PATENT DOCUMENT

Publication Number: US-9153925-B2
Application Number: US-201314025662-A
Country: US
Kind Code: B2

Title: Plug connector having a tab with a plurality of conductors

Abstract:
A dual orientation connector having a connector tab with first and second major opposing surfaces and a plurality of electrical contacts carried by the connector tab. A retainer is positioned at an entrance end of the tab and is overmolded on a portion of a carrier. The carrier has a first portion positioned within the tab, a second portion extending through the retainer and a third portion extending out of the retainer at an angle with respect to the longitudinal plane of the tab. The carrier has a plurality of conductors formed thereon and extending from the first portion to the third portion.

Claims:
What is claimed is: 
     
       1. A plug connector comprising:
 a flange; 
 a tab that extends away from the flange and is configured to be inserted into a corresponding receptacle connector, the tab including a conductive frame and encapsulant filled within the frame and having an entrance end disposed opposite a distal end and first and second opposing major surfaces extending between the flange and the distal end; 
 a retainer positioned at the entrance end of the tab and formed from a material different than the encapsulant; 
 a carrier having a first portion positioned within the conductive frame, a second portion extending through the retainer and a third portion extending out of the retainer at an angle with respect to the longitudinal plane, the carrier having a plurality of conductors formed thereon and extending from the first portion to the third portion, each of the plurality of conductors having a mating surface formed on the first portion and exposed at an outer surface of the plug. 
 
     
     
       2. The plug connector set forth in  claim 1  wherein the conductive frame comprises a metal ground ring that generally defines a shape of the connector tab and includes openings on both the first and second major surfaces. 
     
     
       3. The plug connector set forth in  claim 2  wherein contacts are disposed in the openings on both the first and second major surfaces and the contacts are surrounded by the encapsulant. 
     
     
       4. The plug connector set forth in  claim 1  wherein the conductive frame comprises a substantially u-shaped metallic band disposed around a periphery of the plug connector such that the metallic band surrounds the distal end and third and fourth opposing side surfaces of the plug connector. 
     
     
       5. The plug connector set forth in  claim 1  wherein the carrier extends out of the retainer at an angle of between 65-115 degrees with respect to the longitudinal plane. 
     
     
       6. The plug connector set forth in  claim 1  wherein the third portion of the carrier comprises first and second locating holes. 
     
     
       7. The plug connector set forth in  claim 1  wherein the carrier has a fourth portion oriented substantially parallel to the first portion. 
     
     
       8. A plug connector comprising:
 a connector tab having an entrance end disposed opposite a distal end and first and second major surfaces disposed opposite each other extending between the entrance end and the distal end, wherein the connector tab further has a cavity extending from the entrance end to a pair of windows disposed proximate the distal end on the first and second major surfaces; 
 a plurality of conductors disposed at least partially within the cavity and exiting the connector tab through the entrance end; 
 the plurality of conductors further having an overmolded region, the overmolded region at least partially disposed within the cavity; and 
 an encapsulant, substantially filling the cavity. 
 
     
     
       9. The plug connector set forth in  claim 8  wherein at least a portion of the plurality of conductors is a circuit board. 
     
     
       10. The plug connector set forth in  claim 9  wherein at least a portion of the circuit board is flexible. 
     
     
       11. The plug connector set forth in  claim 9  wherein a portion of the circuit board is flexible and the flexible portion is disposed in the overmolded region. 
     
     
       12. The plug connector set forth in  claim 8  wherein the encapsulant and the overmold are different materials and are both substantially coplanar with a bottom surface of the plug connector. 
     
     
       13. The plug connector set forth in  claim 8  wherein there is a plurality of electrical contacts disposed in each of the pair of windows. 
     
     
       14. A plug connector comprising:
 a tab made at least partially from an electrically conductive material, the tab comprising first and second major surfaces disposed opposite each other, and first and second minor surfaces disposed opposite each other, wherein the first and second major surfaces and the first and second minor surfaces extend from an entrance end of the tab to a distal end of the tab; 
 a plurality of contacts disposed in the first and second major surfaces proximate the distal end wherein the plurality of contacts are disposed entirely below the first and second major surfaces; 
 a plurality of electrical conductors connected to the plurality of contacts and exiting the connector tab through the entrance end wherein at least a portion of the plurality of electrical conductors is secured in an overmolded retainer; and 
 wherein at least a portion of the overmolded retainer is disposed between the first and second major surfaces. 
 
     
     
       15. The plug connector set forth in  claim 14  further comprising a flange disposed at the entrance end of the tab. 
     
     
       16. The plug connector set forth in  claim 14  wherein at least a portion of the plurality of conductors are disposed within the overmolded retainer. 
     
     
       17. The plug connector set forth in  claim 16  wherein the at least a portion of the plurality of conductors that are disposed within the overmolded retainer are formed into a radius. 
     
     
       18. The plug connector set forth in  claim 16  wherein the plurality of conductors comprise a flexible printed circuit board (PCB). 
     
     
       19. The plug connector set forth in  claim 18  wherein the overmolded retainer is formed over a curved portion of the flexible printed circuit board (PCB). 
     
     
       20. The plug connector set forth in  claim 16  wherein the overmolded retainer is held in place by a second material formed by an insert molding operation performed on the tab.

Description:
BACKGROUND OF THE INVENTION 
     The present invention generally relates to electrical connectors and in particular to connector modules that can be readily incorporated into electronic devices and docking stations. 
     A wide variety of electronic devices are available for consumers today. Many of these devices have connectors 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 tablet computer, a laptop computer, a desktop computer or the like. The plug connector in the connector system is often included in an accessory device such as a charging cable, a docking station, an audio sound system or the like. 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 general 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. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of the invention pertain to plug connectors that can function within an ecosystem of products, many of which are adapted to work with dual orientation (also referred to as “reversible”) connectors. Some embodiments of the invention pertain to plug connectors with contacts formed on both sides of the connector that are configured to mate with a receptacle connector in an accessory that often mates with a reversible connector. One example of such an accessory is a docking station. 
     Plug connectors according to certain embodiments of the present invention have a reduced plug length and thickness as compared to currently available electronic connectors, and a smooth consistent feel when inserted and extracted from a corresponding receptacle connector. 
     Other embodiments of the invention pertain to plug connectors with external contacts that include a conductive frame and encapsulant filled within the frame. The plug connector assembly includes a connector tab that extends longitudinally away from a flange. The connector tab includes a first mating surface formed on a first major surface that is opposite a second major surface. In some embodiments a second mating surface may be formed on the second major surface. First and second major surfaces extend from an entrance end to a distal end of the connector tab. A plurality of external electrical contacts are disposed within the first and second mating surfaces. A retainer is positioned at an entrance end of the tab and is overmolded on a portion of a carrier. The carrier has a first portion positioned within the tab, a second portion extending through the retainer and a third portion extending out of the retainer at an angle with respect to the longitudinal plane of the tab. The carrier has a plurality of conductors formed thereon and extending from the first portion to the third portion. 
     In some embodiments the conductive frame may resemble a hollow shell or metal ground ring, while in other embodiments the conductive frame may resemble a u-shaped band. The conductive frame may have a cavity extending from the entrance end to a pair of windows disposed proximate a distal end on the first and second major surfaces. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an front perspective view of a media player connected to a docking station according to an embodiment of the invention; 
         FIG. 2  is a rear perspective view of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3A  is a bottom perspective view of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3B  is a perspective view of a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3C  is a rear perspective view of a conductive frame station according to an embodiment of the invention; 
         FIG. 3D  is a rear perspective view of a carrier assembly installed in a conductive frame station according to an embodiment of the invention; 
         FIG. 3E  is a cross-section of a carrier assembly installed in a conductive frame station according to an embodiment of the invention; 
         FIG. 3F  is a rear perspective view of contact assemblies and a partially assembled plug connector station according to an embodiment of the invention; 
         FIG. 3G  is a front view of contact assemblies being installed in a partially assembled plug connector station according to an embodiment of the invention; 
         FIG. 3H  is a front view of contact assemblies being installed in a partially assembled plug connector station according to an embodiment of the invention; 
         FIG. 3I  is a rear perspective view of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3J  is a cross-section of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3K  is rear perspective view of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 3L  is a cross-section of a plug connector having a carrier and a retainer station according to an embodiment of the invention; 
         FIG. 4  is a process by which a plug connector having a carrier and a retainer may be assembled station according to an embodiment of the invention; 
         FIG. 5  is a process by which a contact assembly may be installed in a plug connector having a carrier station according to an embodiment of the invention; 
         FIG. 6A  is an illustration of a plug connector having a carrier, a circuit assembly and a retainer station according to an embodiment of the invention; and 
         FIG. 6B  is an illustration of a plug connector having a carrier, a circuit assembly and a retainer station according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As discussed earlier, embodiments of the invention may apply to a variety of plug connectors which use a variety of different connector technologies. Accordingly, the invention may be used with many electronic devices that mate with a variety of electrical connectors in order to receive and provide power and data. One example of an electronic device that may be used with embodiments of the present invention is shown in  FIG. 1 . 
       FIG. 1  depicts an illustrative rendering of one particular electronic media device  100  attached to a docking station  125 . Device  100  includes a multipurpose button  105  as an input component, a touch screen display  120  as both an input and output component, and a speaker  125  as an output component, all of which are housed within a device housing  130 . Device  100  also includes a receptacle connector  135  within device housing  130 . Receptacle connector  135  can be positioned within housing  130  such that the cavity of the receptacle connector into which a corresponding plug connector  136  is inserted is located at an exterior surface of device housing  130 . In some embodiments, the cavity opens to an exterior side surface of device  100 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 1 . Embodiments of the invention disclosed herein are particularly suitable for use with plug connectors that are configured to mate with receptacle connector  135 , but in some embodiments can also be used with other plugs. Additionally, in some embodiments, electronic media device  100  may have more than one receptacle connector  135  that can be used to physically interface and connect the device (as opposed to a wireless connection which can also be used) to the other electronic devices. 
     Although device  100  is described as one particular electronic media device, embodiments of the invention are suitable for use with a multiplicity of electronic devices that include a receptacle connector that corresponds to a plug connector including a frame. For example, any device that receives or transmits audio, video or data signals may be used with the invention. In some instances, embodiments of the invention are particularly well suited for use with portable electronic media devices because of their potentially small form factor. As used herein, an electronic media device includes any device with at least one electronic component that may be used to present human-perceivable media. Such devices may include, for example, portable music players (e.g., MP3 devices and Apple&#39;s iPod devices), portable video players (e.g., portable DVD players), cellular telephones (e.g., smart telephones such as Apple&#39;s iPhone devices), video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, PDAs, desktop computers, as well as tablet (e.g., Apple&#39;s iPad devices), laptop or other mobile computers. Some of these devices may be configured to provide audio, video or other data or sensory output. 
     In order to better appreciate the features and aspects of plug connectors according to the present invention, further context for the invention is provided in the following section by discussing one particular implementation of a plug connector according to one embodiment of the present invention. 
       FIG. 2  is a perspective view depicting an eight contact axisymmetric dual orientation plug connector assembly  200  that may include a conductive frame  202  and encapsulant  222  filled within the frame according to embodiments of the present invention. As shown in  FIG. 2 , plug connector assembly  200  includes a connector tab  204  that extends longitudinally away from a flange  206 . Connector tab  204  is sized to be inserted into a corresponding receptacle connector, such as connector  135  (see  FIG. 1 ), during a mating event. Connector tab  204  includes a first mating surface  238  formed on a first major surface  271  that is opposite second major surface  273  of connector tab  204 . In some embodiments a second mating surface  209  (not shown) is formed on second major surface  273 . A plurality of electrical contacts  207 ( 1 ) . . .  207 ( 8 ) are disposed at mating surfaces  238 ,  209 . In some embodiments, electrical contacts  207 ( 1 ) . . .  207 ( 8 ) may be disposed on only one mating surface  238 ,  209  particularly in embodiments employed in docking stations as the electronic device is always mated in the same orientation. Surfaces  271 ,  273  extend from an entrance end  219  to a distal end  218  of connector tab  204 . When connector tab  204  is inserted into a corresponding receptacle connector, major surfaces  271 ,  273  fit within a housing of the receptacle connector or host device into which the receptacle connector is incorporated. 
       FIG. 3A  is a perspective view of the bottom of plug connector assembly  200 . A retainer  223  is positioned at entrance end  219  of tab  204  and may be formed around a carrier  213 . In some embodiments retainer  223  is formed from a material different than encapsulant  222 . In one embodiment retainer  223  is formed from a liquid crystal polymer (LCP) and encapsulant is a nylon-based polymer. In one embodiment, retainer  223  may be made from a polymer capable of withstanding high temperatures so that carrier  213  may be processed after the retainer is formed. More specifically, after the formation of retainer  223 , carrier  213  may have electrical components and/or contacts attached thereto with a process using a relatively high temperature, such as but not limited to soldering. In further embodiments, encapsulant  222  may be a polymer that melts at a low temperature such that conductive frame  202  may be minimally preheated prior to injection of encapsulant. 
     Carrier  213  has a first portion (not shown) positioned within conductive frame  202 , a second portion extending through retainer  223  (not shown) and a third portion  201  extending out of the retainer at an angle with respect to the longitudinal plane of tab  204 . Carrier  213  has a plurality of conductors  214  formed thereon and extending from the first portion to third portion  201 . Each of plurality of conductors  214  has a contact region formed on the first portion and exposed at an outer surface of plug  200 , as explained in more detail below. 
       FIG. 1  depicts an illustrative rendering of one particular electronic media device  100  attached to a docking station  125 . Device  100  includes a multipurpose button  105  as an input component, a touch screen display  120  as both an input and output component, and a speaker  126  as an output component, all of which are housed within a device housing  130 . Device  100  also includes a receptacle connector  135  within device housing  130 . Receptacle connector  135  can be positioned within housing  130  such that the cavity of the receptacle connector into which a corresponding plug connector  136  is inserted is located at an exterior surface of device housing  130 . In some embodiments, the cavity opens to an exterior side surface of device  100 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 1 . Embodiments of the invention disclosed herein are particularly suitable for use with plug connectors that are configured to mate with receptacle connector  135 , but in some embodiments can also be used with other plugs. Additionally, in some embodiments, electronic media device  100  may have more than one receptacle connector  135  that can be used to physically interface and connect the device (as opposed to a wireless connection which can also be used) to the other electronic devices. 
     Reference is now made to  FIGS. 3A-3L ,  4  and  5 , regarding the steps associated with the manufacture and assembly of connector  200  (see  FIG. 3A ) according to one embodiment of the method of the present invention.  FIG. 4  is a flow chart that illustrates the general steps associated with the manufacture and assembly of connector  200  according to one embodiment of the invention.  FIGS. 3A-3L  depict connector  200  at the various stages of manufacture set forth in  FIG. 4 .  FIG. 5  is a flow chart that further details the general step of attaching the contact assembly to the carrier, identified as step  430  in the general manufacturing and assembly process illustrated in  FIG. 4 . 
     Now referring to  FIGS. 3B and 3C , the manufacture of connector  200  may be initiated with the fabrication of conductive frame  202 , the construction of carrier  213 , and the construction of contact assemblies  316   a ,  316   b  (see  FIG. 3F ) each of which can occur independent of the others in any order. In some embodiments, conductive frame  202  may resemble a hollow shell having feet that protrude from each side of the bottom of the shell, while in other embodiments the conductive frame may resemble a u-shaped band, as discussed below. Conductive frame  202  may have a cavity extending from entrance end  219  to a pair of windows  307  disposed proximate distal end  218  on first and second major surfaces  271 ,  273 . In step  422 , conductive frame  202  (see  FIG. 3C ) 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 conductive frame  202 . Pockets  302   a ,  302   b  (only  302   a  is shown in  FIG. 3C ) and window  307  may be machined or molded into conductive frame  202  and the surface of the conductive frame can be smoothed using a media blasting process. Further, it may be desirable to grind or machine surfaces of conductive frame  202  such as flats  319   a ,  319   b  on the top and bottom of the conductive frame. Flats may be formed on first and second major surfaces  271 ,  273 . In some embodiments, flats may cover the entirety of first and second major surfaces  271 ,  273 , while in other embodiments the flats  319   a ,  319   b  may only cover a portion of the first and second major surfaces. Grinding and machining operations can be used to create tightly toleranced features. For example, flats  319   a ,  319   b  may be precision ground to form a pair of surfaces that are substantially flat and a precise distance apart. Tightly toleranced component geometry may be beneficial for subsequent assembly operations and may further benefit the performance of particularly small connectors. In one embodiment, the perimeter of the connector body is less than 30 mm. Conductive frame  202  may be plated with one or more metals to achieve the desired finish. 
     Carrier  213  (see  FIGS. 3A-3C ), which is fabricated in step  424 , may be a traditional epoxy and glass combination known as a printed circuit board (PCB) or may be any equivalent structure capable of routing electrical signals. In general, carrier  213  may be referred to as a PCB having a plurality of conductors formed thereon without limiting the scope of various embodiments. For example, some embodiments may use a flexible carrier  213  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. In further embodiments one portion of carrier  213  may be rigid while one or more other portions may be flexible. In some embodiments the entirety of carrier  213  may be flexible. In some embodiments, carrier  213  may be formed with a set of conductor bonding pads disposed at one end and a set of contact bonding pads disposed at the opposing end. In one embodiment the contact bonding pads are each split along a transverse direction into two separate bonding pads. Carrier  213  may also be equipped with one or more ground spring bonding pads to electrically connect one or more ground springs that make electrical contact with conductive frame  202 . Additionally, in some embodiments, a set of component bonding pads (not shown) may be formed on carrier  213  to electrically connect one or more active or passive electronic components such as, for example, integrated circuits (ICs), resistors or capacitors. The embodiments depicted herein are for example only, other embodiments may have a different arrangement of bonding pads, more or less bonding pads, as well as bonding pads formed on either or both of the opposing sides of carrier  213 , and fewer, more or different electronic components. 
     In embodiments that include electronic components, the components may be disposed on either side of carrier  213 . In some embodiments a conductive epoxy may be used to electrically attach the electronic components to carrier  213 . In other embodiments a solder alloy may be employed using myriad technologies such as, for example, through-hole mounting, stencil print and reflow, chip-on-board, flip-chip or other appropriate connection method. In one embodiment a stencil printing process is used to dispose solder paste on component bond pads. 
     Electronic components are then disposed on the solder paste and a convective heating process can be used to reflow the solder paste, attaching the electronic components to the carrier. The solder alloy may be a lead-tin alloy, a tin-silver-copper alloy, or other suitable metal or metallic alloy. 
     During the electronic component attachment process, solder paste may be deposited on contact bonding pads and reflowed. The reflow processing may form solder bumps  312 ( 1 ) . . .  312 ( 8 ) on the contact pads. The solder paste forms a bump during reflow processing due to the high surface tension of the solder when in its liquid state. 
     In some embodiments, after electronic components are attached to carrier  213 , the assembly may be washed and dried. However, in other embodiments the assembly may not be washed until subsequent processing. In other embodiments a no-clean flux is used to aid the soldering process and there is no wash process. In further embodiments a no-clean or a cleanable flux is used to aid the soldering process and the assembly is washed. Finally, some or all of electronic components may be encapsulated with a protective material such as, for example, an epoxy, a urethane or a silicone based material. In some embodiments the protective encapsulant may provide mechanical strength for improved reliability and/or environmental protection from moisture for sensitive electronic components. In further embodiments the protective encapsulant may improve the dielectric breakdown voltage performance of connector  200 . The encapsulant may be applied with an automated machine or with a manual dispenser. 
     The next step of assembly may involve forming a retainer  223  over a portion of carrier  213  (see  FIG. 3B ). In some embodiments, carrier  213  may have a first portion  310  positioned within conductive frame  202  (see  FIG. 3A ), a second portion  311  extending through retainer  223  and a third portion  201  extending out of the retainer at an angle with respect to the longitudinal plane of tab  204 . In some embodiments third portion  201  extends out of retainer  223  at an angle between 45-135 degrees relative to the longitudinal plane of tab  204 . In other embodiments the angle is between 65-115 degrees. In further embodiments the angle is between 80-100 degrees. Carrier  213  may have a plurality of conductors formed thereon and extending from first portion  310  to third portion  201  wherein each of the plurality of conductors has a contact region formed on the first portion and exposed at an outer surface of tab  204 . 
     In some embodiments, carrier  213  may have a fourth portion  344  that extends from position  201  at an angle. In one embodiment fourth portion  344  is oriented substantially parallel to the longitudinal plane of tab  204 . In some embodiments, first portion  310  is a rigid circuit board, whereas second portion  311 , third portion  201  and fourth portion  344  are flexible circuit boards. In some embodiments, forming second portion  311  into a radius then molding it in place with retainer  223  may improve the reliability of carrier  213 . In other embodiments, retainer  223  may support second portion  311  such that it is formed and maintained in a consistent and accurate position for improved signal integrity. In one embodiment, first portion  310  may be attached to third portion  201  where second portion  311  is an interface region between the first portion and the third portion. Retainer  223  may be formed over second portion  311 . In further embodiments, retainer  223  may aid the assembly of carrier  213  into conductive frame  202 . Retainer  223  may have one or more registration and/or alignment features that orient it within conductive frame  202 . In some embodiments retainer  223  may have a tapered entry portion that aids alignment into entrance end  219  of tab  204 . In further embodiments retainer  223  may have one or more retention features that retain it in entrance end  219  of tab  204 . In some embodiments, retainer  223  may be overmolded on carrier  213 . In other embodiments, retainer may be premolded in one or more pieces and be securable to carrier  213 . In one embodiment, retainer  223  includes two pieces that snap together, securing carrier  213  between them. In some embodiments carrier  213  may have first and second locating holes  388   a ,  388   b  to aid in securing carrier  213  in place while retainer  223  is formed on the carrier. 
     The next step of assembly may involve inserting carrier  213  with retainer  223  through entrance end  219  of tab  204  so that solder bumps  312 ( 1 ) . . .  312 ( 8 ) are positioned within window  307  ( FIG. 4 , step  428 ;  FIGS. 3D and 3E ).  FIG. 3D  depicts carrier  213  inserted into conductive frame  202 .  FIG. 3E  depicts a longitudinal cross-section view of the assembly shown in  FIG. 3D  taken through line A-A. Further, it can be seen that solder bumps  312 ( 1 ) . . .  312 ( 8 ) disposed on contact bonding pads are aligned within window  307 . In some embodiments the next step of assembly comprises depositing flux on solder bumps  312 ( 1 ) . . .  312 ( 8 ) through window  307 . This can be done, for example, with an automated atomized spray nozzle, or by an operator with a dispenser. 
     Next, contact assemblies  316   a ,  316   b  (formed in  FIG. 4 , step  426 ) may be positioned within window  307  on each side of conductive frame  202  for attachment to carrier  213  ( FIG. 4 , step  430 ,  FIGS. 3E-3F ). Each contact assembly  316   a ,  316   b  may include a molded frame that can be formed from a dielectric material such as polypropylene. In other embodiments the frame is made of a liquid crystal polymer that may be partially filled with glass fiber. One embodiment has eight contacts  207 ( 1 ) . . .  207 ( 8 ) that are insert-molded and secured by the frame. The frame may be equipped with one or more alignment posts that protrude from a bottom surface of the frame and may fit within alignment holes in carrier  213  and are designed to align contact assemblies  316   a ,  316   b  with the carrier. In some embodiments, the frame may have alignment tabs disposed on the perimeter of the frame that align each frame within openings  307 . Further, contact assemblies  316   a ,  316   b  may have one or more crushable combs that protrude from the bottom surface of the contact assembly and help ensure correct spacing between the contact assemblies and carrier  213  in the vertical direction. 
     Each contact  207 ( 1 ) . . .  207 ( 8 ) in contact assemblies  316   a ,  316   b  can be made from a variety of conductive materials, for example, phosphor-bronze, copper or stainless steel. Further, the contacts can be plated to improve their performance and appearance with, for example, nickel/gold, multi-layer nickel/gold, nickel/palladium, or any other acceptable metal. The contacts may be cut to size in a progressive stamping and forming process from a metal sheet and insert molded in contact assembly  316   a ,  316   b . Each contact may be comprised of more than one metallic component and further, each contact may have one or more metallic protrusions (not shown) disposed on the bottom surface of the contact assembly. 
     Reference is now made to  FIGS. 3G and 3H  to illustrate the contact assembly attachment process for one particular embodiment. The detailed steps in the flow chart depicted in  FIG. 5  will be used to illustrate the process employed in this embodiment. Conductive frame  202  and carrier  213  may be placed in a fixture to hold the components in place ( FIG. 5 , step  430   a;    FIG. 3G ). Contact assembly  316   a  can be positioned in window  307  of conductive frame  202  and alignment posts  323  may be engaged with guide holes  326  in carrier  213  ( FIG. 5 , step  430   b ). Contact assembly alignment tabs  318  may precisely position contact assembly  316   a  in window  307 . Crushable combs  325 ( 1 ) . . .  325 ( 8 ) may be in physical contact with carrier  213 . 
     Now referring to  FIG. 30H , a hot bar tool  328  with a step  329  can be used to hot bar solder contact assembly  316   a  to carrier  213 . In step  430   c , the hot bar tool may be heated to a temperature above the melting temperature of solder bumps  312 ( 1 ) . . .  312 ( 8 ). For example, if the solder bumps are composed of a tin/silver/copper alloy comprised of approximately three percent silver, one-half percent copper with the remainder tin, the hot bar tool may be heated above 221 degrees centigrade. The higher the temperature of the hot bar tool, the faster the solder may reflow. In step  430   d , the hot bar tool may travel down, in the direction of arrow  331 , towards the contact assembly until it physically touches the top surface of contacts  207 ( 1 ) . . .  207 ( 8 ). In step  430   e , the hot bar tool may push the contact assembly further in the direction of arrow  331 , partially deforming crushable combs  325 ( 1 ) . . .  325 ( 8 ) against carrier  213 . The crushable combs may be designed specifically for this purpose and may impart a controlled amount of force resisting movement of contact assembly  316   a  in the direction of arrow  331 . Alignment tabs  318  and alignment posts  323  may keep the contact assembly centered in window  307  (see  FIG. 3C ) during the assembly process. Step  329  of hot bar tool  328  may be precision formed to maintain the top surface of contacts  207 ( 1 ) . . .  207 ( 8 ) coplanar and at a controlled height during the attachment process. In step  430   e , the contact assembly may be further pushed in the direction of the arrow until contact protrusions  321 ( 1 ) . . .  321 ( 16 ) come into contact with solder bumps  312 ( 1 ) . . .  312 ( 8 ). Hot bar tool  328  may be configured to impart a controlled force in the direction of arrow  331  at this time so no damage to the contact assembly results. 
     As mentioned above, solder bumps  312 ( 1 ) . . .  312 ( 8 ) may be coated with flux. In some embodiments the coating of flux may not only improve the wetting of the solder to contact protrusions  321 ( 1 ) . . .  321 ( 16 ), it may also enable more efficient heat transfer from contacts  207 ( 1 ) . . .  207 ( 8 ) to the solder bumps. In step  430   f , hot bar tool  328  may transfer thermal energy through the contacts and into the solder bumps. Once an adequate amount of thermal energy has been transferred into the solder bumps, they may transition to a liquid state when heated above their melting temperature. Once in a liquid state, the solder bumps offer little resistance to additional movement of contact assembly  316   a  in the direction of arrow  331 . In step  430   g , the contact assembly may then be pushed further by the hot bar tool, causing increased deformation of crushable combs  325 ( 1 ) . . .  325 ( 8 ), until the hot bar tool “stops” on flat  319   a  of conductive frame  202 .  FIG. 3H  depicts the stop position of the hot bar tool. In this figure it can be seen that step  329  of hot bar tool  328  may be used to precisely position the top surface of contacts  207 ( 1 ) . . .  207 ( 8 ) a known distance below flat  319   a  of metal frame  202 . In some embodiments, step  329  has a height between 0.1 and 0.01 mm and thus recesses the contacts  207 ( 1 ) . . .  207 ( 8 ) that same amount from surface  319   a  of metal frame  202 . In other embodiments, step  329  is not included and the contacts are pressed flush with flat  319   a . Also, during step  430   g , contact protrusions  321 ( 1 ) . . .  321 ( 16 ) on the bottom surface of contact assembly  316   a  may be wetted by the liquefied solder bumps  312 ( 1 ) . . .  312 ( 8 ). In step  430   h , the hot bar tool may then be cooled until the liquefied solder bumps cool to a temperature below the liquidus temperature of the solder alloy and solidify. In step  430   i , the hot bar tool may then be then retracted and the assembly can be removed from the fixturing. 
     In some embodiments the contact attachment process is performed on one side of metal frame  202  at a time, while in other embodiments the process is performed simultaneously on both sides of the metal frame. In some embodiments crushable combs  325 ( 1 ) . . .  325 ( 8 ) may deform between 0.02 mm and 0.12 mm. In other embodiments the crushable combs may deform between 0.05 mm and 0.09 mm. In some embodiments the heating of the crushable combs by hot bar tool  328  makes them easier to deform. The partially assembled connector may look like  FIG. 3I  with contact assemblies  316   a ,  316   b  installed in either side of metal frame  202 . The partially assembled connector may then be cleaned. 
     The next step of assembly may involve placing a partially assembled connector (see  FIG. 3I ) in an insert molding tool and forming a thermoplastic or similar encapsulant  222  around contacts  207 ( 1 ) . . .  207 ( 8 ) and within window  307  of metal frame  202  ( FIG. 4 , step  432 ;  FIGS. 3J-3L ). This process may provide a smooth and substantially flat mating surface  238 . The insert mold tool may be configured to inject dielectric encapsulant  222  from entrance end  219  of tab  204 , shown generally by arrow  337 . In one embodiment the insert mold tool has a recessed gate for injecting the dielectric overmold. In some embodiments, dielectric encapsulant  222  may be polyoxymethylene (POM). In other embodiments, dielectric encapsulant  222  may be a nylon-based polymer. 
       FIG. 3K  depicts one embodiment after the insert molding process. In some embodiments, a mating surface  238  may be disposed below first major surface  271  of metal frame  202  and be substantially coplanar with the top surface of contacts  207 ( 1 ) . . .  207 ( 8 ).  FIG. 3L  shows a simplified cross-section A-A of  FIG. 3K  in the region of mating surface  238 . From this illustration it can be seen that mating surface  238  may reside in a depression below first major surface  271  of the conductive frame  202 . In some embodiments the depression may be between 0.01 to 0.1 mm below the top surface of conductive frame  202 . This depression may protect contacts  207 ( 1 ) . . .  207 ( 8 ) from touching surfaces, such as that of a mating device, potentially causing damage to the top surface of the contacts. In some embodiments the recess may extend around the entire perimeter of window  307  (see  FIG. 3C ). In further embodiments the recess may be deeper in some areas and shallower in others. In other embodiments the recess may be deeper towards the rear of the connector and substantially coplanar with first major surface  271  of conductive frame  202  towards distal end  218  of the connector. In yet further embodiments, mating surface  238  of dielectric encapsulant  222  may be substantially coplanar with flat  319   a  or first major surface  271  of metal frame  202 . In some embodiments, dielectric encapsulant  222  may be used to aid in retaining the contacts within the connector. In some embodiments second major surface  273  of connector  200  may be manufactured in a similar fashion as discussed above, while in other embodiments the second major surface may have no contact assembly. 
     Another example plug connector  600  in accordance with an embodiment of the invention is illustrated in  FIGS. 6A and 6B . This embodiment differs from the prior one in that instead of conductive frame  202  (see  FIG. 3C ) resembling a hollow shell, conductive frame  602  resembles a substantially u-shaped band. In addition, contacts  615 ( 1 ) . . .  615 ( 8 ) are disposed in a circuit assembly  688  that is disposed within conductive frame  602 . These figures illustrate perspective views depicting an eight contact axisymmetric dual orientation plug connector assembly  600  that may include conductive frame  602  and encapsulant  622  filled within the frame according to embodiments of the present invention. Encapsulant  622  and carrier  613  have been removed in  FIG. 6B  for clarity. As shown in  FIG. 6A , plug connector assembly  600  includes a connector tab  604  that extends longitudinally away from a flange  606 . Connector tab  604  is sized to be inserted into a corresponding receptacle connector. Connector tab  604  includes a first mating surface  608  formed on a first major surface  610  that is opposite second major surface  612  of connector tab  604 . In some embodiments a second mating surface  609  (not shown) is formed on second major surface  612 . A plurality of electrical contacts  615 ( 1 ) . . .  615 ( 8 ) are disposed within mating surfaces  608 ,  609 . First and second major surfaces  610 ,  612  extend from an entrance end  619  to a distal end  618  of connector tab  604 . When connector tab  604  is inserted into a corresponding receptacle connector, major surfaces  610 ,  612  abut a housing of the receptacle connector or host device into which the receptacle connector is incorporated. 
     A retainer  623  is positioned at entrance end  619  of tab  604  and in some embodiments is formed from a material different than encapsulant  622 . A carrier  613  has a first portion (not shown) positioned within conductive frame  602 , a second portion extending through retainer  623  (not shown) and a third portion  601  extending out of the retainer at an angle with respect to the longitudinal plane of tab  604 . In some embodiments third portion  601  extends out of retainer  623  at an angle between 45-135 degrees. In other embodiments the angle is between 65 -115 degrees. In further embodiments the angle is between 80-100 degrees. Carrier  613  has a plurality of conductors formed thereon and extending from the first portion (not shown) to third portion  601 . Each of the plurality of conductors has a mating surface formed on the first portion and exposed at an outer surface of plug  600 . In some embodiments, carrier  613  may have a fourth portion  644  that is oriented substantially parallel with the longitudinal plane of tab  604 . In one embodiment, first portion is a rigid circuit board, whereas second portion, third portion  601  and fourth portion  644  are flexible circuit boards. In some embodiments, forming the second portion into a radius then molding it in place with retainer  623  may improve the reliability of carrier  613 . Retainer  623  may support the second portion such that it is not bent too far or too little and to maintain it in a consistent and accurate position for improved signal integrity. Retainer  623  may also aid the assembly of carrier  613  into conductive frame  602 . Retainer  623  may have one or more registration and/or alignment features that orient it properly within conductive frame  602 . In some embodiments carrier  613  may have first and second locating holes  687   a ,  687   b  to aid in the formation of retainer  623  on the carrier. 
     Tab  604  includes a substantially u-shaped conductive frame  602  that surrounds a portion of the periphery of connector  600 . Conductive frame  602  extends along an entire length of tab portion  604  and includes first and second opposing extensions  698 ,  699  bent outward forming flange  606 . Metallic band  602  may have retention features  665   a ,  665   b  formed in opposing third side surface  625  and fourth side surface  626 . Retention features  665   a ,  665   b  may be part of a retention system that includes one or more features on plug connector  600  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. 
     As further illustrated in  FIG. 6B , in one embodiment, connector  600  has a circuit assembly  688  that is disposed within conductive frame  602 . Circuit assembly  688  couples contacts  615 ( 1 ) . . .  615 ( 8 ) to terminations  611 . In some embodiments carrier  613  (see  FIG. 6A ) is coupled to circuit assembly  688  with terminations  611 . Carrier  613  may be a traditional epoxy and glass combination known as a printed circuit board (PCB) or may be any equivalent structure capable of routing electrical signals and may have one or more flexible portions as discussed above. In further embodiments, one or more electronic components (not shown) can be operatively coupled to carrier  613  and/or circuit assembly  688  to provide information regarding connector  600  and any accessory or device that connector  600  is part of and/or to perform specific functions, such as authentication, identification, contact configuration and current or power regulation. 
     Conductive frame  602  may be fabricated using a variety of techniques such as, for example, stamping, wire forming, forging, metal injection molding (MIM), cold heading or a billet machining process. In some embodiments, alternative processes such as plastic injection molding and post plating with a metal may be used to form conductive frame  602 . Conductive frame  602  may also have one or more alignment features (not shown) and contact assembly retention features (not shown) for aligning and retaining circuit assembly  688  in conductive frame  602 . In some embodiments, conductive frame  602  may be formed from a metal or metal alloy. In one embodiment, conductive frame  602  is formed from stainless steel. In further embodiments, conductive frame  602  may be plated with a metal, such as but not limited to, nickel or gold. 
     In some embodiments, dielectric encapsulant  622  may be polyoxymethylene (POM). In other embodiments, dielectric encapsulant  622  may be a nylon-based polymer that may be filled with glass fiber. Further embodiments may employ other materials. 
     In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. 
     The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the invention, and what is intended by the applicants to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.

Metadata:
Filing Date: 20130912
Publication Date: 20151006
Grant Date: 20151006
Priority Date: 20130912
Inventors: GOLKO ALBERT J.
JONES WARREN Z.
KAMEI IBUKI
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/04", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/205", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49147", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/60", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49147", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 52626033