PATENT DOCUMENT

Publication Number: US-11677174-B2
Application Number: US-202117180841-A
Country: US
Kind Code: B2

Title: Decoupled spring and electrical path in connector interface

Abstract:
Connectors that support high-speed data transfers and have a high signal quality, good reliability, and are readily manufactured. One example can provide a connector receptacle that supports high-speed data transfers and has a high signal quality by employing connector contacts that include multiple structures.

Claims:
What is claimed is: 
     
       1. A connector comprising:
 a tongue; 
 a first support structure on a top of the tongue having a plurality of portions joined by a cross-member; 
 a second support structure on a bottom of the tongue having a plurality of portions joined by a cross-member; 
 a first flexible circuit board; 
 a first plurality of contacts supported by the first support structure and extending parallel to the plurality of portions of the first support structure and soldered to a top side of the first flexible circuit board; and 
 a second plurality of contacts supported by the second support structure and extending parallel to the plurality of portions of the second support structure. 
 
     
     
       2. The connector of  claim 1  wherein the first support structure is plastic. 
     
     
       3. The connector of  claim 2  further comprising an enclosure around the first support structure and the second support structure. 
     
     
       4. The connector of  claim 3  wherein the first support structure and the second support structure are attached to the tongue. 
     
     
       5. The connector of  claim 3  wherein the connector is a connector receptacle. 
     
     
       6. The connector of  claim 1  wherein the first support structure is metal. 
     
     
       7. The connector of  claim 1  wherein the first flexible circuit board is attached to the first support structure using a pressure-sensitive adhesive. 
     
     
       8. The connector of  claim 1  wherein the connector is a connector receptacle. 
     
     
       9. A connector comprising:
 a passage in an enclosure and around a tongue, the passage defining a front opening; 
 a first support structure on a top of the tongue; 
 a second support structure on a bottom of the tongue; 
 a first flexible circuit board, wherein the first flexible circuit board comprises: 
 a first layer supporting a plurality of first traces and a first ground plane; 
 a second layer supporting a plurality of second traces under the first ground plane, second traces in the plurality of second traces coupled to corresponding first traces in the plurality of first traces by a plurality of vias; and 
 a third layer supporting a second ground plane under the plurality of second traces; 
 a first plurality of contacts supported by the first support structure and attached to a top side of the first flexible circuit board, each of the first plurality of contacts attached to a corresponding first trace in the plurality of first traces on the first layer of the first flexible circuit board; and 
 a second plurality of contacts supported by the second support structure. 
 
     
     
       10. The connector of  claim 9  wherein the first support structure is plastic. 
     
     
       11. The connector of  claim 9  wherein the first support structure is metal. 
     
     
       12. The connector of  claim 11  wherein the enclosure is around the first support structure and the second support structure. 
     
     
       13. The connector of  claim 12  wherein the first support structure and the second support structure are attached to the tongue. 
     
     
       14. The connector of  claim 9  wherein the first flexible circuit board is attached to the first support structure using a pressure-sensitive adhesive. 
     
     
       15. The connector of  claim 9  wherein each of the first plurality of contacts are soldered to a corresponding first trace in the plurality of first traces on the first layer of the first flexible circuit board. 
     
     
       16. The connector of  claim 9  wherein the connector is a connector receptacle. 
     
     
       17. A connector system comprising:
 a connector receptacle comprising: 
 a passage surrounding a tongue, the tongue having a length from a back of the passage to a leading edge of the tongue, the passage defining a front opening; 
 a first support structure on a top of the tongue; 
 a second support structure on a bottom of the tongue; 
 a first flexible circuit board extending along a majority of a length of the tongue; 
 a first plurality of contacts supported by the first support structure and soldered to a top side of the first flexible circuit board; and 
 a second plurality of contacts supported by the second support structure; and 
 a connector insert comprising: 
 a first contact to mate with a first contact in the plurality of first contacts when the connector insert is mated with the connector receptacle. 
 
     
     
       18. The connector system of  claim 17  further comprising a magnetic element in the connector insert and a magnetic element on the tongue. 
     
     
       19. The connector system of  claim 18  wherein the connector insert further comprises a shield around the first contact. 
     
     
       20. The connector system of  claim 19  wherein the first support structure and the second support structure are supported by the tongue.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 16/581,101 filed Sep. 24, 2019, which claims the benefit of U.S. provisional application No. 62/735,391, filed Sep. 24, 2018; which are incorporated by reference. 
    
    
     BACKGROUND 
     Power and data can be provided from one electronic device to another over cables that can include one or more wires, fiber optic cables, or other conductors. Connector inserts can be located at each end of these cables and can be inserted into connector receptacles in the communicating electronic devices. 
     Large amounts of data can be transferred among these connected electronic devices. But data transfers can be costly in terms of time and computing power. In order to reduce these data transfer times, it can be desirable that these connectors be capable of supporting high data rates. That is, it can be desirable that these connectors provide a high signal quality or signal integrity to allow high speed data transfers among connected electronic devices. 
     These connector inserts can be inserted into connector receptacles many times over the lifetime of an electronic device. Some devices can be connected to chargers, home or car audio equipment, or other types of electronic devices several times a day. Accordingly, it can be desirable that these connector inserts and connector receptacles be reliable and be able to withstand a high number of insertions and extractions. 
     Also, some of these electronic devices become tremendously popular. As a result, connector receptacles on the electronic devices and connector inserts on cables can be sold in very large quantities. Therefore, it can be desirable that these connectors be readily manufactured such that customer demand for them can be met. 
     Thus, what is needed are connectors that support high-speed data transfers and have a high signal quality, good reliability, and are readily manufactured. 
     SUMMARY 
     Accordingly, embodiments of the present invention can provide connectors that support high-speed data transfers and have a high signal quality, good reliability, and are readily manufactured. 
     An illustrative embodiment of the present invention can provide a connector receptacle that supports high-speed data transfers and has a high signal quality by employing connector contacts that include multiple structures. These multiple-structure contacts can use different structures for the various functions that can be performed by connector contacts. For example, spring contact forces can be provided by spring fingers, where the spring fingers do not actually convey signals or power but are utilized to provide a good mechanical and electrical connection between contacts in mated connectors. Since signals are not routed through the spring fingers, they can be formed of materials that are selected to provide a good spring force without regards to their conductivity. Since the remaining structures do not need to provide a spring force, contacts on a flexible printed circuit board (or flexible circuit board) can serve as electrical contacts to convey signals for the connector. In this way, signals at contacts of the connector can be routed through traces in the flexible circuit board. Traces on the flexible circuit board can be shielded, they can be part of a strip-line, or they can be (or can be part of) another routing structure used to improve signal quality and signal integrity. These routing techniques can reduce cross-talk, reduce electromagnetic interference, and enable a high data rate. Also, since the traces in the flexible circuit board can begin at contacting portions of the flexible circuit boards, stubs which can be located at an end of a traditional beam contact, can be reduced or eliminated for further improved high-frequency performance. 
     Differential signals conveyed by traces in these flexible circuit boards can be well-shielded. For example, a high-speed differential signal can be conveyed on two contacts formed on, or attached to, traces on an outside surface of the flexible circuit board. The two traces can connect to two vias of the flexible circuit board. The differential signal can then be conveyed by the vias to two traces on a middle layer of the board. Each pair of traces can be laterally shielded by ground or power supplies, as well as a ground plane on the bottom layer and a ground plane on the top layer. Positioning the vias such that there is short distance between the contacts and the vias can also help to shield the differential signals by allowing the ground planes to be positioned close to the contacts. 
     In these and other embodiments of the present invention, spring fingers can be located against a housing or shield of a connector insert. A flexible circuit board can have a portion that can be located on a surface of the spring fingers away from the housing or shield. The flexible circuit board can be glued or otherwise fixed to the spring fingers using pressure-sensitive adhesive, heat activated adhesive, temperature-sensitive adhesive, or other adhesive, laser or spot welding, or other appropriate material or process. Contacts can be formed on surfaces of contacting portions of the flexible circuit board away from the spring fingers. The contacts formed on the surface the contacting portions of the flexible circuit board can directly and electrically connect to contacts of a corresponding connector. The contacts can be plated, formed by vapor deposition, soldered, or formed in other ways on the contacting portions of the flexible circuit board 
     In these and other embodiments of the present invention, each spring finger can provide support for one contacting portion of a flexible circuit board. This arrangement can work well to ensure that each contact on a contacting portion of a flexible circuit board has a force to push it against a corresponding contact when the contact on the contacting portion of the flexible circuit board is mated with the corresponding contact of a corresponding connector. 
     In these and other embodiments of the present invention, each spring finger can provide support for two contacting portions of a flexible circuit board. Having two contacting portions supported by each spring finger can help to ensure that each contact on a contacting portion of a flexible circuit board has a force to push it against a corresponding contact when the contact on the contacting portion of the flexible circuit board is mated with the corresponding contact of a corresponding connector. 
     In these and other embodiments of the present invention, each spring finger can provide support for more than two contacting portions of a flexible circuit board. For example, each spring finger can provide support for each of the contacting portions of a flexible circuit board. Having a limited number of spring fingers can help to simplify the assembly and manufacturing of components for a connector. 
     In these and other embodiments of the present invention, the spring fingers and contacting portions can be arranged in various ways. Again, each spring finger can support one, two, three, or more contacting portions. Each contacting portion can support one or more contacts. For example, a spring finger may support a contacting portion having one contact. A spring finger may support a contacting portion having two contacts. A single spring finger can support a single contacting portion having all the contacts of a row. Other configurations are also possible. 
     In these and other embodiments of the present invention, the spring fingers can be conductive. These spring fingers can be formed of steel, stainless steel, spring steel, copper, bronze, ceramic, or other material. The spring fingers can be held in place by being partially encased in, or attached to, a housing for the connector. The housing can be formed of plastic, a ferritic or other magnetic material (to form a magnetic element), or other conductive or nonconductive material. The spring fingers can be held in place by being attached to, or formed as part of, a shield around the connector. The spring fingers can also be held in place by a housing that is shielded by the shield. The spring fingers can be formed by stamping, metal-injection molding, forging, deep drawing, or other process. 
     In these and other embodiments of the present invention, the spring fingers can be nonconductive. These spring fingers can be formed of plastic, LDS plastic, ceramic, or other material. The spring fingers can be held in place by being partially encased in, or formed with, a housing for the connector. The housing can be formed of plastic, a ferritic or other magnetic material (to form a magnetic element), or other conductive or nonconductive material. The spring fingers can be formed by molding, injection molding, or other process. The spring fingers can be formed as part of the housing for the connector. 
     In these and other embodiments of the present invention, traces in the flexible circuit boards can electrically connect to conductors in a cable, traces in other flexible circuit boards, one or more printed circuit boards, or other appropriate routing paths. This can save space in a connector as compared to conventional beam contacts. This saved space can be used for various purposes. For example, one or more electrical components can be placed on the flexible circuit boards. One or more magnets can be placed in the connectors to provide an increase in retention force of a connector insert in a connector receptacle. 
     In these and other embodiments of the present invention, one or more magnets can be located in a connector insert. The magnets can magnetically attract a magnetic element on a tongue of a corresponding connector receptacle when the connector insert is mated with the corresponding connector receptacle. The magnetic element on the tongue can be formed of a ferritic or other magnetic material. For example, a tongue can include a metal-injection molded frame, where the injected metal forms a magnetic element. Magnets in the connector receptacle can attract a magnetic element near a front of the connector insert when the connector insert is mated with the corresponding connector receptacle, where the magnetic element is formed of ferritic or other magnetic material. In these and other embodiments, the magnets can be positioned, either spatially or by orientation, such that they allow the connector insert to be inserted into the connector receptacle in either of two rotational orientations separated by 180 degrees. 
     These multi-structure contacts can be used in various ways in connectors consistent with embodiments of the present invention. For example, these multi-structure contacts can be used as contacts in a connector insert where the multi-structure contacts directly and electrically connect to contacts on a tongue in a corresponding connector receptacle when the connector insert and the corresponding connector receptacle are mated. These multi-structure contacts can be used as contacts in a connector receptacle where the multi-structure contacts directly and electrically connect to contacts on a tongue of a corresponding connector insert when the corresponding connector insert and the connector receptacle are mated. These multi-structure contacts can also be used as contacts on a tongue of a connector insert where the multi-structure contacts directly and electrically connect to contacts in a corresponding connector receptacle when the connector insert and the corresponding connector receptacle are mated. These multi-structure contacts can be used as contacts on a tongue of a connector receptacle where the multi-structure contacts directly and electrically connect to contacts of a corresponding connector insert when the corresponding connector insert and the connector receptacle are mated. 
     While embodiments of the present invention can be useful as USB Type-C connector inserts and connector receptacles, these and other embodiments of the present invention can be used as connector receptacles in other types of connector systems, such as a Peripheral Component Interconnect express (PCIe) connector system. 
     In various embodiments of the present invention, spring fingers, contacts, shields, and other conductive portions of a connector receptacle or connector insert can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. The nonconductive portions, such as spring fingers, housings and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The printed circuit boards or other boards used can be formed of FR-4 or other material. 
     Embodiments of the present invention can provide connector receptacles and connector inserts that can be located in, and can connect to, various types of devices such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, smart phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. These connector receptacles and connector inserts can provide interconnect pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™ Joint Test Action Group (JTAG), test-access-port (TAP), Peripheral Component Interconnect express, Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention can provide connector receptacles and connector inserts that can be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles and connector inserts can be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     Various embodiments of the present invention can incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention can be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    illustrates an electronic system that can be improved by the incorporation of embodiments of the present invention; 
         FIG.  2    illustrates a cutaway side view of a connector insert according to an embodiment of the present invention; 
         FIG.  3    illustrates a front portion of a connector insert according to an embodiment of the present invention; 
         FIG.  4    illustrates another connector insert according to an embodiment of the present invention; 
         FIG.  5    illustrates a connector system according to an embodiment of the present invention; 
         FIG.  6    illustrates another connector system according to an embodiment of the present invention; 
         FIG.  7    illustrates another connector system according to an embodiment of the present invention; 
         FIG.  8    illustrates a connector receptacle according to an embodiment of the present invention; 
         FIG.  9    illustrates another connector insert according to an embodiment of the present invention; 
         FIG.  10    is an exploded view of the connector insert of  FIG.  9   ; 
         FIG.  11    is a cutaway side view of a portion of the connector insert of  FIG.  9   ; 
         FIG.  12    illustrates a portion of a connector insert and associated structures according to an embodiment of the present invention; 
         FIG.  13    illustrates layers of a multilevel flexible circuit board according to an embodiment of the present invention; and 
         FIG.  14    illustrates contacts on a surface of a flexible circuit board according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG.  1    illustrates an electronic system that can be improved by the incorporation of an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, monitor  130  can be in communication with computer  100 . Computer  100  can be substantially housed in device enclosure  102 . Computer  100  can provide video or other data over cable  120  to monitor  130 . Video data can be displayed on the video screen  132  of monitor  130 . Computer  100  can similarly include a screen  104 . In these and other embodiments the present invention, other types of devices can be included, and other types of data can be shared or transferred among the devices. For example, computer  100  and monitor  130  can be portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, smart phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. 
     Cable  120  can be one of a number of various types of cables. For example, it can be a Universal Serial Bus (USB) cable such as a USB Type-C cable, Thunderbolt, DisplayPort, Lightning, or other type of cable. Cable  120  can include compatible connector insert  110  and compatible connector insert  124  that plug into connector receptacle  122  on computer  100  and connector receptacle  134  on monitor  130 . Examples of connector inserts  110  and connector receptacles (which can be the same or different as connector inserts  124 , connector inserts  900 , and connector receptacle  134 ) are shown in the following figures. 
       FIG.  2    illustrates a cutaway side view of a connector insert according to an embodiment of the present invention. Connector insert  110  can accept a tongue  510  of a connector receptacle  122  (shown in  FIG.  5   .) Contacts  924  (shown in  FIG.  12   ) on contacting portions  222  in connector insert  110  can mate with contacts (not shown) on tongue  510  when connector insert  110  is mated with connector receptacle  122 . Contacts  924  in connector insert  110  can be multi-structure contacts. In this example, these contacts  924  can include a metal layer (not shown) on traces  1322  (shown in  FIG.  13   ) on contacting portions  222  of flexible circuit board  220 , which can be attached to spring fingers  210 . These multi-structure contacts can be located in a top and bottom of a passage in connector insert  110  (or  900  as shown in  FIG.  10   .) In these and other embodiments of the present invention, these contacts can be located in either a top or bottom of the passage in connector insert  110  (or  900  as shown in  FIG.  10   .) Spring fingers  210  can be supported by housings  212 . Contacting portions  222  can be electrically isolated by shield  240 . Shield  240  can electrically connect to rear shield  242 . Flexible circuit boards  220  can connect to boards  250 . Flexible circuit boards  220  can be multilayer or single layer flexible circuit boards. Boards  250  can be supported by housing  230 . Contacts  252  on boards  250  can electrically connect to route paths  260 . Route paths  260  can be wires, such as wires in a cable, additional flexible circuit boards, or other routing structures. 
     Spring fingers  210  can each support individual contacting portions  222 , they can each support two contacting portions  222 , or they can support more than two contacting portions  222 . Spring fingers  210  can be in contact with shield  240  or they can be separate from shield  240 . 
     More specifically, in these and other embodiments of the present invention, each spring finger  210  can provide support for one contacting portion  222  of a flexible circuit board  220 . This arrangement can work well to ensure that each contact  924  on a contacting portion  222  of flexible circuit board  220  has a force to push it against a corresponding contact (not shown) when the contact  924  on the contacting portion  222  of the flexible circuit board  220  is mated with the corresponding contact. 
     In these and other embodiments of the present invention, each spring finger  210  can provide support for two contacting portions  222  of a flexible circuit board  220 . Having two contacting portions  222  supported by each spring finger  210  can help to ensure that each contact  924  on a contacting portion  222  of flexible circuit board  220  has a force to push it against a corresponding contact when the contact  924  on the contacting portion  222  of the flexible circuit board  220  is mated with the corresponding contact. 
     In these and other embodiments of the present invention, each spring finger  210  can provide support for contacts  924  on more than two contacting portions  222  of a flexible circuit board  220 . For example, each spring finger  210  can provide support for each of the contacts  924  on the flexible circuit board  220 . Having a limited number of spring fingers  210  can help to simplify the assembly and manufacturing of components for a connector insert  110 . 
     Spring fingers  210  can be conductive. Spring fingers  210  can be held in place by being partially encased in, or attached to, housing  212 . Housing  212  can be formed of plastic, a ferritic or other magnetic material (to form a magnetic element), or other conductive or nonconductive material. Spring fingers  210  can be held in place by being attached to, or formed as part of, a shield around the connector, or a housing in the connector. Spring fingers  210  can be formed of steel, copper, bronze, spring steel, stainless steel, ceramic, or other material. Spring fingers  210  can be formed by stamping, metal-injection molding, forging, deep drawing, or other process. 
     In these and other embodiments of the present invention, spring fingers  210  can be nonconductive. Spring fingers  210  can be held in place by being partially encased or formed with housing  212 . Spring fingers  210  can be attached to flexible circuit boards  220  using a pressure-sensitive adhesive, heat activated adhesive, temperature-sensitive adhesive, or other adhesive, laser or spot welding, or other material or process. Spring fingers  210  can be made of plastic, LCPs, rubber, foam, or other material. Spring fingers  210  can be formed by molding, injection molding, or other process. Housing  230  can be formed of plastic, and can be formed by injection molding or other process. 
     In these and other embodiments of the present invention, flexible circuit boards  220  can connect to boards  250 . Route paths in flexible circuit boards  220  can electrically connect to traces in boards  250 , which can terminate in contacts  252 . Contacts  252  can be located on boards  250 . In these and other embodiments of the present invention, flexible circuit boards  220  can instead bypass boards  250  and connect to route paths  260  via contacts  252 , which can be located on flexible circuit boards  220 . 
     In these and other embodiments of the present invention, route paths  260  can be routed in different directions. This can allow connector insert  110  to have cable that extends from connector insert  110  at a right angle or other angle to a contacting direction that connector insert  110  is inserted into connector receptacle  122  (shown in  FIG.  5   .) 
       FIG.  3    illustrates a front portion of a connector insert according to an embodiment of the present invention. Again, contacts  924  (shown in  FIG.  12   ) on contacting portions  222  of connector insert  110  can mate with contacts (not shown) on top and bottom surfaces of tongue  510 . Contacts  924  on contacting portions  222  can be formed on surfaces of flexible circuit boards  220 , or attached to traces on surfaces of flexible circuit board  220 . Spring fingers  210  can mechanically support contacting portions  222  of flexible circuit boards  220 . Housing  212  can support spring fingers  210 . Shield  240  can electrically isolate contacting portions  222 . 
     In these multi-structure contacts, spring fingers  210  can provide mechanical support and contacting force for contacts  924  on contacting portions  222 . That is, the spring fingers might not actually convey signals or power but instead can be utilized to provide a good mechanical electrical connection between contacts in mated connectors. Since signals are not routed through spring fingers  210 , they can be formed of materials that are selected to provide a good spring force without regard to their conductivity. Since the remaining structures in the multi-structure contacts are not required to provide a spring force, contacts  924  on flexible circuit board  220  can convey signals for the connector insert  110 . Contacts  924  on contacting portions  222  can connected to traces (not shown) of flexible circuit board  220 . Flexible circuit board  220  can be a multilayer flexible circuit board to help improve signal quality. The traces of flexible circuit board  220  can use the multiple layers to provide matched traces, shielding, strip-lining, and other routing structure that can be used to improve signal quality and signal integrity. These routing techniques can reduce cross-talk, reduce electromagnetic interference, and enable a high data rate. Also, since the traces of flexible circuit board can begin (terminate) at contacting portions  222 , stubs, which can be located at an end of a traditional beam contact, can be reduced or eliminated for further improved high-frequency performance. 
     By forming contacts in this way, traditional beam contacts are not needed. The absence of these beam contacts can result in free space inside a connector insert. This space can be used for components, which can be located on flexible circuit boards  220 , boards  250 , route paths  260 , or elsewhere connector insert. The ability to locate components on these boards directly can enable the elimination of a paddle board that can otherwise be needed. The use of a boot over the paddle board can similarly be eliminated. 
     In these and other embodiments of the present invention, one or more magnets can also be located in the connector insert. An example is shown in the following figure. 
       FIG.  4    illustrates another connector insert according to an embodiment of the present invention. As before, contacts  924  (show in  FIG.  12   ) on contacting portions  222  on flexible circuit boards  220  can electrically connect to contacts (not shown) on tongue  510 . Flexible circuit boards  220  can be attached to surfaces of spring fingers  210 . Spring fingers  210  can be supported by housing  212 . Flexible circuit boards  220  can terminate at contacts  252  on boards  250  and signals on flexible circuit boards  220  can be routed by route paths  260 . 
     Again, the absence of beam contacts can provide additional space in connector insert  110 . In this example, a magnet  425  can be included in connector insert  110 . This magnet  425  can include a south pole  410  and a north pole  420 . The south pole  410  and north pole  420  can attract a magnetic element (not shown) on tongue  510 . For example, tongue  510  can include a metal-injection molded frame, where the injected metal forms a magnetic element. This can help to secure connector insert  110  in place in connector receptacle  122 . An example is shown in the following figure. 
       FIG.  5    illustrates a connector system according to an embodiment of the present invention. In this example, connector insert  110  can be inserted in recess or passage  552  in device enclosure or receptacle housing  550 , which can be the same or similar to device enclosure  102  in  FIG.  1   . Device enclosure or receptacle housing  550  can at least substantially house an electronic device that includes connector receptacle  122 . Device enclosure or receptacle housing  550  can instead be a housing for connector receptacle  122 . 
     As before, connector insert  110  can include contacts  924  (show in  FIG.  12   ) on contacting portions  222  that can physically and electrically connect to contacts (not shown) on tongue  510  of connector receptacle  122 . Contacts  924  can be formed on contacting portions  222 . Contacting portions  222  can be supported by spring fingers  210 , which can be supported by housing  212 . In this example housing  212  can include a magnetic element (not shown.) Flexible circuit boards  220  can terminate at contacts  252  on board  250 . Route paths  260  can be connected to contacts  252 . Connector insert  110  can include shield  240 . 
     Connector insert  110  can be mated with connector receptacle  122 . Connector receptacle  122  can include a magnet  525  having a south pole  530  and a north pole  540 . Route paths  520  can be connected to tongue  510  and can be attached to board  560 . 
     In this example, magnet  405  in connector insert  110  can electrically attract a magnetic element (not shown) on tongue  510  of connector receptacle  122 . For example, tongue  510  can include a metal-injection molded frame, where the injected metal forms a magnetic element. Magnet  525  in connector receptacle  122  can electrically attract a magnetic element (not shown) in housing  212 . This can help to secure connector insert  110  in place with connector receptacle  122 . These magnets can also provide a tactile response to a user when inserting connector insert  110  into connector receptacle  122 . 
     These multi-structure contacts can be used in various ways in connectors consistent with embodiments of the present invention. For example, these multi-structure contacts can be used as contacts in a connector receptacle where the multi-structure contacts directly and electrically connect to contacts on a tongue of a connector insert. An example is shown in the following figure. 
       FIG.  6    illustrates another connector system according to an embodiment of the present invention. In this example, connector insert tongue  605  can be mated with connector receptacle  122 , which can be located in device enclosure  610 , which can be the same or similar as device enclosure  102  in  FIG.  1   . Device enclosure  610  can instead be a housing for connector receptacle  122 . Connector insert  110  can include magnet  525 , route paths  520 , and tongue  510 . A housing (not shown) can support magnet  525 . 
     Connector receptacle  122  can be part of an electronic device that can be at least substantially housed by device enclosure  610 . Connector receptacle  122  can include contacts  924  (shown in  FIG.  12   ) on contacting portions  222  that can physically and electrically connect to contacts (not shown) on tongue  605  of connector insert  110 . Contacts  924  on contacting portions  222  can be formed on flexible circuit boards  220 . Contacting portions  222  can be supported by spring fingers  210 , which can be supported by housing  212 . In this example housing  212  can include a magnetic element (not shown.) Flexible circuit boards  220  can terminate at contacts  252  on board  250 . Route paths  260  can be connected to contacts  252 . Connector receptacle  122  can be at least partially shielded by shield  240 . 
     Again, these multi-structure contacts can be used in various ways in connectors consistent with embodiments of the present invention. For example, these multi-structure contacts can be used as contacts on a tongue of a connector insert where the multi-structure contacts directly and electrically connect to contacts in a connector receptacle when the connector insert and connector receptacle are mated. An example is shown in the following figure. 
       FIG.  7    illustrates another connector system according to an embodiment of the present invention. In this example, connector insert  110  can include contacting portions  222  on flexible circuit boards  220 . Flexible circuit boards  220  can be supported by spring fingers  210  on tongue  510 . Spring fingers  210  can be supported by tongue portion or housing  212 , which can be located on, or can be part of, tongue  705 . Contacts  924  (shown in  FIG.  12   ) on contacting portions  222  can physically and electrically contact connector receptacle contacts (not shown). These connector receptacle contacts can be supported by device enclosure  710 . Device enclosure  710  can at least substantially house an electronic device that includes connector insert  110 . Device enclosure  710  can instead be a portion of a housing for connector receptacle  122 . 
     Again, these multi-structure contacts can be used in various ways in connectors consistent with embodiments of the present invention. For example, these multi-structure contacts can be used as contacts on a tongue of a connector receptacle where the multi-structure contacts directly and electrically connect to contacts in a connector insert when the connector insert and connector receptacle are mated. An example is shown in the following figure. 
       FIG.  8    illustrates a connector receptacle according to an embodiment of the present invention. In this example, connector receptacle  122  can include contacting portions  222  on flexible circuit boards  220 . Flexible circuit boards  220  can be supported by spring fingers  210  on tongue  805 . Spring fingers  210  can be supported by tongue portion or housing  212 . Contacts  924  (show in  FIG.  12   ) on contacting portions  222  can physically and electrically contact connector receptacle contacts (not shown). Tongue  805  can emerge from an opening  812  in device enclosure  810 . Device enclosure  810  can at least substantially house an electronic device that includes connector receptacle  122 . Device enclosure can be the same or similar to device enclosure  102  in  FIG.  1   . Device enclosure  810  can instead be a portion of a housing for connector receptacle  122 . 
       FIG.  9    illustrates another connector insert according to an embodiment of the present invention. Connector insert  900  can be a USB type C connector insert, though embodiments of the present invention can be incorporated in other types of connector inserts and connector receptacles. Connector insert  900  can be used as connector insert  124  in  FIG.  1   . Connector insert  900  can include housing  950  having openings  952  for ground contacts  972 . Housing  950  can be formed of plastic or other nonconductive material, and can be formed by injection molding or other process. Housing  950  can be shielded by shield  940 . Shield  940  can be metallic or otherwise conductive and can be formed by stamping, 3-D printing, deep-drawing, forging, molding, or other process. Shield  940  and housing  950  can have front opening  942 . Front opening  942  can accept a tongue of a corresponding connector receptacle (not shown) and shield  940  can electrically connect to ground contacts (not shown) in the connector receptacle when connector insert  900  and the corresponding connector receptacle are mated. Flexible circuit boards  920  and  930  can be routed from a back end of connector insert  900 . 
       FIG.  10    is an exploded view of the connector insert of  FIG.  9   . Connector insert  900  can include housing  950 . Housing  950  can support side ground contacts  960  in slots  956 . Side ground contacts  960  can include contacting portions  962  that can physically and electrically connect to contacts on the side of a tongue (not shown) in a corresponding connector receptacle (not shown.) Housing  950  can further support ground contact structures  970  in slots  954 . Ground contact structures  970  can include ground contacts  972  that can be exposed at openings  952  of housing  950 . Ground contacts  972  can physically and electrically connect to ground pads (not shown) on the tongue of the corresponding connector receptacle. Housing  950  can further support spring fingers  910  and  912  at notches  957 . 
     In this example, spring fingers  910  and  912  can be the same or substantially similar to spring fingers  210  shown above, and they can be formed, operate, and be used in the same or similar manners. 
     Spring fingers  910  and  912  can each support individual contacting portions  922  and  932 , they can each support two contacting portions  922  and  932 , or they can support more than two contacting portions  922  and  932 . Spring fingers  910  and  912  can be in contact with shield  940  or they can be separate from shield  940 . 
     More specifically, in these and other embodiments of the present invention, each spring finger  910  and  912  can provide support for one contacting portion  922  and  932  of flexible circuit board  920  and  930 . This arrangement can work well to ensure that each contact  924  on a contacting portion  922  or  932  of flexible circuit boards  920  and  930  has a force to push it against a corresponding contact (not shown) when each contact  924  on the contacting portions  922  and  932  of the flexible circuit boards  920  and  930  is mated with the corresponding contact. 
     In these and other embodiments of the present invention, each spring finger  910  and  912  can provide support for two contacting portions  922  and  932  of flexible circuit boards  920  and  930 . Having two contacting portions  922  and  932  supported by each spring finger  910  and  912  can help to ensure that each contact  924  on a contacting portion  922  and  932  of flexible circuit boards  920  and  930  has a force to push it against a corresponding contact when each contact  924  on the contacting portions  922  and  932  of flexible circuit boards  920  and  930  is mated with the corresponding contact. 
     In these and other embodiments of the present invention, each spring finger  210  can provide support for contacts  924  on more than two contacting portions  222  of a flexible circuit board  220 . For example, each spring finger  910  and  912  can provide support for each of the contacts  924  on flexible circuit boards  920  and  930 . Having a limited number of spring fingers  910  and  912  can help to simplify the assembly and manufacturing of components for a connector insert  900 . 
     In this example, spring fingers  910  and  912  can be individual spring fingers, though in these and other embodiments of the present invention, some or all of the spring fingers  910  and  912  can be joined. Similarly, each contacting portion  922  and  932  can be separate as shown, or some of all of contacting portions  922  and  932  can be joined. Each spring finger  910  and  912  can support one, two, three, or more contacting portions  922  and  932  of flexible circuit boards  920  and  930 . Spring fingers  910  and  912  can be connected by connecting pieces  914 . 
     In these and other embodiments of the present invention, spring fingers  910  (and  912 ) and contacting portions  922  (and  932 ) can be arranged in various ways. Again, each spring finger  910  can support one, two, three, or more contacting portions  922 . Each contacting portion  922  can support one or more contacts  924 . For example, a spring finger  910  may support a contacting portion  922  having one contact  924 . A spring finger  910  may support a contacting portion  922  having two contacts  924 . A single spring finger  910  can support a single contacting portion  922  having all the contacts  924  of a row. Other configurations are also possible. 
     Spring fingers  910  and  912  can be conductive. Spring fingers  910  and  912  can be held in place by being partially encased in, or attached to, housing  950 . Spring fingers  910  and  912  can be held in place by being attached to, or formed as part of, a shield around the connector, or a housing in the connector. Spring fingers  910  and  912  can be formed of steel, copper, bronze, spring steel, stainless steel, ceramic, or other material. Spring fingers  910  and  912  can be formed by stamping, metal-injection molding, forging, deep drawing, or other process. 
     In these and other embodiments of the present invention, spring fingers  910  and  912  can be nonconductive. Spring fingers  910  and  912  can be held in place by being partially encased or formed with housing  950 . Spring fingers  910  and  912  can be formed as part of the housing  950  for the connector. Spring fingers  910  and  912  can be attached to flexible circuit boards  920  and  930  using a pressure-sensitive adhesive, heat activated adhesive, temperature-sensitive adhesive, or other adhesive, laser or spot welding, or other material or process. Spring fingers  910  and  912  can be made of plastic, LCPs, rubber, foam, or other material. Spring fingers  910  and  912  can be formed by molding, injection molding, or other process. 
     Flexible circuit boards  920  and  930  can include contacting portions  922  and  932  that can be aligned and fixed to spring fingers  910  and  912 . Contacting portions  922  can be adhesively attached to spring fingers  910 , while contacting portions  932  can be adhesively attached to spring fingers  912 . Keeping spring fingers  910  and  912  separate and not joined can improve the planarization of contacts  924  (shown in  FIG.  13   ) on contacting portions  922  and  932  of flexible circuit boards and  20  and  930 . Housing  950  can be enclosed in shield  940 . Shield  940  and housing  950  can include front opening  942  for accepting the tongue of the corresponding connector receptacle. 
       FIG.  11    is a cutaway side view of a portion of the connector insert of  FIG.  9   . In this example, spring finger  910  can be attached to notch  957  on housing  950  (shown in  FIG.  10   ) by tab  915  on connecting piece  914 . Flexible circuit board  920  can include a thicker portion  927  for durability reasons. Thicker portion  927  of flexible circuit board  920  can include a contacting portion  922  over contacting point  917  of spring finger  910 . A contact  924  (shown in  FIG.  13   ) can be formed over contacting point  917  and can extend over some or all of thicker portion  927 . In these and other embodiments of the present invention, thicker portion  927  can be omitted, and flexible circuit board  920  can have a uniform width along the length of spring finger  910 . 
     In these and other embodiments of the present invention, signals can be routed from contacts on a flexible circuit board to a second flexible circuit board, printed circuit board, or other appropriate substrate. An example of how this can be done is shown in the following figure. 
       FIG.  12    illustrates a portion of a connector insert and associated structures according to an embodiment of the present invention. In this example, spring fingers  910  can be joined by connecting piece  914 . Spring fingers  910  can provide support for contacting portions  922  (shown in  FIG.  11   ) of flexible circuit board  920 . Contacts  924  can be formed on a bottom surface of flexible circuit board  920 . Contacts  924  can make electrical connections with contacts  1292  on tongue  1290 . Tongue  1290  can be a tongue of a corresponding connector receptacle (not shown) that is mated to this connector insert. Contacts  924  can electrically connect to traces  928  in flexible circuit board  920 . Some or all of traces  928  can connect to traces (not shown) in printed circuit board  1210  through vias  1220 . Some or all of traces  928  can instead connect through vias  1220  to traces  1212  on a surface of printed circuit board  1210 . 
     Again, flexible circuit boards  220 ,  920 , and  930  can be multilevel flexible circuit boards. An example is shown in the following figure. In this example, bottom, middle, and top layers of a flexible circuit board can be included. 
       FIG.  13    illustrates layers of a multilevel flexible circuit board according to an embodiment of the present invention. In this example, flexible circuit board  920  (which can be the same as flexible circuit boards  220  and  930 ) can include a bottom layer  1310 , a middle layer (shown here as Layer2)  1312 , and a top layer  1314 . In these and other embodiments of the present invention, one or more of these layers can be omitted or one or more other layers can be added. Contacts  924  (shown in  FIG.  12   ) can be attached to traces  1322  and  1323  on contacting portions  922 . Contacts  924  can be soldered, attached by adhesive, or attached in other ways to contacting portions  922 . For example, pressure-sensitive adhesive, heat activated adhesive, temperature-sensitive adhesive, or other adhesive can be used. Traces  1322  and  1323  can electrically connect to vias  1340 . Vias  1340  can electrically connect to each other on bottom layer  1310 , middle layer  3012 , and top layer  1314 , and can provide a routing path for signals on traces  1322  to reach traces  1350  and  1360  on middle layer  1312 . Wider traces  1350  can be used by ground or power supplies, while the narrower traces  1360  can be used for signals, such as high-speed differential signals. Ground plane  1332  on bottom layer  1310  and ground plane  1333  on top layer  1314  can shield traces  1360 . Traces  1323  can electrically connect to ground plane  1332  and ground plane  1333 . Traces  1350  and  1360  can connect to vias  1220 . Vias  1220  can connect to each other on bottom layer  1310 , middle layer  3012 , and top layer  1314 . Vias  1220  can connect to vias  929  on printed circuit board  1210 . Vias  929  can connect to route paths on different layers (not shown) in printed circuit board  1210 . Vias  1220  can also connect to traces  1212 . 
     In this way, high-speed differential signals conveyed by flexible circuit board  920  can be well-shielded. This shielding can protect the differential signals being conveyed on flexible circuit board  920 , and can prevent differential signals being conveyed on flexible circuit board  920  from coupling to other signals or circuits. For example, a differential signal can be conveyed on two traces  1322  to two vias  1340  on bottom layer  1310 . The differential signal can then be conveyed on two of the traces  1360 . Each pair of traces  1360  can be shielded by ground or power supplies on traces  1350 , as well as ground plane  1332  on bottom layer  1310  and ground plane  1333  on top layer  1314 . The short distance between contacts  924  on traces  1322  and the vias  1340  can also help to shield the differential signals by allowing ground plane  1332  on bottom layer  1310  and ground plane  1333  on top layer  1314  to extend close to contacts  924 . 
     The additional shielding provided by placing ground planes  1332  and  1333  close to the contacts  924  means that the connector has a shorter region where the signals conveyed by contacts  924  are not carried on a transverse electromagnetic (TEM) transmission line. A TEM transmission line (for example the stripline as shown here) has a well-defined impedance with less variation, giving much better return loss, less crosstalk, less mode conversion, and lower insertion loss. 
     Since the TEM transmission line can be positioned close to contacts  924 , the non-TEM zone (unshielded length of traces  1360 ) of the signal path for signals conveyed by contacts  924  can be made short. This can provide several benefits. It can push the onset of a given level of near-end cross-talk (NEXT) and far-end cross-talk (FEXT) coupling to higher frequencies, moving significant coupling above the operating frequency (the data rate of the signals conveyed by contacts  924 .) For example, when the non-TEM zone is a first factor shorter, the coupling effects can be moved higher in frequency by approximately the same first factor. By reducing the unshielded length of traces  1360 , coupling can be moved above the data rate of the signals they convey. 
     There can be resonances formed in connectors by a conductor loop on a ground, power supply, or any net which has multiple contacts. These multi-contacts nets can form transmission line resonators due to the shorted loops created in that net. Shortening these loops such that they have a reduced electrical length can push the resonant frequency higher, above the connectors target operating frequency or data rate of signals on traces  1360 . Making these loops electrically shorter by a first factor increases the resonance frequencies by approximately the first factor. 
     The shorter contact region and the strip line structure of the flex circuit can further result in more of the common-mode current finding a path through the flex contacts  924  and traces  1360  as opposed to other structures, such as ground planes  1332  and  1333 . This can result in a reduction in common-mode current in the shield, which can reduce EMI proportional to the reduction of common-mode shield current reduction. The design enables a lower common-mode impedance discontinuity by the shorter non-TEM zone. It can also help to maintain symmetry of a ground, differential signal, and power supply pin group. Further, the conductor shape of power supply traces  1350  can be tailored to improve the coupling between the power supply on traces  1350  and ground planes  1332  and  1332 . 
     In these and other embodiments of the present invention, a shape of power supply traces  1350  can be adjusted in a flex assembly, where power supply coupling to ground and other power supply traces might not be easily executed in a traditional pin field. Coupling components, such as capacitors, can also be included to increase coupling. These features can enable common-mode continuity across the connector as the power supply becomes a more effective return path for residual common-mode currents related to the signals on contacts  924  and traces  1360 . 
     The body of the flex between spring fingers  910  (shown in  FIG.  12   ) and contacts  924  can further reduce cross-talk. For example, ground vias (not shown) can be stitched between signal pairs and from traces  1323  on a top layer  1314  of flexible circuit board  920  to ground. 
       FIG.  14    illustrates contacts on a surface of a flexible circuit board according to an embodiment of the present invention. In this example, contacts  924  can be formed on a surface of contacting portions  222  of flexible circuit board  920 . Contacts  924  can be plated, formed by vapor deposition, soldered, or formed in other ways on contacting portions  922  of flexible circuit board  920  (and flexible circuit board  220  and  930  in the other examples.) Contacts  924  can be connected through vias  1340  to traces  1360  in flexible circuit board  920 . The close position of via  1342  contacts  924  can reduce the length of a trace for which a signal on contact  924  is unshielded by ground planes  1332  and  1333  and traces  1350 , as shown in  FIG.  13   . Contacts  924  can be multi-structure contacts in that they are formed of a metal layer fixed to a metal trace  1322  on a contacting portion  922  of flexible circuit board  920 , which can be attached to spring finger  910 . 
     While embodiments of the present invention can be useful as USB Type-C connector inserts and connector receptacles, these and other embodiments of the present invention can be used as connector receptacles in other types of connector systems, such as a Peripheral Component Interconnect express (PCIe) connector system. 
     In various embodiments of the present invention, spring fingers, contacts, shields, and other conductive portions of a connector insert or connector receptacle can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. The conductive portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. The nonconductive portions, such as the housings, spring fingers, and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. The nonconductive portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. The printed circuit boards used can be formed of FR-4 or other material. The contacts can be plated, formed by vapor deposition, soldered, or formed in other ways on the flexible circuit boards. 
     Embodiments of the present invention can provide connector receptacles and connector inserts that can be located in, and can connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. These connector receptacles and connector inserts can provide interconnect pathways for signals that are compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, High-Definition Multimedia Interface® (HDMI), Peripheral Component Interconnect express, Digital Visual Interface (DVI), Ethernet, DisplayPort, Thunderbolt™, Lightning™, Joint Test Action Group (JTAG), test-access-port (TAP), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. Other embodiments of the present invention can provide connector receptacles and connector inserts that can be used to provide a reduced set of functions for one or more of these standards. In various embodiments of the present invention, these interconnect paths provided by these connector receptacles can be used to convey power, ground, signals, test points, and other voltage, current, data, or other information. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20210221
Publication Date: 20230613
Grant Date: 20230613
Priority Date: 20180924
Inventors: AMINI, MAHMOUD R.
PANSARE, NIKHIL S.
CORNELIUS, WILLIAM P.
BAEK, SEUNGYONG
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R12/79", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/113", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6581", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/113", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 69885134