PATENT DOCUMENT

Publication Number: US-8777666-B2
Application Number: US-201213607566-A
Country: US
Kind Code: B2

Title: Plug connector modules

Abstract:
A plug connector module that includes a metal frame having a base portion, an insertion end and a cavity that extends from the base portion into the insertion end. The insertion end is configured to be inserted into a cavity of a corresponding receptacle connector. A substrate extends through the base portion of the frame and into the insertion end. A first plurality of external contacts is positioned in a first opening and a second plurality of contacts positioned within a second opening. One or more electronic components is coupled to the substrate, and a first encapsulant that covers and environmentally seals the one or more electronic components. A second encapsulant covers and environmentally seals a metal shield and at least a portion of a leg that extends from the shield.

Claims:
What is claimed is: 
     
       1. A plug connector module comprising:
 a metal frame having a base portion, an insertion end and a cavity that extends from the base portion into the insertion end, the insertion end being configured to be inserted into a cavity of a corresponding receptacle connector and having width, height and length dimensions along with first and second opposing exterior surfaces extending in the width and length dimensions, the first exterior surface including a first opening and the second exterior surface including a second opening directly opposite the first opening; 
 a substrate that extends through the base portion of the frame and into the insertion end, the substrate having a plurality of contact bonding pads at one end positioned within the frame, a plurality of conductor bonding pads at the opposing end and at least one ground pad contact between the contact bonding pads and conductor bonding pads; 
 a first plurality of external contacts positioned within the first opening and bonded to some of the plurality of contact bonding pads on the substrate; 
 a second plurality of contacts positioned within the second opening and bonded to some of the plurality of contact bonding pads on the substrate; 
 one or more electronic components coupled to the substrate; 
 a first encapsulant that covers and environmentally seals the one or more electronic components; 
 a metal shield coupled to the base portion of the metal frame and encasing a portion of the substrate and the one or more electronic components, the metal shield having a leg that is substantially perpendicular to the substrate and coupled to the substrate at the ground pad; and 
 a second encapsulant that covers and environmentally seals the ground pad and at least a portion of the leg. 
 
     
     
       2. The plug connector module set forth in  claim 1  wherein the metal shield comprises first and second halves that are welded to the base portion and welded to each other at mating plates on opposing sides of the shield. 
     
     
       3. The plug connector module set forth in  claim 2  wherein each half of the metal shield further comprises first and second wings that extend out of the respective half in a plane parallel to the substrate. 
     
     
       4. The plug connector module set forth in  claim 3  wherein the first wing of the first half of the metal shield includes at least one hole that is aligned with a hole on the first wing of the second half of the metal shield and wherein the second wing of the first half of the metal shield includes at least one hole that is aligned with a hole on the second wing of the second half of the metal shield. 
     
     
       5. The plug connector module set forth in  claim 1  wherein each of the first and second plurality of contacts consist of eight contacts spaced in a single row. 
     
     
       6. The plug connector module set forth in  claim 5  wherein each of the first and second plurality of contacts includes a ground contact designated for ground, a first pair of data contacts configured to enable communication using a first communication protocol, a second pair of data contacts configured to enable communication using a second communication protocol different than the first protocol, a power in contact designated to carry a first power signal at a first voltage, a power out contact capable of carrying a second power signal at a second voltage lower than the first voltage, and an ID contact capable of carrying a configuration signal that identifies the communication protocols used by the first and second pairs of data contacts. 
     
     
       7. The reversible plug connector set forth in  claim 6  wherein the first pair of data contacts in the first row and second row are positioned in a mirrored relationship directly opposite each other and the second pair of data contacts in the first row and second row are positioned in a mirrored relationship directly opposite each other. 
     
     
       8. The reversible plug connector set forth in  claim 6  wherein the ground contacts in the first and second row are positioned in a cater corner relationship with each other across a centerline of the connector. 
     
     
       9. The reversible plug connector set forth in  claim 6  wherein the first power contacts in the first and second row are positioned in a cater corner relationship with each other across a centerline of the connector. 
     
     
       10. The reversible plug connector set forth in  claim 6  wherein the ID contacts in the first and second row are positioned in a cater corner relationship with each other across a first quarter line of the connector. 
     
     
       11. The reversible plug connector set forth in  claim 6  wherein the second power contacts in the first and second row are positioned in a cater corner relationship with each other across a second quarter line of the connector. 
     
     
       12. The plug connector set forth in  claim 6  wherein each of the first and second pairs of data contacts is positioned directly between two of the following contacts: the ground contact, the first power contact, the second power contact or the ID contact. 
     
     
       13. The plug connector set forth in  claim 1  wherein the one or more electronic components includes an integrated circuit programmed with identification and configuration information about the plug connector that can be communicated to a host device during a mating event. 
     
     
       14. The plug connector set forth in  claim 1  wherein the one or more electronic components includes an integrated circuit with an authentication module programmed to perform an authentication routine. 
     
     
       15. A plug connector module comprising:
 a metal frame having a base portion, an insertion end and a cavity that extends from the base portion into the insertion end, the insertion end being configured to be inserted into a cavity of a corresponding receptacle connector and having width, height and length dimensions along with first and second opposing exterior surfaces extending in the width and length dimensions, the first exterior surface including a first opening and the second exterior surface including a second opening directly opposite the first opening; 
 a substrate that extends through the base portion of the frame and into the insertion end, the substrate having a plurality of contact bonding pads at one end positioned within the frame, a plurality of conductor bonding pads at the opposing end and at least one ground pad contact between the contact bonding pads and conductor bonding pads; 
 a first set of eight external contacts spaced apart along a single row and positioned within the first opening and bonded to at least some of the plurality of contact bonding pads on the substrate; 
 a second set of eight external contacts spaced apart along a single row and positioned within the second opening and bonded to at least some of the plurality of contact bonding pads on the substrate, wherein the second set of eight external contacts is positioned directly opposite the first set of eight external contacts; 
 one or more electronic components coupled to the substrate; 
 a first encapsulant that covers and environmentally seals the one or more electronic components; 
 a metal shield coupled to the base portion of the metal frame and to the ground pad and encasing a portion of the substrate and the one or more electronic components, wherein the metal shield includes first and second halves that are attached to the base portion and attached to each other at mating plates on opposing sides of the shield, the first half including first and second wings that extend out of the first half in a plane parallel to the substrate and the second half including a third and fourth wings that extend out of the second half in a plane parallel to the substrate; and 
 a second encapsulant that covers and environmentally seals the ground pad and at least a portion of the leg. 
 
     
     
       16. The plug connector module set forth in  claim 15  wherein the first wing of the first half of the metal shield includes at least one hole that is aligned with a hole on the third wing of the second half of the metal shield and wherein the second wing of the first half of the metal shield includes at least one hole that is aligned with a hole on the fourth wing of the second half of the metal shield. 
     
     
       17. The plug connector module set forth in  claim 15  wherein each of the first and second sets of contacts includes a ground contact designated for ground, a first pair of data contacts to enable communication using a first communication protocol, a second pair of data contacts to enable communication using a second communication protocol different than the first protocol, a first power contact designated to carry a first power signal at a first voltage, a second power contact designated to carry a second power signal at a second voltage lower than the first voltage, and an ID contact capable of carrying a configuration signal that identifies the communication protocols used by the first and second pairs of data contacts. 
     
     
       18. The reversible plug connector set forth in  claim 17  wherein the ground contacts in the first and second row are positioned in a cater corner relationship with each other across a centerline of the connector. 
     
     
       19. The reversible plug connector set forth in  claim 17  wherein the first power contacts in the first and second row are positioned in a cater corner relationship with each other across a centerline of the connector. 
     
     
       20. The reversible plug connector set forth in  claim 17  wherein the ID contacts in the first and second row are positioned in a cater corner relationship with each other across a first quarter line of the connector.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to electrical connectors and in particular to connector modules that can readily be incorporated into electronic devices and cables. 
     A wide variety of electronic devices are available for consumers today. Many of these devices have connectors that that facilitate communication with and/or charging of a corresponding device. Typically these connectors are part of a male plug connector and female receptacle connector system in which the plug connector can be inserted into and mated with the receptacle connector so that digital and analog signals can be transferred between the contacts in each connector. More often than not, the female connector in the connector system is included in a host electronic device such as a portable media player, a smart phone, a table computer, a laptop computer, a desktop computer or the like. More often than not, the plug connector in the connector system is included in an accessory device such as a charging cable, a docking station or an audio sound system. In some instances, however, devices, for example cable adapters, include both receptacle and plug connectors. Also, in some instances, the plug connector/receptacle connector pairing can be part of a large ecosystem of products that includes both host electronic devices and accessory devices designed to work together. Thus, the same format plug connector can be incorporated into many different accessories, which in turn can be designed to operate with multiple different host devices that include the corresponding receptacle connector. 
     The various accessories and devices that are part of the ecosystem may be manufactured by many different companies in many different locations throughout the world. The connectors, on the other hand, may be manufactured by companies different than those that manufacture the accessories and device and may be manufactured at different locations. Thus, the connectors may be shipped from a connector manufacturing facility to another manufacturing facility. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention pertain to plug connectors modules that have been designed and manufactured to be incorporated into various electronic devices and accessories. While the plug connector modules can be incorporated into an electronic device or accessory at the same location where the module is manufactured, the modules are particularly well suited to be shipped to other manufacturing facilities away from the location that the module was manufactured. 
     Some embodiments of connector modules according to the present invention include a frame that defines an external connector tab that is adapted to be inserted into a corresponding receptacle connector. The frame supports a plurality of external contacts on first and second opposing sides of the tab. A substrate, such as a printed circuit board (PCB), is housed within the frame and includes contact bonding pads coupled to the contacts, as well as various electronic components that are part of the connector and conductor bonding pads that enable the connector to be operatively coupled to the electronic device or accessory that it is later incorporated into. A shield can, made out of metal or another suitable conductive material, can be bonded to a rear portion of the frame to enclose a portion of the PCB that extends outside the frame. The connector tab and electronic components can be environmentally sealed leaving the conductor bonding pads exposed so that they can be bonded to at a later time. In some embodiments, the shield can includes substantially flat extension portions on each of side of the shield can and each extension portion includes at least one holes that facilitates attaching the shield can and thus the connector module to an electronic device or assembly. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a simplified perspective view of a plug connector  100  that can be part of a connector module according to some embodiments of the present invention; 
         FIGS. 1B and 1C  are simplified top and bottom views, respectively, of connector  100  shown in  FIG. 1 ; 
         FIG. 2  is a diagram illustrating a pinout arrangement of connector  100  according to one embodiment of the invention; 
         FIG. 3  is a simplified perspective view of a plug connector module  200  according to one embodiment of the present invention; 
         FIG. 4  is a flowchart depicting steps associated with manufacturing connector module  200  according to one embodiment of the invention; 
         FIGS. 5A-5D  are simplified perspective views depicting connector module  200  at different stages of manufacture discussed with respect to  FIG. 4  according to an embodiment of the present invention; 
         FIG. 6  is a simplified perspective view of a plug connector module  300  according to another embodiment of the present invention; 
         FIG. 7  is a simplified perspective view of a shield cans used in the manufacture of connector module  300  according to an embodiment of the present invention; and 
         FIG. 8  is a flowchart depicting additional steps associated with manufacturing connector modules  200  and  300  according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to certain embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known details have not been described in detail in order not to unnecessarily obscure the present invention. 
     Referring first to  FIGS. 1A-1C  which depict a partially formed connector  100  according to an embodiment of the invention.  FIG. 1A  is a simplified perspective view of connector  100  and  FIGS. 1B and 1C  are simplified top and bottom plan views, respectfully, of connector  100 . At this stage of manufacture, connector  100  includes a frame  105  and a plurality of contacts  106  positioned at an external surface of the connector. Frame  105  provides structural support for connector  100  and contacts  106  and includes an insertion end  112  and a flange end  114  at a base portion of frame  105 . Insertion end  112  is configured to be inserted into a corresponding receptacle connector during a mating event and flange end  114  provides both a face  115  that can act as a stopping point for the mating event and a rim  118 . In one connector  100  is a dual orientation connector that can be inserted into its receptacle in either of two orientations rotated 180 degrees from each other and insertion end  112  has 180 degree symmetry. Frame  105  can be made from metal or any other appropriate conductive material. In one particular embodiment, frame  105  is made from stainless steel and can be referred to as a ground ring. 
     The insertion end of connector  100  includes first and second opposing sides  105   a ,  105   b  extending in the width and length dimensions of the frame, third and fourth opposing sides  105   c ,  105   d  extending between the first and second sides in the height and length dimensions, and an end  105   e  extending in the width and height dimensions between the first and second sides as well as between the third and fourth sides at the distal end of the connector. Sides  105   a - 105   e  frame an interior cavity (not shown) that can house portions of connector  100 . In some embodiments, insertion end  112  of connector  100  is between 5-10 mm wide, between 1-3 mm thick and has an insertion depth (the distance from the tip of tab  44  to spine  109 ) of between 5-15 mm. Also in some embodiments, insertion end  112  has a length that is greater than its width which is greater than its thickness. In other embodiments, the length and width of insertion end  112  are within 0.2 mm of each other. In one particular embodiment, insertion end  112  is 6.7 mm wide, 1.5 mm thick and has an insertion depth (the distance from the tip of insertion end  112  to face  115  of between 6-8 mm, and in one particular implementation an insertion depth of 6.6 mm. 
     Contacts  106  can be formed on a single side of connector  100  or on both sides and can be any number of contacts arranged in any effective manner. In the embodiment shown in  FIGS. 1A-1C , contacts  106  include a first set of eight contacts spaced in a single row on side  105   a  of the connector as well as second set of eight contacts spaced in a single row on opposing side  105   b  of the connector. For convenience, the contacts are numbered in  FIGS. 1A-1C  as contacts  106 ( 1 ) . . .  106 ( 8 ) on the first side and  106 ( 9 ) . . .  106 ( 16 ) on the second side. First and second sets of contacts are formed in contact regions  106   a ,  106   b , respectively, which are defined by first and second openings in frame  105  that have dielectric material space between the contacts and between the contacts and the frame as described below. Contacts  106  can be made from any appropriate conductive material such as copper and plated with gold and can be used to carry a wide variety of signals including digital signals and analog signals as well as power and ground as previously discussed. In one embodiment, each contact  106  has an elongated contact surface. In one embodiment the overall width of each contact is less than 1.0 mm at the surface, and in another embodiment the width is between 0.75 mm and 0.25 mm. In one particular embodiment, a length of each contact is at least 3 times as long at the surface than its width, and in another embodiment a length of each contact  106 ( i ) is at least 5 times as long at the surface than its width 
     Connector  100  also includes retention features  102   a ,  102   b  formed as curved pockets in the sides of frame  105  that are adapted to engage with one or more features on the corresponding receptacle connector to secure the connectors together when the plug connector is inserted into the receptacle connector. 
     A substrate  104 , such as a printed circuit board (PCB) is housed within frame  105 . As shown in  FIGS. 1A-1C , a portion of substrate  104  extends out past the rear opening of the frame. Substrate  104  includes a plurality of contact bonding pads (not shown) that can correspond in number to the plurality of contacts  106  and that are positioned directly beneath the contacts in contact regions  106   a ,  106   b . Substrate  104  also includes one or more electronic components  108   a ,  108   b , such as integrated circuits, a plurality of conductor bonding pads  110  and ground pads  116 . Each bonding pad can be connected to one or more contact bonding pads by electrical traces that run along substrate  104  (not shown). 
     In some embodiments, electronic components  108   a ,  108   b  may include one or more integrated circuits (ICs), such as Application Specific Integrated Circuit (ASIC) chips that provide information regarding connector  100  and any accessory or device that connector  100  is part of and/or to perform specific functions, such as authentication, identification, contact configuration and current or power regulation. As an example, in one embodiment an identification (ID) module is embodied within an IC operatively coupled to the contacts of connector  100 . The ID module can be programmed with identification and configuration information about the connector and/or its associated accessory that can be communicated to a host device during a mating event. As another example, an authentication module programmed to perform an authentication routine, for example a public key encryption routine, with circuitry on the host device can be embodied within an IC operatively coupled to connector  100 . The ID module and authentication module can be embodied within the same IC or within different ICs. As still another example, in embodiments where connector  100  is part of a charging accessory, a current regulator can be embodied within one of IC&#39;s  108   a  or  108   b . The current regulator can be operatively coupled to contacts that are able to deliver power to charge a battery in the host device and regulate current delivered over those contacts to ensure a constant current regardless of input voltage and even when the input voltage varies in a transitory manner. 
       FIG. 2  depicts an implementation of a pinout for one particular embodiment of plug connector  100 . The depicted pinout includes eight contacts  106 ( 1 ) . . .  106 ( 8 ) on each side of connector  100  that can correspond to the contacts in  FIGS. 1A-1C . Each contact in contact region  106   a  is electrically connected via connections on or through substrate  104  to a corresponding contact in contact region  106   b . Thus, the sixteen contacts of connector  100  act as eight electrically distinct contacts. Some of the connected contacts are mirrored contacts (i.e., electrically connected to a contact directly opposite itself) while other contacts are in a cater corner relationship with each other across either a centerline  59  of the connector or across one of two quarter lines  59   a ,  59   b  of the connector as described below (as used herein, the term “quarter line” does not encompass the centerline). 
     Specifically, as shown in  FIG. 2  the depicted pinout includes a first pair of mirrored data contacts (Data 1) and a second pair of mirrored data contacts (Data 2) where each individual mirrored data contact is electrically connected to a corresponding data contact directly opposite itself on the opposing side of the connector. A power contact (Power) includes two contacts positioned in a cater corner relationship with each other across centerline  59 -contacts  106 ( 5 ),  106 ( 13 ), while the ground contact (GND) includes two contacts positioned in a cater corner relationship with each other across centerline  59 -contacts  106 ( 1 ),  106 ( 9 ). The accessory power contact (ACC_PWR) and accessory ID contact (ACC_ID), on the other hand, are positioned in a cater corner relationship with counterpart contacts across quarter lines  59   a  and  59   b , respectively. 
     Power contact (Power) can be sized to handle any reasonable power requirement for a portable electronic device, and for example, can be designed to carry between 3-20 Volts from an accessory to charge a host device connected to connector  100 . Ground contact (GND) provides a dedicated ground contact at one end of the row of contacts as far away as possible from the power contact. Ground is also provided through the ground ring  105  via contacts in the side of the corresponding receptacle connector within retention features  102   a ,  102   b . The additional, dedicated ground contact within contact regions  106   a ,  106   b , however, provides additional ground coverage and provides a benefit in that the contact integrity of the ground contacts  106 ( 1 ),  106 ( 9 ) can be specifically designed to carry the electrical ground signal (e.g., using gold plated copper contacts) without being constrained by the hardness or other requirements associated with the contacts in the side of ground ring  105  that ensure the ground ring is sufficiently robust to withstand multiple thousands of use cycles. 
     Each pair of data contacts, Data 1 and Data 2, can be positioned between one of the Power or GND contacts, each of which carries a DC signal, and one of the ACC_PWR or ACC_ID contacts, which carry either a lower voltage accessory power signal (a DC signal) or a relatively low speed accessory ID signal. The data contacts can be high speed data lines that operate at rate that is at least two orders of magnitude faster than that of the accessory ID signal making it look essentially like a DC signal to the high speed data lines. Thus, positioning the data contacts between either the power contacts or ground contacts and the ACC contacts improves signal integrity by sandwiching the data contacts between contacts designated for DC signals or essentially DC signals. 
     In one embodiment, the pinout of  FIG. 2  represents the signal assignments of a plug connector  100  in a plug connector/receptacle connector pairing that can be the primary physical connector system for an ecosystem of products that includes both host electronic devices and accessory devices. Examples of host devices include smart phones, portable media players, tablet computers, laptop computers, desktop computers and other computing devices. An accessory can be any piece of hardware that connects to and communicates with or otherwise expands the functionality of the host. Many different types of accessory devices can be specifically designed or adapted to communicate with the host device through connector  100  to provide additional functionality for the host. Plug connector  100  can be incorporated into each accessory device that is part of the ecosystem to enable the host and accessory to communicate with each other over a physical/electrical channel when plug connector  100  from the accessory is mated with a corresponding receptacle connector in the host device. Examples of accessory devices include docking stations, charge/sync cables and devices, cable adapters, clock radios, game controllers, audio equipment, memory card readers, headsets, video equipment and adapters, keyboards, medical sensors such as heart rate monitors and blood pressure monitors, point of sale (POS) terminals, as well as numerous other hardware devices that can connect to and exchange data with the host device. 
     It can be appreciated that some accessories may want to communicate with the host device using different communication protocols than other accessories. For example, some accessories may want to communicate with the host using a differential data protocol, such as USB 2.0, while other accessories may want to communicate with the host using an asynchronous serial communication protocol. In one embodiment the two pairs of data contacts (Data 1 and Data 2) can be dedicated to two pairs of differential data contacts, two pairs of serial transmit/receive contacts, or one pair of differential data contacts and one pair of serial transmit/receive contacts depending on the purpose of connector  100  or function of the accessory connector  100  is part of. As an example that is particularly useful for consumer-oriented accessories and devices, the four data contacts can accommodate two of the following three communication interfaces: USB 2.0, Mikey Bus or a universal asynchronous receiver/transmitter (UART) interface. As another example that is particularly usefully for debugging and testing devices, the set of data contacts can accommodate two of either USB 2.0, UART or a JTAG communication protocols. In each case, the actual communication protocol that is used to communicate over a given data contact can depend on the accessory as discussed below. 
     As mentioned above, connector  100  may include one or more integrated circuits that provide information regarding the connector and any accessory or device it is part of and/or perform specific functions. The integrated circuits may include circuitry that participates in a handshaking algorithm that communicates the function of one or more contacts to a host device that connector  100  is mated with. For example, an ID module can be embodied within IC  108   a  as discussed above and operatively coupled to the ID contact (ACC_ID) and an authentication module can be embodied in IC  108   a  with the ID module or in a separate IC, such as IC  108   b . The ID and authentication modules each include a computer-readable memory that can be programmed with identification, configuration and authentication information relevant to the connector and/or its associated accessory that can be communicated to a host device during a mating event. For instance, when connector  100  is mated with a receptacle connector in a host electronic device, the host device may send a command over its accessory ID contact (that is positioned to align with the ID contact of the corresponding plug connector) as part of a handshaking algorithm to determine if the accessory is authorized to communicate and operate with the host. The ID module can receive and respond to the command by sending a predetermined response back over the ID contact. The response may include information that identifies the type of accessory or device that connector  100  is part of as well as various capabilities or functionalities of the device. The response may also communicate to the host device what communication interface or communication protocol the connector  100  employs on each of data contact pairs Data 1 and Data 2. If connector  100  is part of a USB cable, for example, the response sent by the ID module may include information that tells the host device that contacts in the first data pair, Data 1, are USB differential data contacts. If connector  100  is a headset connector, the response may include information that tells the host that contacts in the second data pair, Data 2, are Mikey Bus contacts. Switching circuitry within the host can then configure the host circuitry operatively coupled to the contacts in the receptacle connector accordingly. 
     During the handshaking routine the authentication module can also authenticate connector  100  (or the accessory it is part of) and determine if connector  100  (or the accessory) is an appropriate connector/accessory for the host to interact with using any appropriate authentication routine. In one embodiment authentication occurs over the ID contact prior to the identification and contact switching steps. In another embodiment authentication occurs over one or more of the data contacts after they are configured according to a response sent by the accessory. 
     Reference is now made to  FIGS. 3 and 4 , where  FIG. 3  is a simplified perspective view of a connector module  200  according to an embodiment of the invention that is particularly useful in the manufacture of connector cables and cable adapters, and  FIG. 4  is a flow chart depicting the steps associated with manufacturing module  200  according to one embodiment. As shown in  FIG. 3 , connector module  200  includes connector  100  along with a shield can  210  and various encapsulants, such as ground pad encapsulant  250 , that protect the electronic components and other portions of connector  100  from moisture. As shown in  FIG. 3 , conductor contact pads  110  are not enclosed within shield can  210  or encased within encapsulant. Instead, conductor contact pads  110  are positioned at the end of substrate  104  and readily available to be bonded to by wires, a flex circuit or other type of conductor when connector module  200  is incorporated into an electronic device or cable. 
     Module  300  can be formed by starting with plug connector  100  ( FIG. 4 , step  150 ) and encapsulating all the various electronic components formed on substrate  104  with a liquid encapsulant that will seal the components and protect them from moisture and other environmental components ( FIG. 4 , step  152 ). The liquid encapsulant can be applied over each side of substrate  104  to fully cover each of electronic components  108   a ,  108   b  and others that are attached to the substrate. In one embodiment, encapsulant is a UV/moisture curably acylate polymer applied using in jet dispense operation over each side individually. The polymer is then cured to form a substantially rectangular block of encapsulant  205  that fully encases the electronic components and a portion of substrate  104  as shown in  FIG. 5A . 
     Next, metal shield can  210  is attached to ground ring  105  and substrate  104  (step  154 ;  FIG. 5B ). In one embodiment, shield can  210  includes two halves  210   a ,  210   b  as shown in  FIG. 5C  that are identical and are machined from, for example, stainless steel. Reference numbers for elements in each shield include a surface of either a or b in the  FIG. 5C  depending on whether the component is part of shield can  210   a  or shield can  210   b . Since the elements are identical in each shield can, however, for convenience of description the suffix is mostly left out of the discussion below. Each half includes a curved surface  212  that extends from a first mating plate  214  to a second mating plate  216 . Each of mating plates  214 ,  216  provides a substantially flat portion at an outer periphery. 
     Shield cans  210   a  and  210   b  can each be positioned on connector module  200  such that a head portion  218  of the shield cans is in contact with rim  118 . In this alignment, the head portion  218  can be welded to rim  118 , mating plate  214   a  can be welded to plate  214   b  and plate  216   a  can be welded to plate  216   b  (step  154 ). Each shield can  210   a ,  210   b  further includes a leg  220  that aligns with bonding pads  112 , which are connected to ground. After the shield cans are firmly welded to each other and to ground ring  105 , legs  220   a  and  220   b  can be soldered to the bonding pads to form solder bonds  225  to further secure the shield cans to the connector and further connected the shield can to ground (step  156 ;  FIG. 5D ). A second encapsulation step then covers the soldered legs and ground pads  112  with a liquid encapsulant that will further seal the connector module to protect it from moisture and other environmental components (step  158 ). As with step  152 , the liquid encapsulant can be applied over each side of substrate  104  to fully cover ground pads  112  and shield can legs  220   a ,  220   b . In one embodiment, encapsulant is a UV/moisture curably acylate polymer applied in jet dispense operation over each side individually. The polymer is then cured to form a substantially rectangular block of encapsulant  250  that fully encases ground pads and a bottom portion of legs  220   a ,  220   b  as shown in  FIG. 3 . 
     Shield cans  210   a ,  210   b  can also be welded to rim  118  of ground ring  105  along. Once the shield cans are welded to each other and to ground ring  105 , they form an enclosure around a portion of connector module  200  that extends from the flange end of ground ring  205  to the connector bonding pads covering encapsulant block  205  and other portions of the connector. Also, the half shield cans are sized to be welded to each other.  210 A,  210 B s 218  portion includes a front bonding po attachment section applied can the components on each side of substrate  104 . 
       FIG. 6  is a simplified perspective view of a plug connector module  300  according to another embodiment of the present invention. Connector module  300  is similar to connector module  200  except that shield cans  310   a ,  310   b  (shown in  FIG. 7 ) that enclose the electronic components and initial encapsulant block  205  include wings  314  and  316  that extend out of the shield can in a plane substantially parallel to substrate  104  and provide a substantially flat mating surface similar to mating portions  214 ,  216 . Wings  314 ,  316  also provide additional real estate for one or more holes  322 . Each of holes  322  in wing  314   a  aligns with a corresponding hole in wing  314   b  and each hole  322  in wing  316   a  aligns with a corresponding hole in wing  314   b . This enables holes  322  to be used as an attachment point, for example with a screw and nut assembly or a rivet or any other suitable attachment means, to secure connector module  300  to an electronic device or accessory that it is incorporated into. To provide a more secure connection, some embodiments include two holes  322  spaced apart along a length of each wing  314 ,  316 . 
     Reference is now made to  FIG. 8  regarding the steps associated with the manufacture and assembly of connector  100  according to one embodiment of the invention ( FIG. 4 , step  150 ). Connector  100  includes three primary parts: ground ring  105 , substrate  104  with attached electronic components, and a contact assembly that includes a dielectric frame that supports each of the individual contacts  106 . These three components can be manufactured separate from each other (steps  160 ,  162  and  164 ) and are brought together in a final assembly process to be assembled in connector  100 . 
     Ground ring  105  may be fabricated using a variety of techniques such as, for example, a metal injection molding process (MIM), a cold heading process or a billet machining process. A MIM process may provide a great deal of flexibility in achieving a desired geometry and can result in a part that is close to the final desired shape with minimal post machining operations. In some embodiments, alternative processes such as plastic injection molding and plating may be used to form ground ring  105 . Pockets  102   a ,  102   b  and the openings that form contact regions  106   a ,  106   b  may be machined or molded into the ground ring as well. The surface of the ground ring can be smoothed using a media blasting process. Further, it may be desirable to grind or machine surfaces of the ground ring such as flats  105   a ,  105   b  on the top and bottom of the ground ring and plate the ground ring with one or more metals to achieve a desired finish. Grinding and machining operations can be used to create tightly toleranced features. Tightly toleranced component geometry may be beneficial for subsequent assembly operations and may further benefit the performance of particularly small connectors. 
     Substrate  104  may be a traditional epoxy and glass PCB or may be any equivalent structure capable of routing electrical signals. For example, some embodiments may use a flexible structure comprised of alternating layers of polyimide and conductive traces while other embodiments may use a ceramic material with conductive traces or a plastic material processed with laser direct structuring to create conductive traces. The PCB may be formed with a set of conductor bonding pads  110  disposed at one end, ground pads  112  disposed adjacent to the pads  110  and a set of contact bonding pads (not shown) disposed at the opposing end. The PCB may also be equipped with one or more ground spring bonding pads to electrically connect one or more ground springs that provide spacing between substrate  104  and the inner edges of ground ring  105  when the substrate is inserted into the ground ring. Additionally, a set of component bonding pads may be formed on the substrate to electrically connect one or more active or passive electronic components as previously discussed. Such components can be attached with a conductive epoxy, a solder alloy or by using myriad other technologies, such as, through-hole mounting, stencil print and reflow, chip-on-board, flip-chip and the like. 
     The first step of the assembly process may involve inserting substrate  104  through a back opening of ground ring  105  so that the contact bonding pads and their solder bumps formed on the substrate are positioned within the windows of the ground ring (step  166 ). Next, the contact assemblies may be positioned within each window of ground ring  105  so the contacts in each assembly can be attached to substrate  104  (step  168 ). Each contact assembly may include a molded frame that can be formed from a dielectric material such as polypropylene that is insert molded around the contacts while the contacts are still attached to a lead frame. The contacts can then be pressed into the solder and heated with a hot bar to form solder joints between each contacts and its respective solder bump. After the contacts are connected to substrate  104 , dielectric material may be injected into ground ring  105 , for example from the back opening of the ground ring, around substrate  104  and around each of contacts  106  (step  170 ) forming a substantially flush exterior surface between the dielectric and contacts in each of contact regions  106   a ,  106   b . The dielectric material may be polyoxymethylene (POM), a nylon-based polymer or other suitable dielectric and provides structural strength to connector  100  as well as moisture protection by sealing internal components of the connector from the outside environment. After the dielectric molding process, the partially completed connector is ready to be encapsulated by either shield cans  210  or  310  as described above with respect to  FIG. 4 . 
     As will be understood by those skilled in the art, the present invention may be embodied in many other specific forms without departing from the essential characteristics thereof. Also, while a number of specific embodiments were disclosed with specific features, a person of skill in the art will recognize instances where the features of one embodiment can be combined with the features of another embodiment. For example, some specific embodiments of the invention set forth above were illustrated with pockets as retention features. A person of skill in the art will readily appreciate that any of the other retention features described herein, as well as others not specifically mentioned, may be used instead of or in addition to the pockets. Also, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the inventions described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20120907
Publication Date: 20140715
Grant Date: 20140715
Priority Date: 20120907
Inventors: GOLKO ALBERT J.
STANLEY CRAIG M.
THOMPSON PAUL J.
JONES WARREN Z.
KAMEI IBUKI
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R24/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/648", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R29/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6594", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R29/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6658", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6594", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 48190814