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14639", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/0006", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/504", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6599", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14639", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2045/0006", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/648", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C2045/14122", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/36", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14065", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C45/14631", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 49118810