PATENT DOCUMENT

Publication Number: US-9755337-B2
Application Number: US-201514843905-A
Country: US
Kind Code: B2

Title: Waterproof board-to-board connectors

Abstract:
Board-to-board connectors that may provide durable and reliable connections, may save board space, and may be easy to manufacture. One example may provide board-to-board connectors that provide durable connections by providing a seal between board-to-board plugs and receptacles. The seal may be an O-ring, gasket, or other seal. The seal may protect contacts on the board-to-board connectors from exposure to fluids, such as water or other corrosive fluids. This seal may provide a level of redundancy with one or more seals protecting a device from external fluids, such as a seal at or in the device enclosure.

Claims:
What is claimed is: 
     
       1. A board-to-board connector comprising:
 a board-to-board connector insert comprising a first plurality of contacts and a frame, wherein the frame has an upper surface, a surface perpendicular to the upper surface, and a notch in the surface perpendicular to the upper surface; 
 a board-to-board connector receptacle comprising a corresponding second plurality of contacts, wherein the board-to-board connector receptacle is configured to be inserted into the frame of the board-to-board connector insert; and 
 a seal between the board-to-board connector insert and the board-to-board connector receptacle, wherein the seal is an O-ring and the O-ring is located in the notch of the board-to-board connector insert. 
 
     
     
       2. The board-to-board connector of  claim 1  wherein the O-ring is attached to the board-to-board connector insert and completely surrounds the first plurality of contacts to form a continuous seal. 
     
     
       3. The board-to-board connector of  claim 2  wherein the O-ring has a circular cross section. 
     
     
       4. The board-to-board connector of  claim 2  wherein the O-ring is a multi-lobed O-ring. 
     
     
       5. The board-to-board connector of  claim 2  wherein the seal is coated with a lubricant. 
     
     
       6. The board-to-board connector of  claim 1  wherein the seal is formed using silicone. 
     
     
       7. An electronic device comprising:
 a first board comprising a first plurality of traces; 
 a board-to-board receptacle attached to the first board, the board-to-board receptacle comprising a first plurality of contacts electrically connected to the first plurality of traces; 
 a board-to-board insert inserted in the board-to-board receptacle, the board-to-board insert comprising a second plurality of contacts electrically connected to the first plurality of contacts; 
 a seal between the board-to-board receptacle and the board-to-board insert, wherein the seal is a pressure-sensitive adhesive; and 
 a second board attached to the board-to-board insert, the second board comprising a second plurality of traces electrically connected to the second plurality of contacts. 
 
     
     
       8. A method of manufacturing a board-to-board connector, the method comprising:
 molding a housing for a board-to-board connector at least partially around a plurality of contacts to form a board-to-board connector plug; 
 forming a silicone ring on a shell; 
 attaching the shell to the board-to-board connector plug; and 
 piercing the silicone ring with contacts on a board-to-board connector receptacle to connect the board-to-board connector plug to the board-to-board connector receptacle. 
 
     
     
       9. The method of  claim 8  wherein the housing is plastic. 
     
     
       10. The method of  claim 8  wherein forming the silicone ring on the shell comprises insert molding the silicone ring along an inside edge of the shell. 
     
     
       11. The method of  claim 8  wherein molding the housing for the board-to-board connector comprises injection molding the housing around portions of the plurality of contacts. 
     
     
       12. The board-to-board connector of  claim 1  wherein the board-to-board connector receptacle comprises a frame to receive the board-to-board connector insert, the frame includes a notch, and the O-ring is located in the notch. 
     
     
       13. The board-to-board connector of  claim 12  wherein the board-to-board connector insert has an upper surface, the board-to-board connector receptacle has a surface parallel to the upper surface, and the notch is in the surface parallel to the upper surface. 
     
     
       14. The board-to-board connector of  claim 1  wherein the board-to-board connector insert comprises a clip, the board-to-board connector receptacle comprises a notch, and the clip is seated within the notch when the board-to-board connector insert is inserted into the board-to-board connector receptacle. 
     
     
       15. The board-to-board connector of  claim 1  wherein the first plurality of contacts pierces the seal and forms an electrical connection with the second plurality of contacts when the board-to-board connector insert is inserted into the board-to-board connector receptacle. 
     
     
       16. The board-to-board connector of  claim 2  wherein the O-ring is a ring with a circular cross section and the O-ring is formed from a material selected from the group consisting of: silicon, silicone, rubber, plastic, nylon, elastomers, liquid-crystal polymers, and ceramics. 
     
     
       17. The electronic device of  claim 7  wherein the pressure-sensitive adhesive is double-sided. 
     
     
       18. The electronic device of  claim 7  further comprising potting material that seals the first board to the board-to-board receptacle.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional application No. 62/044,917, filed on Sep. 2, 2014, which is incorporated by reference. 
    
    
     BACKGROUND 
     The number of types of electronic devices that are commercially available has increased tremendously the past few years and the rate of introduction of new devices shows no signs of abating. Devices, such as tablet, laptop, netbook, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors, and others, have become ubiquitous. 
     The functionality of these devices has likewise greatly increased. This in turn has led to increased complexity inside of these electronic devices. For example, several boards, such as flexible circuit boards, printed circuit boards, and others, are often included in a single device. These boards may be connected together using board-to-board connectors. 
     These board-to-board connectors should typically be durable and reliable. That is, they should be durable to help ensure that the device has a long operational life. They should also form a reliable connection, otherwise disconnections between circuits and components on different boards could occur leading to a loss of functionality or failure of the device. With a reliable connection, if the device is dropped or otherwise jarred, a disconnection may be avoided. 
     Often these connectors may be large. This, in turn, may consume board area and space inside an electronic device. This may result in either the device having less functionality, a larger size, or a combination of the two. Smaller connectors may save space, allowing more functionality in a device, they may allow a device to be smaller, or a combination of each. 
     Further board-to-board connectors may also be somewhat complicated to manufacture. This may lead to increased device costs. Connectors that may be easier to manufacture may provide reduce costs. This manufacturability may be enhanced by being able to reconnect the board-to-board connectors more one or more times. 
     Thus, what is needed are board-to-board connectors that may provide durable and reliable connections. These board-to-board connectors may save board space and may be easy to manufacture. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide board-to-board connectors that may provide durable and reliable connections. These board-to-board connectors may save board space and may be easy to manufacture. An illustrative embodiment of the present invention may provide board-to-board connectors that provide durable connections by providing a seal between board-to-board inserts and receptacles. The seal may be an O-ring, gasket, or other seal. The seal may protect contacts on the board-to-board connectors from exposure to fluids, such as water or other corrosive fluids. This seal may provide a level of redundancy with one or more seals protecting a device from external fluids. If the device is exposed to a corrosive fluid, the external seals may provide a first line of protection. Fluid that may pass the external seal may be blocked by the seal on a board-to-board connector, thereby protecting board-to-board connector contacts and other structures. This may allow an electronic device to maintain functionality even when fluids may enter the device through a seal at or in a device enclosure. This may help protect a device&#39;s functionality and help to provide the device with a long life. 
     Another illustrative embodiment of the present invention may provide a board-to-board connector that provides a reliable connection by providing a seal between board-to-board inserts and receptacles. Again, the seal may be an O-ring, gasket, or other seal. The seal may help keep a board-to-board insert seated in a board-to-board receptacle. This seal may help to keep the insert in place when the device housing the board-to-board connector is subject to shock or other possibly damaging event. 
     Another illustrative embodiment of the present invention may provide board-to-board connectors that have a small size by utilizing a seal that consumes a small volume. As before, the seal may be an O-ring, gasket, or other seal. The seal may be positioned such that a height of a board-to-board connector is not increased by its inclusion. In other embodiments of the present invention, the seal may be positioned such that a width of a board-to-board connector is not increased by its inclusion. 
     Another illustrative embodiment of the present invention may provide board-to-board connectors that are readily manufactured. In one embodiment of the present invention, manufacturability may be improved by utilizing a seal that is readily manufactured, such as an O-ring, gasket, or other seal. The O-ring, gasket, or other seal may be placed or seated in a notch in a board-to-board connector insert, receptacle, or both. This increased in manufacturability may extend to the assembly process of the device as well. For example, embodiments of the present invention may provide waterproof or water resistant board-to-board connectors that may be connected and disconnected without losing the waterproofing or resistance. This is particularly important where devices may need to be reworked during assembly such that the board-to-board connectors are connected and disconnected one or more times. 
     Various embodiments of the present invention may utilize various types of seals. Again, these seals may be O-rings, gaskets, or other types of seals. The seals may be O-rings having at least a roughly circular cross section. Other types of O-rings, such as multi-lobed O-rings may be used. Embodiments may also employ a seal formed of glue, double-sided tape, or other adhesive or adhesive layer, such as a pressure-sensitive adhesive, or other elastomer or other material. The seal may be formed as part of either or both the board-to-board connector receptacle or insert. For example, either the connector receptacle or insert may be formed using a two-shot process where the first shot uses a relativity rigid plastic or other material for a frame and a second shot uses a relatively softer, flexible plastic, elastomer, or other material. In other embodiments of the present invention, a layer may be placed between a connector receptacle and insert before insertion. During insertion, contacts in either the receptacle or insert may pierce the layer to form electrical connections with corresponding contacts in either the insert or receptacle. The layer may be removable to allow for rework or reinsertion of the insert into the receptacle. The layer may be formed of silicone or other material. The O-rings, gaskets, or other types of seals may be lubricated with grease, oil, or other substance to facilitate insertion and extraction of a board-to-board insert into and out of a board-to-board receptacle. 
     In various embodiments of the present invention, a board-to-board connector insert may include a notch. An O-ring or other seal may be placed or seated in the notch. The notch may be along an outside edge of a connector insert housing. In other embodiments of the present invention, the notch may be along a surface of the connector insert housing that is parallel to a board supporting the insert. In other embodiments of the present invention, the notch may be located along an inside edge of a housing for a board-to-board connector receptacle. In still other embodiments of the present invention, the notch may be along a surface of the connector receptacle housing that is parallel to a board supporting the insert. O-rings, gaskets, or other seals may be located in these notches. 
     When the insert is inserted into the corresponding receptacle, the O-ring may be in contact with a face of a housing for the receptacle (or insert.) This face may be flat or it may be undercut. The undercut may be used to increase an insertion force that is needed to insert a board-to-board connector insert into a board-to-board connector receptacle and an extraction force that is necessary to extract a board-to-board connector insert from a board-to-board connector receptacle. For example, where a connector and a seal is made using a two-shot process, an extraction force may be tuned by adjusting the durometrics or hardness of the material used to form the seal, the size of the seal, and the depth of the undercut. By tuning the extraction force, the reliability of the connection may be increased and the ability to rework or remake the connection may be preserved. These insertion and extraction forces may replace or supplement insertions and extraction forces that may be provided by clips and notches on either or both a board-to-board connector insert and connector receptacle. 
     Another illustrative embodiment of the present invention may provide a board-to-board connector system. This system may include a plug and a receptacle. A silicone ring or gasket may form a seal between a shell of the receptacle and a shell of the plug. This seal may prevent the ingress of moisture into the board-to-board connector system. The receptacle may include a housing in a shell. The housing may include a number of slots for contacts. The housing may further include an opening to accept a raised portion on the plug. The plug may include a housing. The plug housing may include a raised portion to mate with an opening in the receptacle housing. Plug contacts may be exposed along the top and sides of the raised portion. Plug contacts may terminate in surface mount portions. A silicone ring or gasket may be formed along an inside portion of the plug shell. When the plug is mated with the receptacle, the raised portion of the plug may be inserted into the opening of the receptacle. The receptacle housing and shell of the receptacle may fit in the recess formed by the shell and silicone ring or gasket of the plug. 
     Various embodiments of the present invention may utilize various additional techniques for waterproofing or increasing water resistance. For example, a board-to-board connector receptacle or insert may be mounted to a board. The attachment to a board may be potted or sealed using a potting material such as epoxy or other adhesive, a liquid plastic, or other potting material. Alternately, an entire board may be potted or sealed. In these embodiments the board-to-board connector may not be potted in order to allow the board-to-board connector to be reworked or reconnected. This waterproofing, or increase in water resistance may work in conjunction with a seal between the board-to-board insert and receptacle and any seals in a housing of the electronic device to help waterproof or increase the water resistance of the overall device. The boards themselves may be protected with a conformal coating or other protective layer to further improve the waterproofing or water resistance of the device. 
     Accordingly, when a device is exposed to a fluid, one or more seals at or in a housing or enclosure may protect internal circuits and components. If water or other fluid does get inside the device, components and circuits on a board may be protected by the conformal or other coating, the potting between the board and board-to-board connector, and the seal between the board-to-board receptacle and insert. In still other embodiments of the present invention, a device may be designed to allow fluid ingress. In this case, these board-to-board connectors may protect contacts and other structures from damage due to exposure from these fluids. 
     Another illustrative embodiment of provides a board-to-board connector for connecting traces on a first board to traces on a second board. One embodiment may provide an electronic device comprising a first board comprising a first plurality of traces. A board-to-board receptacle may be attached to the first board. The board-to-board receptacle may include a first plurality of contacts electrically connected to the first plurality of traces. A board-to-board insert may be inserted in the board-to-board receptacle. The board-to-board insert may include a second plurality of contacts electrically connected to the first plurality of contacts. A seal may be located between the board-to-board receptacle and board-to-board insert. A second board may be attached to the board-to-board insert. The second board may include a second plurality of traces electrically connected to the second plurality of contacts. 
     The board-to-board connector receptacles and inserts employed by embodiments of the present invention may be connected to various types of boards. For example, they may be connected to flexible circuit boards, printed circuit boards, or other appropriate substrates. These boards may include various layers having traces or planes on them, where the various traces and planes are connected using vias between layers. A flexible or printed circuit board may be formed as part of a larger flexible or printed circuit board that may form a logic or motherboard in an electronic device. In other embodiments of the present invention, these boards may be formed of conductive or metallic traces and planes in or on a nonconductive body. The nonconductive body may be formed of plastic or other materials. 
     In various embodiments of the present invention, the components of the board-to-board connectors may be formed in various ways of various materials. For example, contacts and other conductive portions of board-to-board connectors may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions, such as the receptacle and insert housings, O-rings, gaskets, and other portions, may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, elastomers, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. 
     Embodiments of the present invention may provide connector receptacles that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector receptacles may provide pathways for signals that are compliant with various standards such as Universal Serial Bus (USB), High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     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 portion of an electronic system according to an embodiment of the present invention; 
         FIG. 2  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 3  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 4  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 5  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 6  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 7  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 8  illustrates a portion of an electronic system according to an embodiment of the present invention; 
         FIG. 9  illustrates a portion of a board-to-board connector according to an embodiment of the present invention; 
         FIG. 10  illustrates a portion of a board-to-board connector according to an embodiment of the present invention; 
         FIG. 11  illustrates a board-to-board connector system according to an embodiment of the present invention; 
         FIG. 12  illustrates a side view of a portion of an electronic device according to an embodiment of the present invention; 
         FIG. 13  illustrates another board-to-board connector system according to an embodiment of the present invention; 
         FIG. 14  illustrates a side view of a portion of an electronic device according to an embodiment of the present invention; 
         FIGS. 15-17  illustrate steps in the assembly of a plug according to an embodiment of the present invention; and 
         FIGS. 18-19  illustrate steps in the assembly of a receptacle according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates a portion of an electronic system according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. Also, while the term waterproof may be used herein, it is understood that embodiments of the present invention may provide waterproofing or at least an increased resistance to water (or other fluid.) 
     This figure includes a board-to-board connector having a seal. This seal may act in conjunction with one or more seals in or at a device housing or enclosure to provide a redundant level of waterproofing or increase in water (or other fluid) resistance. This increase in water resistance may protect contacts in the board-to-board connector, as well as traces in boards and components connected to the boards attached to the board-to-board connector. That is, this seal may provide an additional increase in water resistance that may otherwise be provided by seals, such as seals at or in a device enclosure or housing. In other embodiments of the present invention, this board-to-board connector may be submersible. In this case, the seal may provide a front line of water resistance. 
     Specifically, this figure includes a board-to-board connector including board-to-board connector insert  110  and board-to-board connector receptacle  120 . Connector insert  110  may be attached to a first board  140 . Connector receptacle  120  may be attached to a second board  150 . Traces in a first board  140  may be electrically connected to contacts in insert  110 . These contacts may be located in various positions on connector insert  110  in various embodiments of the present invention. For example, these contacts may be located at positions  112 ,  114 , or  116 , or combinations thereof. Traces in the second board  150  may be electrically connected to contacts in connector receptacle  120 . These contacts may be located in various positions on connector receptacle  120  in various embodiments of the present invention. For example, these contacts may be located at positions  122 ,  124 ,  126 ,  128 , or combinations thereof. 
     A seal  130  may be located between connector insert  110  and connector receptacle  120 . This seal may be an O-ring, gasket, or other type of seal. For example, seal  130  may be an O-ring having a circular cross section as shown. In other embodiments of the present invention, seal  130  may be a multi-lobed O-ring. In various embodiments of the present invention, the seal  130  may be lubricated or covered with grease, oil, or other lubricant to facilitate the insertion and extraction of connector insert into and out of connector receptacle  120 . 
     In this embodiment of the present invention, notch  119  may be formed in a housing of board-to-board connector insert  110 . Seal  130  may be stretched radially around the housing of the connector insert  110 . More specifically, seal  130  may be located or seated in notch  119 . In this way, the inclusion of seal  130  may have no or only a limited effect in the overall height, width, and length of the board-to-board connector. When connector insert  110  is inserted into connector receptacle  120 , seal  130  may contact sealing surface or face  122 . 
     In various embodiments of the present invention, it may be highly desirable to be able to rework or replace either or both boards  140  and  150 . Accordingly, embodiments of the present invention may provide a board-to-board connector where the inserts may be readily and repeatedly inserted into and extracted from a corresponding receptacle. Moreover, this force may be adjusted by varying the durometrics or hardness of seal  130 . Also, in various embodiments of the present invention, a mating face  122  of a connector receptacle may be undercut or be shaped in other ways to adjust the insertion and extraction forces. In this way, a holding force of a connector insert in a connector receptacle may be adjusted to improve the reliability of a connection formed by the board-to-board connector. 
     In various embodiments of the present invention, the waterproofing or fluid resistance of this board-to-board connector may be supplemented in various ways. For example, in this example and the other embodiments of the present invention, the areas or edges of attachment between a board-to-board insert and a board-to-board receptacle and their corresponding boards may be potted or otherwise sealed. For example, an area or edge of attachment between a board  140  and board-to-board connector insert  110  may be potted at locations  160 . This potting, and the other potting shown in these examples, may be done with adhesives, such as epoxy, liquid or high viscosity plastic, or other material. In still other embodiments of the present invention, board  140  may itself may be covered with a waterproof or water resistant coating, such as a potting material, conformal coating, or other such coating. Similarly, an area or edge of attachment between board  150  and board-to-board connector receptacle  120  may be potted at locations  162 . In still other embodiments the present invention, board  150  may be covered with a waterproof or water resistant coating, such as a parting material, conformal coating, or other such coating. 
       FIG. 2  illustrates a portion of an electronic device according to an embodiment of the present invention. More specifically, this figure illustrates a board-to-board connector where a board-to-board connector insert has been inserted into a board-to-board connector receptacle. In this example, seal  130  is compressed such that the ingress path between the board-to-board connector insert  110  and board-to-board connector receptacle  120  is blocked by seal  130 . The ingress path between board-to-board connector insert  110  and board  140  may be blocked by potting  160 . Similarly, an ingress path between board-to-board receptacle  120  and board  150  may be blocked by potting material  162 . This may protect the contacts in the center  210  of the board-to-board connector from exposure to water or other corrosive fluids. 
     When a connector insert is mated with a connector receptacle, traces in a first board may be electrically connected to traces in a second board. In this example, traces in board  140  may be electrically connected to contacts in a center region  210  of board-to-board connector insert  110 . These contacts may form electrical connections with corresponding contacts in a center portion  210  of board-to-board connector receptacle  120 . The contacts in connector receptacle  120  may be electrically connected to traces in board  150 . In this way, electrical components or circuits on board  140  may be electrically connected to components or circuits on board  150 . 
     In the above examples, seal  130  may be located in a notch  119  formed in an outer edge of board-to-board connector insert  110 . In other embodiments of the present invention, seal  130  may be located in a notch formed in an inner edge of board-to-board connector receptacle  120 . For example, the notch may be located in face  122  of board-to-board connector receptacle  120 . In still other embodiments of the present invention, seal  130  may be located in a notch formed in another surface of the connector insert or receptacle. An example is shown in the following figure. 
       FIG. 3  illustrates a portion of an electronic device according to an embodiment of the present invention. In this example, a board-to-board connector insert  310  may be attached to a first board  340  and a board-to-board connector receptacle  320  may be attached to a second board  350 . A seal  330  may be used to block a fluid ingress path between board-to-board connector insert  310  and board-to-board connector receptacle  320 . Seal  330  may be placed or seated in notch  332  in a top surface of connector receptacle  320 . Seal  330  may contact a top surface  312  or connector insert  310 . The board-to-board connector insert  310  and board-to-board connector receptacle  320  may include contacts and may be potted to their respective boards as shown above. 
       FIG. 4  illustrates a portion of an electronic device according to an embodiment of the present invention. In this figure, board-to-board connector insert  310  has been inserted into board-to-board connector receptacle  320 . Seal  330  may be compressed to block and ingress path between board-to-board connector insert  310  and board-to-board connector receptacle  320 . 
     Clips  410  may be included on a connector insert  310 . Clips  410  may be seated in notches  420  in connector receptacle  320 . These clips  410  and notches  420  may help keep connector insert  310  seated in connector receptacle  320 . This may further help to keep seals  130  under compression to form an effective fluid ingress block. During insertion, clips  410  may deflect then retract into notch  420  to allow the insertion of connector insert  310  into connector receptacle  320 . This action may provide a snap as the connector insert  310  is inserted into and extracted from connector receptacle  320 . 
     Again, the seals employed by embodiments the present invention may be formed in various ways and of various materials. An example is shown in the following figure. 
       FIG. 5  illustrates a portion of an electronic device according to an embodiment of the present invention. In this example, board-to-board connector insert  510  may be attached to board  540 . This attachment, as in the other examples, may be sealed with potting material  560 . Board-to-board connector receptacle  520  may be attached to a second board  550 . As in the other examples, this attachment may be sealed with a potting material, shown here as potting material  562 . 
     In this example, board-to-board connector insert  510  may be formed using a double or two-shot manufacturing process. Specifically, the housing  512  may be molded around a plurality of contacts (not shown) located in positions as shown in  FIG. 1 . This mold may be relatively rigid. A second shot may form seal  530 . Seal  530  may be relatively more flexible than housing  512  and may be an elastomer or formed of another material. Seal  530  may mate with sealing face  590  after insertion. As in the other examples, sealing face  590  may be undercut to more securely hold seal  530  in place. By adjusting a size and hardness of seal  530 , and a depth of an undercut on face  590 , insertion and extraction forces for board-to-board connector insert  510  and board-to-board connector receptacle  530  may be tuned. This tuning may be used to adjust fluid resistance provided by seal  530 , as well as to adjust the insertion and extraction forces needed to insert and remove connector insert  510  into and from connector receptacle  520 . 
       FIG. 6  illustrates a portion of an electronic device according to an embodiment of the present invention. In this example, when board-to-board connector insert  510  is mated with board-to-board connector receptacle  520 , seal  530  may contact sealing surface or face  590  to block an ingress path between connector insert  510  and connector receptacle  520 . 
     Again, seals between board-to-board connector inserts and board-to-board connector receptacles may be formed of various materials. An example is shown in the following figure. 
       FIG. 7  illustrates a portion of an electronic device according to an embodiment of the present invention. This figure includes a board-to-board connector insert  710  attached to a first board  740 . A board-to-board connector receptacle  720  may be attached to a second board  750 . In this example, adhesive  730  may engage a sealing surface  712  to block an ingress path between a connector insert  710  and connector receptacle  720 . Adhesives  730  may be formed of a pressure sensitive adhesive, epoxy, double-sided tape, or other adhesive. This adhesive may also be used to adjust insertion and extraction force for this board-to-board connector. As with each of the other examples shown, the connectors in this embodiment may include contacts in locations shown in  FIG. 1  and they may be potted as in the other examples. 
       FIG. 8  illustrates a portion of an electronic device according to an embodiment of the present invention. In this example, adhesive layer  730  may block an ingress path between board-to-board connector insert  710  and board-to-board connector receptacle  720 . As in other embodiments of the present invention, either or both connector inserts  710  or connector receptacles  720  may include clips  810  and notches  820 . These clips and notches may secure connector insert  720  in place in connector receptacle  720 . This may keep a force applied to adhesive layer  730 , thereby improving the fluid resistance provided. 
     In other embodiments of the present invention, other types of seals may be used. For example, seals may be provided around one or more contacts. An example is shown in the following figure. 
       FIG. 9  illustrates a portion of a board-to-board connector according to an embodiment of the present invention. In this example, a sealing layer  930  may be located between a first contact  910  and a second contact  920 . Contact  910  may be in a connector insert or receptacle, while contact  920  may be in a corresponding connector receptacle or insert. Sealing layer  930  may be a silicone or other type of layer that may provide an increased fluid resistance between a board-to-board connector insert and a board-to-board connector receptacle. Sealing layer  930  may be placed around individual contacts, or it may be a layer placed between an insert and receptacle. When the board-to-board connector insert is inserted into the board-to-board connector receptacle, sealing layer  930  may be pierced, allowing an electrical connection between contacts  910  and  920 . Sealing layer  930  may be cored or have material removed in various locations to allow the silicone or other material to flow laterally when this electrical connection is formed. An example is shown in the following figure. 
       FIG. 10  illustrates a portion of a board-to-board connector according to an embodiment of the present invention. In this example, a board-to-board connector insert has been inserted into a board-to-board connector receptacle. Contact  910  has pierced sealing layer  930  to make an electrical contact with contact  920 . 
       FIG. 11  illustrates a board-to-board connector system according to an embodiment of the present invention. This example includes a receptacle  1110  and a plug  1150 . Silicone ring or gasket  1180  may form a seal between shell  1140  of receptacle  1110  and shell  1190  of plug  1150 . This seal may prevent the ingress of moisture into the connector. 
     Receptacle  1110  may include housing  1120  in shell  1140 . Housing  1120  may include a number of slots  1124  for contacts  1130 . Housing  1120  may further include an opening  1122  to accept a raised portion  1162  on plug  1150 . Shell  1140  may include flange  1142 . 
     Plug  1150  may include housing  1160 . Housing  1160  may include a raised portion  1162  to mate with opening  1122  in housing  1120  of receptacle  1110 . Contacts  1170  may be exposed along the top and sides of raised portion  1162 . Contacts  1170  may terminate in surface mount portions  1172 . Shell  1190  may include flange  1192 . Silicone ring or gasket  1180  may be formed along an inside portion of shell  1190 . 
     When plug  1150  is mated with receptacle  1110 , raised portion  1162  of plug  1150  may be inserted into opening  1122  of receptacle  1110 . Housing  1120  and shell  1140  of receptacle  1110  may fit in the recess formed by shell  1190  and silicone ring or gasket  1180  of plug  1150 . A side view of this is shown in the following figure. 
       FIG. 12  illustrates a side view of a portion of an electronic device according to an embodiment of the present invention. In this example, plug  1150  may be mounted on a flexible circuit board, printed circuit board, or other appropriate substrate  1210 . Receptacle  1110  may be mounted on a flexible circuit board, printed circuit board, or other appropriate substrate  1220 . 
     Traces or pads on flexible or printed circuit board  1210  may be electrically connected to surface mount portions  1172  of contacts  1170  in plug  1150 . Flexible or printed circuit board  1210  may be mechanically supported by a cowling or other structure (not shown.) Contacts  1170  may further include a stabilizing portion  1174 . Stabilizing portion  1174  may be embedded in housing  1160 . Contact  1170  may include a U-shaped portion exposed on a surface of raised portion  1162  of housing  1160 . Plug  1150  may further include shell  1190  and silicone ring or gasket  1180 . 
     Contacts  1170  may electrically connect to contacts  1130  in receptacle  1110 . Contacts  1130  may further include barb  1134  that be secured in place in housing  1120 . Contacts  1130  may further include through-hole portions  1132  to connect to traces in flexible or printed circuit board  1220 . Flexible or printed circuit board  1220  may be mechanically supported by cowling or other structure  1230 . Receptacle  1110  may further include shell  1140 . Shell  1140  may include flange  1142 . Flange  1142  may be soldered to flexible or printed circuit board  1220  to provide further protection against moisture ingress by preventing leakage between shell  1140  and flexible or printed circuit board  1220 . 
     Silicone ring or gasket  1180  may be located between shell  1190  of plug  1150  and shell  1140  of receptacle  1110 . This silicone ring or gasket  1180  may prevent moisture ingress into the board-to-board connector. 
     Traces in flexible or printed circuit board  1210  may electrically connect to traces in flexible or printed circuit board  1220  through surface mount portion  1172 , contacts  1170 , contacts  1130 , and through-hole portions  1132 . 
     Shell  1140  of receptacle  1110  and shell  1190  of plug  1150  may be electrically connected to ground or other potential, or they may be floating. They may contact or otherwise be electrically connected to each other, or they be separate. In one embodiment of the present invention, they may each be grounded and they may contact each other to form a faraday cage around contacts  1130  in receptacle  1110  and contacts  1170  in plug  1150 . In another embodiment of the present invention, they may each be floating and separate from each other. 
     In this example, contacts  1170  are shown as having surface mount portions  1172 , though in other embodiments of the present invention, contacts  1170  may be through-hole contacts having through-hole portions to connect to traces in flexible or printed circuit board  1210 . Similarly, while contacts  1130  are shown as having through-hole portions  1132 , in other embodiments of the present invention, contacts  1130  may be surface-mount contacts having surface-mount portions to connect to traces in flexible or printed circuit board  1220 . 
     As with the above examples, this board-to-board connector may provide a connector that may allow reworking during assembly. For example, flexible or printed circuit board  1220  attached to receptacle  1110  may be connected to plug  1150 . If it is found that flexible or printed circuit board  1220  is nonfunctional, flexible or printed circuit board  1220  may be extracted, and a new flexible or printed circuit board  1220  and receptacle  1110 , or a reworked flexible or printed circuit board  1220  and receptacle  1110 , may be inserted into plug  1150 . 
       FIG. 13  illustrates another board-to-board connector system according to an embodiment of the present invention. This example includes a receptacle  1310  and a plug  1350 . Silicone ring or gasket  1380  may form a seal between shell  1340  of receptacle  1310  and shell  1390  of plug  1350 . This seal may prevent the ingress of moisture into the connector. 
     Receptacle  1310  may include housing  1320  in shell  1340 . Housing  1320  may include a number of slots  1324  for contacts  1330 . Housing  1320  may further include an opening  1322  to accept a raised portion  1362  on plug  1350 . Shell  1340  may include flange  1342 . 
     Plug  1350  may include housing  1360 . Housing  1360  may include a raised portion  1362  to mate with opening  1322  in housing  1320  of receptacle  1310 . Contacts  1370  may be exposed along the top and sides of raised portion  1362 . Contacts  1370  may terminate in surface mount portions  1372 . Shell  1390  may include flange  1392 . Silicone ring or gasket  1380  may be formed along an inside portion of shell  1390 . A gap  1364  may exist between silicone ring or gasket  1380  and housing  1360  in plug  1350 . 
     When plug  1350  is mated with receptacle  1310 , raised portion  1362  of plug  1350  may be inserted into opening  1322  of receptacle  1310 . Housing  1320  and shell  1340  of receptacle  1310  may fit in the recess formed by shell  1390  and silicone ring or gasket  1380  of plug  1350 . A side view of this is shown in the following figure. 
       FIG. 14  illustrates a side view of a portion of an electronic device according to an embodiment of the present invention. In this example, plug  1350  may be mounted on a flexible circuit board, printed circuit board, or other appropriate substrate  1410 . Receptacle  1310  may be mounted on a flexible circuit board, printed circuit board, or other appropriate substrate  1420 . 
     Traces or pads on flexible or printed circuit board  1410  may be electrically connected to surface mount portions  1372  of contacts  1370  in plug  1350 . Flexible or printed circuit board  1410  may be mechanically supported by a cowling or other structure (not shown.) Contact  1370  may include a U-shaped portion exposed on a surface of raised portion  1362  of housing  1360 . Plug  1350  may further include shell  1390  and silicone ring or gasket  1380 . Shell  1390  may include flange  1392 . Flange  1392  may be soldered to printed circuit board  1410  to provide further protection against moisture ingress by preventing leakage between shell  1390  and flexible or printed circuit board  1410 . 
     Contacts  1370  may electrically connect to contacts  1330  in receptacle  1310 . Contacts  1330  may further include barb  1334  that be secured in place in housing  1320 . Contacts  1330  may further include through-hole portions  1332  to connect to traces in flexible or printed circuit board  1420 . Flexible or printed circuit board  1420  may be mechanically supported by cowling or other structure  1430 . Receptacle  1310  may further include shell  1340 . Shell  1340  may include flange  1342 . Flange  1342  may be soldered to flexible or printed circuit board  1420  to provide further protection against moisture ingress by preventing leakage between shell  1340  and flexible or printed circuit board  1420 . 
     Silicone ring or gasket  1380  may be located between shell  1390  of plug  1350  and shell  1340  of receptacle  1310 . This silicone ring or gasket  1380  may prevent moisture ingress into the board-to-board connector. 
     Traces in printed circuit board  1410  may electrically connect to traces in flexible or printed circuit board  1420  through surface mount portion  1372 , contacts  1370 , contacts  1330 , and through-hole portions  1332 . 
     Shell  1340  of receptacle  1310  and shell  1390  of plug  1350  may be electrically connected to ground or other potential, or they may be floating. They may contact or otherwise be electrically connected to each other, or they be separate. In one embodiment of the present invention, they may each be grounded and they may contact each other to form a faraday cage around contacts  1330  in receptacle  1310  and contacts  1370  in plug  1350 . In another embodiment of the present invention, they may each be floating and separate from each other. 
     In this example, contacts  1370  are shown as having surface mount portions  1372 , though in other embodiments of the present invention, contacts  1370  may be through-hole contacts having through-hole portions to connect to traces on flexible or printed circuit board  1410 . Similarly, while contacts  1330  are shown as having through-hole portions  1332 , in other embodiments of the present invention, contacts  1330  may be surface-mount contacts having surface-mount portions to connect to traces in flexible or printed circuit board  1420 . 
     As with the above examples, this board-to-board connector may provide a connector that may allow reworking during assembly. For example, flexible or printed circuit board  1420  attached to receptacle  1310  may be connected to plug  1350 . If it is found that flexible or printed circuit board  1420  is nonfunctional, flexible or printed circuit board  1420  may be extracted, and a new flexible or printed circuit board  1420  and receptacle  1310 , or a reworked flexible or printed circuit board  1420  and receptacle  1310 , may be inserted into plug  1350 . 
     Receptacle  1310  and plug  1350  may be formed in various ways consistent with embodiments of the present invention. Examples are shown in the following figures. Receptacle  1110  and plug  1150  may be formed in the same or similar manner using the same or similar materials. 
       FIG. 15  illustrates steps in the assembly of a plug according to an embodiment of the present invention. Contacts  1370  may be formed by stamping, printing, or other process. Contacts  1370  may be arranged such that surface mount portions  1372  of contacts  1370  extend in alternating directions as shown. This may provide an increased lateral spacing between surface mount portions  1372 , thereby simplifying the attachment of the plug  1350  to a printed circuit board or other appropriate substrate. Housing  1360  may be injection molded around portions of contacts  1370 . Housing  1360  may include tabs  1510 . Housing  1360  may be formed of plastic or other nonconductive material. 
       FIG. 16  illustrates steps in the assembly of a plug according to an embodiment of the present invention. Silicone ring or gasket  1380  may be insert molded along an inside edge of shell  1390 . Silicone ring or gasket  1180  may be formed of silicone, rubber, or other pliant material. Silicone ring or gasket  1180  may be insert molded, it may be formed separately then attached to shell  1390 , or it may be formed in other ways. Shell  1390  may be metallic and stamped, printed, deep-drawn, or formed using other process. 
       FIG. 17  illustrates steps in the assembly of a plug according to an embodiment of the present invention. Housing  1360  may be mated with shell  1390 . Specifically, tabs  1510  of housing  1560  may be mated with notches  1710  on shell  1390 . Tabs  1510  may be press-fit into notches  1710 , or they may be joined in other ways. As before, gap  1364  may exist between housing  1360  and shell  1390 . 
       FIG. 18  illustrates steps in the assembly of a receptacle according to an embodiment of the present invention. In this example, housing  1320  may be insert molded into shell  1340 . Housing  1320  may be plastic or other nonconductive material. Shell  1340  may be metallic and stamped, printed, deep-drawn, or formed using other process. 
       FIG. 19  illustrates steps in the assembly of a receptacle according to an embodiment of the present invention. Contacts  1330  may be inserted into openings  1324  in housing  1320 . The result may be receptacle  1310 . Contacts  1330  may be formed by stamping, printing, or other process. Contacts  1330  may be press-fit into openings  1324  in housing  1320  or inserted into openings  1324  in housing  1320  in other ways. 
     Again, embodiments of the present invention may provide connector receptacles that may be located in, and may connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These connector receptacles may provide pathways for signals that are compliant with various standards such as Universal Serial Bus (USB), High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles may be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     The board-to-board connector receptacles and inserts employed by embodiments of the present invention may be connected to various types of boards. For example, they may be connected to flexible circuit boards, printed circuit boards, or other appropriate substrates. These boards may include various layers having traces or planes on them, where the various traces and planes are connected using vias between layers. A flexible or printed circuit board may be formed as part of a larger flexible or printed circuit board that may form a logic or motherboard in an electronic device. In other embodiments of the present invention, these boards may be formed of conductive or metallic traces and planes in or on a nonconductive body. The nonconductive body may be formed of plastic or other materials. 
     In various embodiments of the present invention, the components of the board-to-board connectors may be formed in various ways of various materials. For example, contacts and other conductive portions of board-to-board connectors may be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions may be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They may be plated or coated with nickel, gold, or other material. The nonconductive portions, such as the receptacle and insert housings, O-rings, gaskets, and other portions, may be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions may be formed of silicone or silicone, rubber, hard rubber, plastic, nylon, elastomers, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. 
     The above examples of embodiments of the present invention may have many common elements. For example, the contacts and their positions in the connector inserts and receptacles may be the same or different among each embodiment. The potting done at the connections and edges of the connector inserts and receptacles may likewise be the same or different among each embodiment. The boards also may be the same or different among each embodiment. 
     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: 20150902
Publication Date: 20170905
Grant Date: 20170905
Priority Date: 20140902
Inventors: BRZEZINSKI MAKIKO K.
BUSHNELL TYLER S.
NAZZARO DAVID I.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R43/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5219", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/716", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/716", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5219", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 56165376