PATENT DOCUMENT

Publication Number: US-9660376-B2
Application Number: US-201514714348-A
Country: US
Kind Code: B2

Title: Connector insert having a cable crimp portion with protrusions and a receptacle having a label in the front

Abstract:
A magnetic connector system having a durable and reliable construction and a reduced height while maintaining sufficient holding strength. A connector insert may utilize a crimping piece to crimp a braiding of a cable. The crimping piece may be fixed to an attraction plate and a board in the insert for mechanical reliability. Retention clips may be used to fix a shell to the attraction plate. A connector receptacle may employ a magnetically conductive label to improve holding strength.

Claims:
What is claimed is: 
     
       1. A connector insert comprising:
 an insulative housing having a number of passages; 
 a plurality of contacts, each having tail portions and located in a corresponding passage in the insulative housing; 
 a printed circuit board having a first plurality of circuit board contacts along a front edge, each soldered to a tail portion of a corresponding contact in the plurality of contacts; 
 an attraction plate having an opening to allow access to the plurality of contacts; 
 a crimping portion crimped over an end of a cable and having a plurality of protrusions, wherein the plurality of protrusions are attached to a back of the attraction plate and the crimping portion is soldered to a printed circuit board contact at a rear of the printed circuit board; 
 a plurality of retention clips on sides of the attraction plate; and 
 a shell having a cutout portion to accept the retention clips. 
 
     
     
       2. The connector insert of  claim 1  further comprising:
 a first light-emitting diode attached to the printed circuit board; and 
 a light pipe attached to the printed circuit board, wherein the light pipe is angled to pass above the first light-emitting diode, and further angled to pass light to an opening in the shell. 
 
     
     
       3. The connector insert of  claim 2  further comprising:
 a second light-emitting diode attached to the printed circuit board, wherein the light pipe is angled to pass above the first light-emitting diode and the second light-emitting diode. 
 
     
     
       4. The connector insert of  claim 1  wherein the crimping portion further comprises a plurality of fingers, wherein the plurality of fingers extend in a first direction along a length of the cable and are soldered to contacts at a rear of the printed circuit board. 
     
     
       5. The connector insert of  claim 4  wherein the plurality of protrusions extend along a second direction orthogonal to the first direction. 
     
     
       6. The connector insert of  claim 1  further comprising:
 a strain relief partially covered by the shell, and extending behind the shell and around the cable. 
 
     
     
       7. The connector insert of  claim 1  wherein the crimping portion further comprises a plurality of fingers, wherein the plurality of fingers are attached to the printed circuit board. 
     
     
       8. The connector insert of  claim 1  wherein each of the plurality of contacts are spring biased. 
     
     
       9. The connector insert of  claim 1  wherein a rear edge of the printed circuit board has a U-shaped cutout, the rear edge of the printed circuit board further having first and second printed circuit board contacts on facing sides of the U-shaped cutout and a third printed circuit board contact between the first and second printed circuit board contacts, wherein the crimping portion is soldered to the first and second printed circuit board contacts. 
     
     
       10. The connector insert of  claim 9  wherein a central conductor of the cable is soldered to the third printed circuit board contact. 
     
     
       11. A connector insert comprising:
 a printed circuit board having a front edge comprising a first plurality of printed circuit board contacts and a rear edge having a U-shaped cutout, the rear edge having first and second printed circuit board contacts on facing sides of the U-shaped cutout and a third printed circuit board contact between the first and second printed circuit board contacts; 
 an attraction plate; 
 an insulative housing partly located in the attraction plate and having a number of passages; 
 a plurality of contacts, each having tail portions and located in a corresponding passage in the insulative housing, the tail portions soldered to corresponding printed circuit board contacts in the first plurality of printed circuit board contacts at the front edge of the printed circuit board; 
 a crimping portion around an end of a cable and having protrusions extending on each of two sides of the crimping portion, the protrusions attached to a back of the attraction plate, the crimping portion soldered to the first and second printed circuit board contacts; and 
 a shell around the printed circuit board and rear of the attraction plate. 
 
     
     
       12. The connector insert of  claim 11  wherein a central conductor of the cable is soldered to the third printed circuit board contact. 
     
     
       13. The connector insert of  claim 12  further comprising:
 a strain relief having a wide portion inside the shell and extending behind the shell and around the cable. 
 
     
     
       14. The connector insert of  claim 13  further comprising:
 a first light-emitting diode attached to the printed circuit board; and 
 a light pipe attached to the printed circuit board, wherein the light pipe is angled to pass above the first light-emitting diode, and further angled to pass light to an opening in the shell. 
 
     
     
       15. The connector insert of  14  further comprising:
 a second light-emitting diode attached to the printed circuit board, wherein the light pipe is angled to pass above the first light-emitting diode and the second light-emitting diode. 
 
     
     
       16. The connector insert of  claim 11  wherein the crimping portion further comprises a plurality of fingers, wherein the plurality of fingers extend in a first direction along a length of the cable and are soldered to contacts at a rear of the printed circuit board, wherein the plurality of protrusions extend along a second direction orthogonal to the first direction. 
     
     
       17. The connector insert of  claim 11  wherein the plurality of contacts are spring biased. 
     
     
       18. A connector receptacle comprising:
 a plurality of contacts, each having a ninety degree bend; 
 a first housing having first passages for a plurality of contacts, the first passages oriented in a mating direction of the connector receptacle; 
 a second housing behind the first housing and having second passages for the plurality of contacts, the second passages oriented in a direction orthogonal to the mating direction of the connector receptacle; 
 a plurality of magnets, the plurality of magnets positioned around the first housing and in front of the second housing; 
 a shield around magnets and second housing; and 
 a label over the plurality of magnets, wherein the label is formed of a magnetically conductive material, the label having an opening, a front portion of the first housing extending in front of the label. 
 
     
     
       19. The connector receptacle of  claim 18  wherein the plurality of magnets comprises four magnets, two in each of two rows, and arranged to have alternating polarities in and between rows. 
     
     
       20. The connector receptacle of  claim 18  wherein the second housing includes a tab to be inserted in a notch in a device enclosure. 
     
     
       21. The connector receptacle of  claim 18  wherein the plurality of magnets comprises three magnets arranged to have alternating polarities, wherein a middle magnet includes a passage for the first housing. 
     
     
       22. The connector receptacle of  claim 18  wherein the label is attached to the shield.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. Pat. application No. 13/458,853, which claims the benefit of U.S. provisional patent application Nos. 61/522,625, filed Aug. 11, 2011, and 61/599,921, filed Feb. 16, 2012, which are incorporated by reference. 
    
    
     BACKGROUND 
     The number and types of electronic devices available to consumers have increased tremendously the past few years, and this increase shows no signs of abating. Devices such as portable computing devices, tablet, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors and other devices have become ubiquitous. 
     These devices often receive power and share data using various cables. These cables may have connector inserts, or plugs, on each end. The connector inserts may plug into connector receptacles on electronic devices, thereby forming one or more conductive paths for signals and power. 
     These connector inserts and connector receptacles may be magnetic. That is, a magnetic insert may be magnetically attracted to a magnet receptacle, and the two may be held in place in at least one direction by the magnetic attraction. 
     Conventional magnetic connectors have been fairly large in size. But the devices they connect to have often become much thinner, that is, they have a reduced height. This, in turn, leads to a desire for a thinner connector. But when a conventional connector is made thinner, it may not have sufficient holding power to maintain a connection between a connector insert and a connector receptacle. 
     Also, these connectors may be connected and disconnected thousands of times during a device&#39;s lifetime. This may cause a cable to become disconnected from a plug, or it may lead to other mechanical failure. For example, a shell or other housing may become detached from other parts of a plug or connector insert. 
     Thus, what is needed are magnetic connector systems having a durable and reliable construction and a reduced height while maintaining sufficient holding strength. 
     SUMMARY 
     Accordingly, embodiments of the present invention provide magnetic connector systems having a durable and reliable construction and a reduced height while maintaining sufficient holding strength. 
     An illustrative embodiment of the present invention provides a connector insert having a robust and durable construction. This connector insert may include a crimping piece crimped over an end of a cable. The crimping piece may include fingers in a direction of a length of the cable that attach to a printed circuit board. The crimping piece may further include protrusions that extend at right angles from the fingers. These protrusions may be fixed to the back of an attraction plate. These features may form a secure, robust connection between a cable and an attraction plate. 
     This connector insert may also include retention clips on sides of an attraction plate. These retention clips may retract when a shell is slid over the attraction plate, and may relax when they reach a cutout in the shell. This may fix the shell in place relative to the attraction plate in a reliable, easily manufactured manner. 
     This connector insert may also have a light-emitting diode attached to a printed circuit board. The connector may further include a light pipe attached to the printed circuit board, and the light pipe may be angled to pass above the light-emitting diode, and further angled to pass light to an opening in the shell. 
     Another illustrative embodiment of the present invention may provide a connector insert having a reduced height. To maintain sufficient magnetic holding strength with the reduced height, the connector insert may be made wider. This may, in turn, increase a surface area of an attraction plate, thereby increasing connector insert holding strength. 
     Another illustrative embodiment of the present invention may provide a connector receptacle. This connector receptacle may have a pleasing appearance from a front. Specifically, a front of a housing forming a mesa may be oversized, and the housing may be slid into an opening in a label, such that a seam between the housing and label may not be visible to a user. 
     Another illustrative embodiment of the present invention may provide a connector receptacle having a magnetically conductive label. This magnetically conductive label may increase the holding power of magnets behind the label. The label may be attached to a shield that has a lower magnetic conductivity. To reduce lost flux, the overlap between the label and the shield may be reduced by cutting out a portion of the label. 
     Another illustrative embodiment of the present invention may provide a connector system where a connector insert may be “blind mated” to a connector receptacle. That is, the connector insert and connector receptacle may be configured such that when the connector insert is brought into close proximity to the connector receptacle in approximately a correct orientation, the magnetic attraction between the connector insert and the connector receptacle is such that the connector insert may be pulled into contact with the connector receptacle. As part of this blind mating, the physical features of the connector insert and the connector receptacle may be such that they do not pose an obstacle to the formation of this connection. This may provide an easy way for a user to make a connection of a cable to a device. Specifically, the user merely brings the connector insert in approximately a correct orientation and into proximity of the connector receptacle. From there, the magnetic attraction between the connector insert and the connector receptacle brings them into contact. Also, the physical features are such that there may be no obstacles to the formation of the connection. 
     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 a magnetic connector system according to an embodiment of the present invention; 
         FIG. 2  illustrates a connector insert according to an embodiment of the present invention; 
         FIG. 3  illustrates an exploded view of a connector insert according to an embodiment of the present invention; 
         FIG. 4  illustrates a cable crimped by a crimp piece according to an embodiment of the present invention; 
         FIG. 5  illustrates a partial assembly of a connector insert according to an embodiment of the present invention; 
         FIG. 6  illustrates another partial assembly of a connector insert according to an embodiment of the present invention; 
         FIG. 7  illustrates a side view of the partial assembly of  FIG. 6 ; 
         FIG. 8  illustrates a back side of the partial assembly shown in  FIG. 6 ; 
         FIG. 9  illustrates a back side of a partial assembly of a connector insert according to an embodiment of the present invention; 
         FIG. 10  illustrates a rear view of a connector insert according to an embodiment of the present invention; 
         FIG. 11  illustrates a cutaway view of a connector insert according to an embodiment of the present invention; 
         FIG. 12  illustrates a connector receptacle according to an embodiment of the present invention; 
         FIG. 13  illustrates an exploded view of a connector receptacle according to an embodiment of the present invention; 
         FIG. 14  illustrates a housing according to an embodiment of the present invention; 
         FIG. 15  illustrates a closer view of protrusions and notches on housings according to embodiments of the present invention; 
         FIG. 16  illustrates another connector receptacle according to an embodiment of the present invention; 
         FIG. 17  illustrates a bottom view of a connector receptacle according to an embodiment of the present invention; 
         FIG. 18  illustrates an exploded view of a connector receptacle according to an embodiment of the present invention; 
         FIG. 19  illustrates a connector insert according to an embodiment of the present invention; 
         FIG. 20  illustrates an exploded view of a connector insert according to an embodiment of the present invention; 
         FIG. 21  illustrates the assembly of a portion of a connector insert according to an embodiment of the present invention; 
         FIG. 22  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention; 
         FIG. 23  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention; 
         FIG. 24  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention; 
         FIG. 25  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention; 
         FIG. 26  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention; and 
         FIG. 27  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates a magnetic connector 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. 
     The illustrated magnetic connector system may include connector insert  110  and connector receptacle  120 . Connector receptacle  120  may be located in enclosure  130 , which may be an enclosure for a portable computing device, tablet, desktop, or all-in-one computer, cell, smart, or media phone, storage device, portable media player, navigation system, monitor or other device. 
     Connector insert  110  and connector receptacle  120  may be magnetic connectors. That is, connector insert  110  may be held in place relative to connector receptacle  120  in at least one direction by a magnetic force. For example, one or both of connector insert  110  and connector receptacle  120  may include one or more magnets, or magnetic elements or structures. These magnets may attract other magnets or magnetic structures in the other. For example, connector receptacle  120  may include one or more magnets which are attracted to an attraction plate in connector insert  110 . In a specific embodiment of the present invention, connector receptacle  120  includes four magnets arranged to have alternating or opposing polarities which are attracted to an attraction plate made of a ferromagnetic material in connector insert  110 . In another specific embodiment of the present invention, connector receptacle  120  may include three magnets arranged to have alternating polarities. In still other embodiments of the present invention, connector receptacle  120  may include one, two, or more than four magnets. 
     This magnetic connector system may be used to convey power, data, or other voltages or types of signals or information. In a specific embodiment of the present invention, the magnetic connector system conveys power to a device housed by device enclosure  130 . In this embodiment, connector insert  110  may be connected to a power adapter via cable  112 . This power adapter may receive power from a wall outlet, vehicle charger, or other power source. Connector insert  110  may also include circuitry for communicating with the power adapter. Examples of this may be found in co-pending U.S. provisional patent application No. 61/482,195, titled TIME-DOMAIN MULTIPLEXING OF POWER AND DATA, which is incorporated by reference. Connector insert  110  may further include circuitry for determining whether a valid connection to a connector receptacle has been made, and may provide an indication of such a connection using light-emitting diode opening  114 . 
     Connector insert  110  may be held in place in a Y direction relative to connector receptacle  120  using magnetic force. Connector insert  110  may align in X and Z directions relative to connector receptacle  120  through physical features on connector insert  110 , connector receptacle  120 , and device enclosure  130 . These physical features are arranged such that connector insert  110  is not physically bound to connector receptacle  120 . This allows connector insert  110  to be removed by a non-axial force, that is, forces in directions other than those in the Y direction may remove connector insert  110 . An attraction plate on connector insert  110  may have an outside edge designed to fit in an opening in enclosure  130 . The attraction plate on connector insert  110  may have an opening designed to accept a mesa on connector receptacle  120 . Contacts on connector insert  110  may be arranged to mate with contacts on connector receptacle  120  to form electrical pathways. These features are shown in various figures below. 
     Again, many electronic devices, such as portable media players, portable media devices, and laptop, netbook, and tablet computers are becoming thinner. That is, their height is being reduced. Accordingly, embodiments of the present invention may provide magnetic connector systems having a reduced height. Unfortunately, this reduced height may make it easier for connector insert  110  to be inadvertently disconnected from connector receptacle  120 . 
     Specifically, as described above, connector insert  110  may be held in place relative to connector receptacle  120  in a Y direction using magnetic force. Since the thickness of connector insert  110  is reduced in a Z direction, a small force in this direction may dislodge connector insert  110 . That is, due to the reduced thickness, the moment arm in the Z direction needed to disconnect the connector insert from the connector receptacle is reduced. Accordingly, a surface area of an attraction plate in connector insert  110  may be made correspondingly large. This, in turn, may increase the holding strength of the connector insert. An example is shown in the following figure. 
       FIG. 2  illustrates a connector insert  110  according to an embodiment of the present invention. Connector insert  110  may include an attraction plate  210 , shield or cover  220 , cable  230 , and strain relief  240 . Attraction plate  210  may include front surface  212 . Front surface  212  may include opening  260  for contacts  250 ,  252 ,  254 ,  256 , and  258 . In a specific embodiment of the present invention, contacts  250  and  258  may convey ground, contacts  252 , and  256  may convey power, while contact  254  may be used to detect that a connection has been formed. In this specific example, ground contacts  250  and  258  protrude in front of the other contacts, such that ground paths are formed before power is applied when connector insert  110  is mated with a corresponding connector receptacle. 
     Again, connector insert  110  may be relatively thin, that is, it may have a reduced height in the Z direction. To increase the magnetic hold between connector insert  110  and connector receptacle  120 , front surface area  212  of attraction plate  210  may be increased. For example, this may be done by making connector insert  110  wider. By making connector insert  110  wider, front surface area  212  of attraction plate  210  is increased, thereby increasing the holding power of connector insert  110 . 
     Again, connector insert  110  may be inserted and disconnected several thousand times during the lifetime of a device. Therefore, it may be desirable that connector insert  110  be robust and durable. Accordingly, embodiments of the present invention employ several features to increase robustness and durability. For example, the physical connections between a cable and an attraction plate, and a shell and the attraction plate, may be enhanced. Examples are shown in the following figures. 
       FIG. 3  illustrates an exploded view of a connector insert according to an embodiment of the present invention. This figure includes an attraction plate  310 . Attraction plate  310  may be made of ferromagnetic or other magnetic material. In other embodiments of the present invention, attraction plate  310  may be formed of one or more magnets. 
     Retention clips  320  may be located on sides of attraction plate  310 . Retention clips  320  may be used to secure shell  380  relative to attraction plate  310 . Specifically, shell  380  may slide over attraction plate  310 , pushing retention clips  320  against attraction plate  310 . When edge  323  reaches cutout, groove, or slot portion  382  of shell  380 , retention clip  320  may snap back, thereby holding shell  380  in place. 
     Housing  330  may be formed of a non-conducting or insulating material. Contacts  335  may be located in passages  332  in housing  330 . Contacts  335  may attach to circuit board  340  at contacts  343 . Circuit board  340  may include one or more LEDs  342 . Light from LEDs  342  may be guided by light pipe  345  to opening  384  in shell  380 . 
     Braiding in cable  360  may be pulled back and held in place by crimp piece  350 . Crimp piece  350  may include wings or protrusions  352 . Wings  352  may be spot-welded or otherwise fixed to a back of attraction plate  310  to hold cable  360  in place relative to attraction plate  310 . Strain relief  370  may protect cable  360 . Shell  380  may be placed over these components and part of attraction plate  310 . 
     Shell  380  may provide a surface that may be manipulated by a user during insertion and extraction of connector insert  110 . Shell  380  may be plastic, brushed aluminum, or other material. Shell  380  may include openings  382  on one or both sides. These openings may be filled with epoxy or other clear or colored material to prevent debris from entering opening  382 . 
     A connector insert according to an embodiment of the present invention may be assembled in various ways. In a specific embodiment of the present invention, contacts  335  may be inserted into housing  330 . Contacts  335  may then be attached to printed circuit board  340 . Crimp piece  352  may be used to crimp cable  350 . The resulting cable may be attached to printed circuit board  340 . Specifically, fingers  342  may be soldered or otherwise fixed to printed circuit board  340 . This assembly may be inserted in attraction plate  310 . Crimp piece wings  352  may be fixed to a back of attraction plate  310 . Strain relief  370  may be slid over cable  360  and wings  352 . Light pipe  345  may be attached to printed circuit board  340 . Retention clips  320  may be attached to attraction plate  310 . Shell  380  may slide over attraction plate  310  until retaining clips  320  lock in place in notch  382 . 
       FIG. 4  illustrates a cable crimped by a crimp piece according to an embodiment of the present invention. Cable  360  may include a braid and center conductor  362 . Center conductor  362  may be used to convey power, while the braid may be used to convey ground. The braid may be folded back and covered by crimp piece  350 . Crimp piece  350  may be crimped to form a secure connection to cable  360 . Crimp piece  350  may include protrusions or wings  352  and fingers  354 . Wings  352  may be spot welded or otherwise attached to the back of an attraction plate. Fingers  354  may be soldered to a printed circuit board. These connections may provide a secure connection between cable  360  and a connector insert. 
       FIG. 5  illustrates a partial assembly of a connector insert according to an embodiment of the present invention. Contacts  350 ,  352 ,  354 ,  356 , and  358  may be located in housing  330 . These contacts may also be attached to printed circuit board  340 . Printed circuit board  340  may include LEDs  342 . Fingers  354  of crimp piece  350  may be attached to printed circuit board  340 . 
       FIG. 6  illustrates another partial assembly of a connector insert according to an embodiment of the present invention. In this example, light pipe  345  has been placed above LEDs  342 . Light pipe  345  acts as a light guide to transfer light from LEDs  342  to opening  384  in shell  380 . Light pipe  345  may attach to the printed circuit board. Light pipe  345  may be angled to pass above light-emitting diodes  342 , and further angled to pass light to an opening in the shell. 
       FIG. 7  illustrates a side view of the partial assembly of  FIG. 6 . Again, light pipe  345  guides light emitted by diodes  342  into opening  382  and shell  380 . Light pipe  345  may attach to printed circuit board  340  at  346  and extend across LEDs  342 . Portion  347  may be flat to present light to opening  382  in shell  380 . 
       FIG. 8  illustrates a back side of the partial assembly shown in  FIG. 6 . The backside may also include LEDs  342 A and light pipe  345 A. Contacts  350 ,  352 ,  354 ,  356 , and  358  may be soldered to printed circuit board  340 , as shown. 
       FIG. 9  illustrates a back side of a partial assembly of a connector insert according to an embodiment of the present invention. As can be seen, protrusions or wings  352  may be spot or laser welded, or otherwise fixed, to attraction plate  310 . This, along with the attachment of fingers  354  to printed circuit board  340 , provides a robust mechanical support between cable  360  and attraction plate  310 . 
     Again, retention clips  320  may be attached to attraction plate  310 . Shell  380  may slide over this assembly, thereby pressing retention clips  320  flat against the sides of attraction plate  310 . A notch or cutout in shell  380  may allow retention clips  320  to snap back, thereby holding shell  380  in place relative to attraction plate  310 . An example is shown in the following figure. 
       FIG. 10  illustrates a rear view of a connector insert according to an embodiment of the present invention. This connector insert may include shell  380  that partially covers attraction plate  310 . Retention clips  320  may be relaxed and protruding in cutout  382 . This may prevent shell  380  from being slid backward off attraction plate  310  during use. This, in turn, holds shell  380  in place relative to attraction plate  310 , and thereby increases the durability of connector insert  110 . 
     In order to reduce the size of a connector insert according to an embodiment of the present invention, it may be desirable to limit the tolerance of the location of the contacts relative to a front surface of attraction plate. This, in turn, allows shorter contacts to be used, and may therefore reduce the length of a connector insert. An example is shown in the following figure. 
       FIG. 11  illustrates a cutaway view of a connector insert according to an embodiment of the present invention. In this example, the tolerance between leading edge  353  of pin  350  and front edge  311  of attraction plate  310  may be determined by tolerances in a limited number of very short distances. By limiting the number of factors and their lengths, the overall tolerance may be reduced. Specifically, this tolerance is the difference between a sum of the distance D 1  from a front edge  311  of attraction plate  310  to a front of housing  330  plus a thickness D 2  of a front of housing  330 , and a length of a protruding part D 3  of pin  350 . 
       FIG. 12  illustrates a connector receptacle according to an embodiment of the present invention. As shown in  FIG. 1 , receptacle  120  may be inserted or attached to device enclosure  130 . Specifically, a bottom of receptacle  120  may rest on an interior surface of enclosure  130 , and tab  1280  may fit in a notch in enclosure  130 . This may allow for a simple mechanical alignment of connector receptacle  120  in device enclosure  130 . 
     Connector receptacle  120  may include one or more magnets  1240 . For example, connector receptacle  120  may include four, fewer than four, or more than four magnets  1240 . Magnets  1240  may be covered by label  1210 . Label  1210  may be made of ferromagnetic steel or other magnetically conductive material. Label  1210  may attach to shield  1260 . Shield  1260  may be formed of non-magnetically conductive steel. In a specific embodiment of the present invention, label  1210  may be low-carbon steel, such as 10-10 steel. This may be plated with nickel, and then plated with platinum nickel. 
     Label  1210  may attach at tabs  1214  defined by cutout  1212  in shield  1260 . Cutout  1212  may reduce the overlap between label  1210  and shield  1260  in order to reduce magnetic losses. Contacts  1230  may be arranged on a mesa formed by housing  1220 . Housing  1220  may attach to housing  1270 . Housing  1270  may have openings for contacts  1250 . The mesa may have sloped edges to provide a non-binding fit when inserted inside opening  260  in attraction plate  210  of connector insert  110 . 
       FIG. 13  illustrates an exploded view of a connector receptacle according to an embodiment of the present invention. Connector receptacle  120  may include contacts  1250 , housing  1220 , label  1210 , magnets  1240 , spacers  1292  and  1294 , shield  1260 , and housing  1270 . Contacts  1250  may be inserted in housing  1220  and bent at a right angle, as shown. Housing  1220  may pass through label  1210 , magnets  1240 , and spacers  1292  and  1294 . By having housing  1220  fit over label  1210 , seams between housing  1220  and label  1210  may not be visible to a user. Housing  1270  may include openings  1272  for contacts  1250 . This assembly may then be placed in shield  1260 . Tabs  1214  on shield  1210  may be spot welded or otherwise fixed to shield  1260 . 
     Label  1210  may be formed of a ferromagnetic material or other magnetically conductive material. This may increase the magnetic attraction of magnets  1240 . To reduce wasted magnetic flux, label  1210  may be notched by cutout  1212 . More information on labels, and other labels that may be used for or instead of label  1210 , may be found in co-pending U.S. provisional application No. 61/522,620, titled LABEL FOR MAGNETIC CONNECTOR, filed Aug. 11, 2011, which is incorporated by reference. Magnets  1240  may be arranged in an alternating South-North configuration such that magnetic field lines originating in one magnet may terminate in an adjoining magnet. 
       FIG. 14  illustrates housing  1220 . Housing  1220  may include notches  1222  to receive corresponding protrusions on housing  1270 . Specifically, protrusions on housing  1270  may fit in notches  1222  to secure the position of housing  1270  relative to housing  1220 . Housing  1220  may include an oversized front portion  1224 . 
       FIG. 15  illustrates a closer view of protrusions  1272  on housing  1270  and notches  1222  on housing  1220 . 
       FIG. 16  illustrates another connector receptacle according to an embodiment of the present invention. This connector receptacle, or other connector receptacles according to embodiments of the present invention, may be used as connector receptacle  120  in  FIG. 1 , and is labeled here as  120 A. As shown in  FIG. 1 , receptacle  120  may be inserted or attached to device enclosure  130 . Specifically, a bottom of receptacle  120  may rest on an interior surface of enclosure  130 , and tab  1680  may fit in a notch in enclosure  130 . This may allow for a simple mechanical alignment of connector receptacle  120  in device enclosure  130 . 
     Connector receptacle  120 A may include one or more magnets  1640 . For example, connector receptacle  120 A may include three, fewer than three, or more than three magnets. These magnets may be covered by label  1610 . Label  1610  may be made of ferromagnetic steel or other magnetically conductive material. Label  1610  may attach to shield  1660  at points  1614 , by laser or spot welding, or other appropriate method. Shield  1660  may be formed of non-magnetically conductive steel. In a specific embodiment of the present invention, label  1610  may be low-carbon steel, such as 10-10 steel. This may be plated with nickel, and then plated with platinum nickel. 
     Contacts  1630  may be arranged on a mesa formed by housing  1620 . The mesa may have sloped edges to provide a non-binding fit when inserted inside opening  260  in attraction plate  210  of connector insert  110 . Tabs  1679  on a second housing may fit in openings on a top of shield  1660  to provide mechanical support. 
       FIG. 17  illustrates another view of the connector receptacle of  FIG. 16 . Contacts  1650  may be through-hole contacts, as shown, or they may be surface mount or other types of contacts. Contacts  1650  may connect to contacts on a printed circuit board, flexible circuit board, or other appropriate substrate. Again, tab  1680  may fit in a notch in enclosure  130 . Tabs  1662  and posts  1678  may fit in openings in a printed circuit board, flexible circuit board, or other appropriate substrate. 
       FIG. 18  illustrates an exploded view of a connector receptacle according to an embodiment of the present invention. Connector receptacle  120 A may include contacts  1650 , housing  1620 , label  1610 , magnets  1640 , spacer  1694 , shield  1660 , and housing  1670 . Contacts  1650  may be inserted in housing  1620  and bent at a right angle, as shown. Housing  1620  may pass through label  1610 , magnets  1640 , and spacer  1694 . By having housing  1620  fit over label  1610 , seams between housing  1620  and label  1610  may not be visible to a user. Housing  1670  may include openings  1672  for contacts  1650 . This assembly may then be placed in shield  1660 . Tabs  1614  on shield  1610  may be spot welded or otherwise fixed to shield  1660 . 
     Label  1610  may be formed of a ferromagnetic material or other magnetically conductive material. This may increase the magnetic attraction of magnets  1640 . More information on labels, and other labels that may be used for or instead of label  1610 , may be found in co-pending U.S. provisional application No. 61/522,620, titled LABEL FOR MAGNETIC CONNECTOR, filed Aug. 11, 2011, which is incorporated by reference. The three magnets  1640  may be arranged in an alternating South-North-South, or North-South-North configuration such that magnetic field lines originating in one magnet may terminate in an adjoining magnet. The middle magnet in magnets  1640  may include a passage for housing  1620  to pass through. 
     Again, embodiments of the present invention may provide a connector system where a connector insert may be “blind mated” to a connector receptacle. That is, the connector insert and connector receptacle may be configured such that when the connector insert is brought into close proximity to the connector receptacle in approximately a correct orientation, the magnetic attraction between the connector insert and the connector receptacle is such that the connector insert may be pulled into contact with the connector receptacle. 
     This may provide an easy way for a user to make a connection of a cable to a device. Specifically, the user may simply bring the connector insert in approximately a correct orientation and into proximity of the connector receptacle. From there, the magnetic attraction between the connector insert and the connector receptacle may bring them into contact. 
     To facilitate this blind mating, the physical features on the connector insert and connector receptacle may be such that there may be no obstacles to the formation of the connection. For example, opening  260  on attraction plate  210  of connector insert  110  may be such that it readily accepts mesa  1220  or mesa  1620  on connector receptacles. Similarly, attraction plate  210  of connector insert  110  may be such that it readily fits in an opening in device enclosure  130 . 
       FIG. 19  illustrates a connector insert according to an embodiment of the present invention. This connector insert may include attraction plate  1910 , shield or cover  1920 , cable  1930 , and strain relief  1940 . As before, attraction plate  1910  may include a front surface (not shown) having an opening for contacts (not shown). These contacts may include contacts for ground and power. One or more other contacts may be used to detect that a connection with a connector receptacle has been formed, or for other purposes. As before, ground contacts may protrude in front of the other contacts of this connector such that ground paths are formed before power is applied when this connector insert is mated with a corresponding connector receptacle. 
     As before, this connector insert may be relatively thin. That is, it may have a reduced height. To compensate for this, that is, to increase magnetic attraction between this connector insert and a corresponding connector receptacle, an area of the front surface of attraction plate  1910  may be increased. For example, this may be done by making the connector insert wider. By making the connector insert wider, the area of the front surface of attraction plate  1910  may be increased, which may increase the holding power of the connector insert. 
     Again, these connector inserts may be inserted and disconnected several thousand times during the lifetime of the device. Therefore, it may be desirable that this connector insert be robust and durable. Accordingly, embodiments of the present invention may employ several features to increase robustness and durability. For example, the physical connections between cable  1930  and attraction plate  1910 , as well as shell  1920  and attraction plate  1910 , may be enhanced. Examples are shown in the following figures. 
       FIG. 20  illustrates an exploded view of a connector insert according to an embodiment of the present invention. This figure includes attraction plate  2010 . Attraction plate  2010  may be made of a ferromagnetic or other magnetic material. In other embodiments of the present invention, attraction plate  2010  may be formed of one or more magnets, such as rare-earth magnets. 
     Retention clips  2020  may be located on sides of attraction plate  1910 . Retention clips  2020  may be used to secure shell  2080  relative to attraction plate  2010 . Specifically, retention clips  2020  may be biased away from attraction plate  2010 . Shell  2080  may slide over attraction plate  2010 , pushing retention clips  2020  against attraction plate  2010 . When edge  2023  reaches a cutout (not shown) inside of shell  2080 , retention clip  2020  may snapback, thereby holding shall  2080  in place. 
     Housing  2030  may be formed of a non-connecting or insulating material. Contacts  2035  may be located in passages in housing  2030 . Contacts  2035  may attach to circuit board  2040 . Circuit board  2040  may include one or more LEDs  2042 . Light emitted from LEDs  2042  may pass through light pipes or diffuser  2860  to opening  2084  in shell  2080 . Braiding  2062  in cable  2060  may be pulled back and held in place by crimp piece  2050 . Crimp piece  2050  may include wings or protrusions  2052 . Wings  2052  may be spot or laser welded, soldered, or otherwise fixed, to a back of attraction plate  2010  to hold cable  2060  in place relative to attraction plate  2010 . Strain relief  2070  may protect cable  2060 . Shell  2080  may be placed over these components and at least part of attraction plate  2010 . 
     Shell  2080  may provide a surface that may be manipulated by a user during insertion and extraction of the connector insert. Shell  2080  may the plastic, brushed aluminum, or other material. Shell  2080  may include openings  2084  on one or more sides. These openings may be filled with epoxy or other clear or colored material to prevent debris from entering opening  2084 . Again, connector inserts according to embodiments of the present invention may be assembled in various ways. A specific example is shown in the following figures. 
       FIG. 21  illustrates the assembly of a portion of a connector insert according to an embodiment of the present invention. Diffuser  2086  may be attached to shell  2080  such that the diffuser covers opening  2084 . Strain relief  2070  may be inserted in shell  2080 . 
       FIG. 22  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Here strain relief  2070  and shell  2080  are slid over an end of cable  2060 . The end of cable  2060  may be stripped, and the braiding of the cable pulled back over the cable. Crimping piece  2050  may be placed over the end of cable  2060  and crimped. Conductor  2062  may be flattened to assist in its connection to a printed circuit board in the connector insert, as is shown below. 
       FIG. 23  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Contacts  2035  may be inserted into openings  2032  in housing  2030 . LEDs  2042  and other circuitry  2046  may be placed on printed circuit board  2040 . Tail portions  2037  of contacts  2035  may be soldered to corresponding contacts (not shown) on circuit board  2050 , thereby attaching housing  2030  and contacts  2035  to printed circuit board  2040 . 
     Printed circuit board  2040  may include ground contacts  2047  and power contact  2048 . Ground contact  2047  and power contact  2048  may be spot or laser welded, soldered, or otherwise fixed, to crimping piece  2050  and conductor  2026 , respectively, as is shown below. 
       FIG. 24  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Retention clips  2020  may be attached to attraction plate  2010 . Specifically, retention clips  2020  may be attached to attraction plate  2010  by spot or laser welding, soldering, or other appropriate method, at location  2024 . 
       FIG. 25  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Again, crimping piece  2050  may be laser or spot welded, soldered, or otherwise fixed to contact  2047 . Similarly, conductor  2026  may be laser or spot welded, soldered, or otherwise fixed, to contact  2048  on printed circuit board  2040 . 
       FIG. 26  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Again, wings or protrusions  2052  of crimping piece  2050  may be spot or laser welded, soldered, or otherwise fixed, to a back of attraction plate  2010 . 
       FIG. 27  illustrates the assembly of another portion of a connector insert according to an embodiment of the present invention. Again, wings or protrusions  2052  may be spot or laser welded, soldered, or otherwise fixed to a back of attraction plate  2010 . Housing  2080  may be slid over attraction plate  2010 . Again, leading edges  2023  of retention clips  2020  may be biased away from attraction plate  2010 . As shell  2080  is slid over attraction plate  2010 , retention clips  2020  may be pressed against attraction plate  2010 , then released as a slot or cutout (not shown) on the side of shell  2080  is reached. At this point, leading edge  2023  may snap back, thereby holding shell  2080  in place relative to attraction plate  2010 . 
     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: 20150518
Publication Date: 20170523
Grant Date: 20170523
Priority Date: 20110811
Inventors: GAO ZHENG
Pong Joshua J.
LIGTENBERG CHRIS
ANDRE BARTLEY K.
HAMEL BRADLEY J.
DIFONZO JOHN
NARAJOWSKI DAVE
SPRINGER GREG
MONSEF ERIC
KIM MIN CHUL
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R43/205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5808", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/508", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/7172", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/582", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/665", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6471", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/658", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R4/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/048", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7175", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/582", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/665", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7175", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6471", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/048", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R4/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7172", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/5808", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6471", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/508", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7172", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/57", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5808", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6592", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/7175", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/508", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 47668888