PATENT DOCUMENT

Publication Number: US-10050368-B2
Application Number: US-201815894321-A
Country: US
Kind Code: B2

Title: Low-profile spring-loaded contacts

Abstract:
Contact structures that are readily manufactured, where contacts in the contact structures provide a sufficient normal force while consuming a minimal amount of surface area, depth, and volume in an electronic device.

Claims:
What is claimed is: 
     
       1. A keyboard comprising:
 a device enclosure having an opening; 
 a board in the device enclosure; 
 a contact structure in the device enclosure and comprising:
 a housing having a top surface; and 
 a plurality of spring-biased contacts, each partially located in the housing and comprising a contacting portion depressible in a contacting direction, the contacting direction orthogonal to the board, and a tail portion, the tail portion attached to the board and electrically connected to traces on the board, the housing molded around a portion of at least one of the plurality of spring-biased contacts; and 
 
 a cover having a plurality of openings, where for each opening, a contacting portion of a corresponding contact extends through the opening, the cover formed separately from the housing and including an element extending from a bottom of the cover to align the cover to the top surface of the housing, 
 wherein the cover includes a raised portion arranged to fit in the opening of the device enclosure, the raised portion around the openings in the cover, and 
 wherein the plurality of spring-biased contacts are arranged in a line. 
 
     
     
       2. The keyboard of  claim 1  wherein the plurality of spring-biased contacts are coupled to interconnect in the keyboard. 
     
     
       3. The keyboard of  claim 2  wherein the tail portions of the plurality of spring-biased contacts emerge from a bottom of the housing and are coupled to interconnect in the keyboard. 
     
     
       4. The keyboard of  claim 3  wherein each of the plurality of spring-biased contacts are biased by a corresponding one of a plurality of springs. 
     
     
       5. The keyboard of  claim 3  wherein each of the plurality of spring-biased contacts comprises a flexible lever arm. 
     
     
       6. The keyboard of  claim 3  wherein each of the plurality of spring-biased contacts comprises the contacting portion attached to a first end of a flexible lever arm. 
     
     
       7. The keyboard of  claim 6  wherein a barb is formed on a second end of the flexible lever arm for one of the plurality of spring-biased contacts, the barb inserted into the housing. 
     
     
       8. A contact structure comprising:
 a housing having plurality of slots extending parallel with each other; 
 a plurality of contacts each comprising:
 a contact portion in a corresponding one of the plurality of slots, where a portion of the housing is molded around a portion of the contact portion; 
 a flexible arm at a first end of the contact portion; and 
 a contacting portion attached to the flexible arm, wherein the flexible arm angles up away from a bottom plate of the contact structure such that the contacting portion may be depressed towards the bottom plate of the contact structure; 
 
 the bottom plate under the housing and having a plurality of tabs; and 
 a top plate over the housing and comprising a plurality of openings, where for each opening, the contacting portion of a corresponding contact extends through the opening, the top plate further comprising a plurality of notches to accept the tabs on the bottom plate, such that the top plate, housing, and bottom plate are attached, 
 wherein the top plate comprises a raised portion, the raised portion around the openings in the top plate, where the contacting portions of the contacts protrude out of the raised portion. 
 
     
     
       9. The contact structure of  claim 8  wherein the housing further comprises a plurality of notches to accept the tabs on the bottom plate. 
     
     
       10. The contact structure of  claim 9  wherein the raised portion is arranged to fit in an opening of an electronic device. 
     
     
       11. A contact structure comprising:
 a housing having a top surface; 
 a plurality of spring-biased contacts, each partially located in the housing and comprising a contacting portion depressible in a contacting direction, the contacting direction orthogonal to a board, and a tail portion, the tail portion attached to the board and electrically connected to traces on the board, the housing molded around a portion of at least one of the plurality of spring-biased contacts; and 
 a cover having a plurality of openings, where for each opening, a contacting portion of a corresponding contact extends through the opening, the cover formed separately from the housing and, 
 wherein the cover includes a raised portion arranged to fit in an opening of a device enclosure, the raised portion around the openings in the cover, and 
 wherein the plurality of spring-biased contacts are arranged in a line. 
 
     
     
       12. The contact structure of  claim 11  wherein the cover includes an element extending from a bottom of the cover to align the cover to the top surface of the housing. 
     
     
       13. The contact structure of  claim 11  wherein each of the plurality of spring-biased contacts comprises a spring. 
     
     
       14. The contact structure of  claim 11  wherein the contacting portions of the plurality of spring-biased contacts protrude out of the raised portion. 
     
     
       15. The contact structure of  claim 11  wherein each of the plurality of spring-biased contacts comprises a contacting portion attached to a first end of a flexible lever arm. 
     
     
       16. The contact structure of  claim 15  wherein a barb is formed on a second end of the flexible lever arm for one of the plurality of spring-biased contacts, the barb inserted into the housing.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/138,224, filed Apr. 26, 2016, which is a nonprovisional of U.S. provisional patent application No. 62/215,592, filed Sep. 8, 2015, which are incorporated by reference. 
    
    
     BACKGROUND 
     The number of types of electronic devices that are commercially available has increased tremendously the past few years and the rate of introduction of new devices shows no signs of abating. Devices, such as tablet, laptop, netbook, desktop, and all-in-one computers, cell, smart, and media phones, storage devices, portable media players, navigation systems, monitors, and others, have become ubiquitous. 
     Power and data may be provided from one device to another over cables that may include one or more wire conductors, fiber optic cables, or other conductor. Connector inserts may be located at each end of these cables and may be inserted into connector receptacles in the communicating or power transferring devices. In other systems, contacts on the devices may come into direct contact with each other without the need for intervening cables. 
     In systems where contacts on two electronic devices come into direct contact with each other, it may be difficult to generate enough normal force to ensure a good electrical connection between contacts in the two devices. To provide a sufficient normal force, contacts may often have a substantial depth and consume a relatively large volume of space in the electronic device. The loss of this space may mean that the electronic device is either larger or only includes a reduced set of functionality. 
     These electronic devices may be manufactured in large numbers. A corresponding number of contact structures may be manufactured for use in these devices. Any simplification in the manufacturing process of these contact structures may yield tremendous savings in the manufacturing of these electronic devices. 
     Thus, what is needed are contact structures that are readily manufactured, where contacts in the contact structures provide a sufficient normal force while consuming a minimal amount of surface area, depth, and volume in an electronic device. 
     SUMMARY 
     Accordingly, embodiments of the present invention may provide contact structures that are readily manufactured, where contacts in the contact structures provide a sufficient normal force while consuming a minimal amount of surface area, depth, and volume in an electronic device. 
     An illustrative embodiment of the present invention may provide contact structures that may provide movable contacts at a surface of an electronic device. The contact structures may include a nonconductive housing supporting one, two, three, or more conductive contacts. Each contact may be located at an end of a flexible lever arm, where a remote end of the arm may be fixed to the housing. The contacts may have contacting portions that emerge from corresponding openings in the housing. 
     These contact structures may be manufactured in various ways. For example, the contacting portions may be attached to ends of the flexible lever arms by riveting, soldering, or the contacting portions and the flexible lever arms may be formed as a single piece. The contacting portions may be formed of the same or different materials. For example, the contacting portions may be formed of a material that provides a low resistance and low corrosion, while the flexible lever arms may be formed of a material chosen for its flexibility and its ability to withstand fatigue and cold-working. The contacting portion may have a narrowed tail extending from a wider body, where the narrowed tail may be inserted into an opening at an end of the flexible lever arm. The narrowed tail may extend through and beyond the flexible lever arm. Force may be applied to the narrowed tail causing it to expand outward, for example in a riveting process. The contacting portion may be held in place in the opening on the flexible lever arm on one side by the expanded narrowed tail and on the other side by the wider body. Each flexible lever arm may have a surface-mount contacting portion at an end remote from the contacting portion. Each flexible lever arm may further include a barb to be inserted into a notch or groove in the contact structure housing. In other embodiments of the present invention, one or more contacts, such as the center contact, may have the housing insert molded around it such that it does not require a barb. The contacts may be arranged in a line in the housing, though they may be arranged in other patterns. Contacts that are centrally located in the housing may be inserted into the housing from a bottom side and fixed in place by inserting their barbs into slots or grooves in the housing. Again, in other embodiments of the present invention these center contacts may have the housing insert molded around it. Support structures may be placed under the contacting portions of the central contacts to limit their travel such that they cannot be pushed all the way into the housing, though these may not be useful when the housing is insert molded around the center contact. Contacts located at the ends may be slid into the housing using slots in the housing. The side contacts may also be fixed in place by inserting their barbs into slots or grooves in the housing. Insulating tape may be used to electrically insulate the housing. A cover having openings for the contacting portions may be fit over the housing. The cover may have a raised portion around the openings for the contacts to fit in an opening of a device enclosure of the electronic device housing the contact structure. 
     Another illustrative embodiment of the present invention may provide contact structures that may provide movable contacts at a surface of an electronic device. The contact structures may include a nonconductive housing having slots for a number of conductive contacts. Each contact may include a contacting portion attached to a flexible lever arm. The flexible lever arm may attach to a contact length that may be located in a slot in the housing. A cover may fit over the housing. The cover may include a raised portion having a number of openings, each opening for a corresponding contacting portion of a contact. The openings may be located in raised portion. The raised portion may fit in an opening of a device enclosure of the electronic device housing the contact structure. The contact structure may further include a bottom plate. The bottom plate may include side tabs that fit in notches or slots in sides of the housing and cover to fix the cover and housing in place relative to the bottom plate. 
     Another illustrative embodiment of the present invention may provide contact structures that may provide movable contacts at a surface of an electronic device. This contact structure may include a nonconductive housing supporting one, two, three, or more conductive contacts. Each contact may be a spring-biased contact. The spring-biased contacts may have contacting portions that emerge from corresponding openings in the housing. 
     These contact structures may be manufactured in various ways. For example, the spring-biased contacts may be attached to a flexible circuit board. Terminal contacts on the spring-biased contacts may be soldered into opening in the flexible circuit board. A layer of double-sided adhesive may be used to fix the flexible circuit board to a bracket. Threaded inserts may be placed in one or more openings in the bracket, or the ends of the brackets may include threaded openings. For example, the threaded inserts may be press-fit into openings near ends of the bracket. A cap may be formed where the cap may include openings for contacting portions of the spring-biased contacts. The openings may be located on a raised portion that may be arranged to fit in an opening of a device enclosure of the electronic device housing the contact structure. The cap may include gaskets that form rings around the contacting portions of the spring-biased contacts between the contacting portions and inside edges of the openings in the raised portion of the cap. The cap may be formed as a double-shot injection molded part where the gaskets are the second injection-molded shot. The cap may be fixed to the flexible circuit board using a double-sided adhesive layer. A lid, which may be part of a device enclosure for the device housing the contact structure, may be fixed over the top of the contact structure by screws or other fasteners that may be fit into openings in the lid and inserted into the threaded inserts. The raised portion of the cap may fit into a central opening in the lid. A gasket may be placed around the raised portion of the cap and between the cap and the lid to prevent the ingress of liquid, moisture, debris, or other substances into the electronic device housing the contact structure. 
     The spring-biased contacts may be formed in various ways. For example, a housing have a central hole may be provided. A spring may be fit into the central hole. A contacting portion having a backside opening may be fit over the spring such that one end of the spring is in the central hole of the housing and the other end of the spring is in the backside opening of the contacting portion. A terminal structure may be fit over the contacting portion and top of the housing. A tab on the contacting portion may be under the terminal structure such that the contacting portion is held in place. Tabs on the terminal structure may fit in notches or slots in the housing to secure the terminal structure in place relative to the housing. The terminal structure may include through-hole portions that may be inserted and soldered in place in openings in the flexible circuit board. 
     Embodiments of the present invention may provide contact structures that may be located in 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, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These contact structures may provide pathways for signals and power 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), Directed Automated Random Testing (DART), universal asynchronous receiver/transmitters (UARTs), clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. In various embodiments of the present invention, the data signal may be unidirectional or bidirectional and the power supply may be unidirectional or bidirectional. 
     Various embodiments of the present invention may incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention may be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system according to an embodiment of the present invention; 
         FIG. 2  illustrates a contact structure in a device enclosure according to an embodiment of the present invention; 
         FIG. 3  illustrates a portion of an electronic device according to an embodiment of the present invention; 
         FIG. 4  illustrates a side view of a contact structure according to an embodiment of the present invention; 
         FIGS. 5-11  illustrate a method of assembling a contact structure according to an embodiment of the present invention; 
         FIG. 12  illustrates another contact structure in a device enclosure according to an embodiment of the present invention; 
         FIG. 13  illustrates a contact structure according to an embodiment of the present invention; 
         FIG. 14  illustrates a contact structure in a device enclosure according to an embodiment of the present invention; 
         FIG. 15  is an exploded view of a contact structure according to an embodiment of the present invention; 
         FIG. 16  illustrates a spring-biased contact according to an embodiment of the present invention; and 
         FIG. 17  is an exploded view of a spring-biased contact of  FIG. 16 . 
     
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       FIG. 1  illustrates an electronic system according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, host device  110  may be connected to accessory device  120  in order to share data, power, or both. Specifically, contacts  112  on host device  110  may be electrically connected to contacts  220  on accessory device  120 . Contacts  112  on host device  110  may be electrically connected to contacts  220  on accessory device  120  via cable  130 . In other embodiments of the present invention, contacts  112  on host device  110  may be directly and electrically connected to contacts  220  on accessory device  120 . 
     To facilitate a direction connection between contacts  112  on host device  110  and contacts  220  on accessory device  120 , contacts  220  may be part of a surface-mount contact structure. An example of a surface-mount contact structure that may include contacts  220  is shown in the following figures. 
       FIG. 2  illustrates a contact structure in a device enclosure according to an embodiment of the present invention. In this example, a raised portion  212  of a contact structure may be placed in an opening in device enclosure  230 . The raised portion  212  of the contact structure may include openings for a number of contacts  220 . 
     Contacts  220  may be low-profile contacts. Such contacts may allow a contact structure to provide contacts for a connector without consuming a large volume in the electronic device housed by enclosure  230 . In various embodiments the present invention, contacts  220  may be spring-biased contacts. For example, contacts  220  may be biased by a spring, flexible arm, or other flexible structure such that they may be pushed or depressed and may return to their original position once released. Spring-biased contacts may provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  220  and corresponding contacts of a second connector on a second device (not shown.) 
     Accordingly, embodiments of the present invention may provide contact structures having low-profile, spring-biased contacts. An example is shown in the following figure. 
       FIG. 3  illustrates a portion of an electronic device according to an embodiment of the present invention. This figure illustrates a contact structure  300  having a raised portion  212  on a cover  210  that is fit on a top side of housing  310 . Raised portion  212  may be arranged to fit an opening  232  in device enclosure  230 . Contact structure  300  and may support a number of contacts  220  each in openings in raised portion  212 . Contacts  220  may emerge from bottom of housing  300  and be connected to interconnect  320 . 
     In this example, contact structure  300  may include three contacts  220 . In other embodiments of the present invention, contact structure  300  may include one, two, or more than three contacts  220 . Also, while in this example each of the contacts  220  are located in a single raised portion  212 , in other embodiments of the present invention, more than one raised portion  212  may be employed, and one or more contact  220  may be located in portions of contact structure  300  other than the one or more raised portions  212 . Also, while the three contacts  220  are shown as being in a line, in other embodiments of the present invention, contacts  220  may be arranged in other patterns. 
       FIG. 4  illustrates a side view of a contact structure according to an embodiment of the present invention. Contact structure  300  may be located in an electronic device having housing  230 . As before, raised portion  212  of cover  210  of contact structure  300  may be located in an opening in device enclosure  230 . Housing  310  of contact structure  300  may support contacts having contacting portions  221 ,  222 , and  223 . These contacting portions  221 ,  222 , and  223  may be attached to ends of flexible lever arms  420 ,  424 , and  428 . Each flexible arm may terminate in a second end and may include a barb, which may be inserted into notches or grooves in housing  310 . Specifically, flexible lever arm  420  may include barb  421 , flexible lever arm  424  may include barb  425 , and flexible lever arm  428  may include barb  429 . In other embodiments of the present invention, the center contact may have housing  310  insert molded around it and barb  425  may not be needed. 
     During assembly, the central contact including contact portion  222  may be inserted through an opening in a bottom of housing  210 . Without more, contacting portion  222  could be pushed deep into housing  310 . In some instances, contacting structure  222  could be pushed below cover  210 . If contacting portion  222  were to be laterally offset at this time, contacting portion  222  may not emerge from its opening in cover  210 . Accordingly, a bottom stop portion  430  may be located under contacting portion  420 . Bottom stop portion  430  may limit a depth to which contacting portion  222  may be depressed, thereby preventing possible damage to contact structure  300 . In other embodiments of the present invention, the center contact may have housing  310  insert molded around it such that bottom stop portion  430  may not be needed. 
     Contacts structure  300  may be formed in various ways. An example is shown in the following figure. 
       FIGS. 5-11  illustrate a method of assembling a contact structure according to an embodiment of the present invention. In  FIG. 5 , contacts for a contact structure according to an embodiment of the present invention, such as contact structure  300 , may be formed. These contacts may include contacting portions  221 ,  222 , and  223 . Ends of contacting portions  221 ,  222 , and  223  may be attached to flexible lever arms  420 ,  424 , and  428 . Flexible lever arm  420  may terminate in a first barb  421  and include a surface-mount contact portion  520 . Flexible lever arm  424  may include barb  425  and may terminate in surface-mount contacting portion  521 . Flexible lever arm  428  may include barb  429  and may terminate in surface-mount contacting portion  522 . In other embodiments of the present invention, the center contact may have housing  310  insert molded around it and barb  425  may not be needed. 
     Contacting portions  221 ,  222 , and  223  may be riveted to flexible lever arms  420 ,  424 , and  428 . Specifically, contacting portion  221  may include a narrowed tail portion  228  below ledge  227 . Narrowed end portion  228  may be inserted into opening  236  in flexible lever arm  420 . Ledge  227  may rest on a top surface of flexible lever arm  420  around opening  226 . Narrowed end  228  may have a force applied such that it widens, for example, by riveting. In this way, contacting portion  221  may be secured to flexible arm  420  by ledge  427  and the widened portion of narrowed tail  228 . When contacting structure  300  is mounted on a board or other appropriate substrate, surface-mount contacting portions  520 ,  521 , and  522  may be soldered to contacts on the board thereby forming interconnect path from contacting portions  221 ,  222 , and  223  to interconnect traces on the board. 
     In  FIG. 6 , a central contact including contacting portion  221  may be inserted through an opening in a bottom of housing  210 . At least some of contacting portion  221  may emerge from a top surface of housing  310 . In other embodiments, housing  310  may be insert molded around the central contact. 
     In  FIG. 7 , central contact  221  has inserted through a bottom opening in housing  210 . Since central contact  221  is inserted through a bottom opening in housing  210 , central contacting portion  221  could inadvertently be pushed all the way to the bottom of housing  310 . To prevent this, embodiments of the present invention may attach a bottom stop portion  430  to a bottom of housing  310 . Bottom stop portion  430  may include a raised portion  710  below contacting portion  221 . This raised portion  710  may restrict the travel range of contacting portion  221 . This may prevent contacting portion  221  be pushed all the way into housing  310 , thereby damaging contacting structure  300 . In other embodiments of the present invention, the center contact may have housing  310  insert molded around it and bottom stop portion  430  may not be needed. 
     In  FIG. 8 , side contacts including contacting portions  221  and  223  may be inserted into housing  310  using slots  810  and  812 . Flexible lever arm  420  may be pushed into housing  310  until barb  421  is inserted into a groove or notch in housing  210 . Similarly, flexible lever arm  428  may be pushed into housing  310  until barb  428  is inserted into a groove or notch in housing  310 . 
     In  FIG. 9 , a piece of insulating tape  910  may be wrapped around a portion of the top, sides, and bottom of housing  310 . Insulating tape  910  may include openings  912  for surface-mount contacting portions  520 ,  521 , and  522  of the contacts in housing  310 . Insulating tape  910  may include top surface tabs  914 . Top surface tabs  914  may be sandwiched between top cover  210  and housing  310 , thereby helping to maintain insulating tape  910  in place. In various embodiments of the present invention, insulating tape  910  may be Mylar tape or other type of tape or insulating layer. 
     In  FIG. 10 , a cover  210  may be placed over housing  310 . Again, top surface tabs  914  of insulating tape  910  may be placed between top cover  310  and housing  310 , thereby holding insulating tape  910  in place. Top cover  210  may include a raised portion  212  having openings  213  for contacts  220 . 
       FIG. 11  illustrates a completed contact structure  300  according to an embodiment of the present invention. 
     In various embodiments of the present invention, different portions of contact structure  300  and other contact structures may be formed of various materials. For example, housing  310  and cover  210  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions  221 ,  222 , and  223 , may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Flexible lever arms  420 ,  444 , and  428  may be formed of spring metal, sheet-metal, copper alloy, or other complaint material. 
     In various embodiments of the present invention, different portions of contact structure  300  and other contact structures may be formed in various ways. For example, housing  310  and cover  210  may be formed using injection or other molding, printing, or other technique Contact portions  221 ,  222 , and  223  and flexible lever arms  420 ,  424 , and  428  may be machined, stamped, coined, forged, printed, or formed in different ways. Contact portions  221 ,  222 , and  223  may be attached to flexible lever arms  420 ,  424 , and  428  by riveting, soldering, spot-welding, or other technique, or they may be formed as a single unit. Housing  310  and cover  210  may be formed around contacts  220  using injection molding. 
       FIG. 12  illustrates another contact structure in a device enclosure according to an embodiment of the present invention. In this example, a raised portion  1210  of a contact structure may be fit in an opening in device enclosure  1200 . Raised portion  210  may include contacts  1220  each surrounded by an individual raised portion  1212 . 
     Contacts  1220  may be low-profile contacts. Such contacts may allow a contact structure to provide contacts for a connector without consuming a large volume in the electronic device housed by enclosure  1200 . In various embodiments the present invention, contacts  1220  may be spring-biased contacts. For example, contacts  1220  may be biased by a spring, flexible arm, or other flexible structure such that they may be pushed or depressed and may return to their original position once released. Spring-biased contacts may provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  1220  and corresponding contacts of a second connector on a second device (not shown.) 
     Accordingly, embodiments of the present invention may provide contact structures having low-profile, spring-biased contacts. An example is shown in the following figure. 
       FIG. 13  illustrates a contact structure according to an embodiment of the present invention. This contact structure may include housing  1320  having a number of slots for contact portions  1222 . Contact portions  1222  may connect to contacting portions  1220  via flexible arms  1224 . 
     This contact structure may further include a top plate or cover  1310  having a raised portion  1210 . Raised portion  1210  may include further raised portions  1212  around each opening  1213 . Each opening  1213  may allow a connection to be made to contacting portion  1220 . 
     This contact structure may further include a bottom plate  1330 . Bottom plate  1330  may include tabs  1350  to fit in notch  1352  in top plate or cover  1310  and notch  1354  in housing  1320  to secure top plate or cover  1310 , housing  1320 , and bottom plate  1330  together as a unit. 
     In various embodiments of the present invention, different portions of this contact structure and other contact structures may be formed of various materials. For example, housing  1320 , cover  1310 , and bottom plate  1330  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions  1220  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Flexible lever arms  1224  and contact portions  1222  may be formed of spring metal, sheet-metal, copper alloy, or other complaint material. 
     In various embodiments of the present invention, different portions of this contact structure and other contact structures may be formed in various ways. For example, housing  1320 , cover  1310 , and bottom plate  1330  may be formed using injection or other molding, printing, or other technique Contacting portions  1220 , flexible lever arms  1224 , and contact portions  1222  may be machined, stamped, coined, forged, printed, or formed in different ways. Contact portions  1220  may be attached to flexible lever arms  1224  by riveting, soldering, spot-welding, or other technique, or they may be formed as a single unit. Housing  1320 , cover  1310 , and bottom plate  1330  may be formed around contacts  1220  using injection molding. 
       FIG. 14  illustrates a contact structure in a device enclosure according to an embodiment of the present invention. In this example, a raised portion  1410  of a contact structure may be fit in an opening in a device enclosure. Raised portion  1410  may include contacts  1420 . This contact structure may include bracket  1430 . Bracket  1430  may be fixed to a lid, device enclosure, or other structure by inserting fasteners into threaded inserts  1432 . 
     Contacts  1420  may be low-profile contacts. Such contacts may allow a contact structure to provide contacts for a connector without consuming a great deal of volume in the electronic device housed by the enclosure. In various embodiments the present invention, contacts  1420  may be spring-biased contacts. For example, contacts  1420  may be biased by a spring, flexible arm, or other flexible structure such that they may be pushed or depressed and may return to their original position once released. Spring-biased contacts may provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  1420  and corresponding contacts of a second connector on a second device (not shown.) 
     This contact structure may be assembled in various ways. An example is shown in the following figure. 
       FIG. 15  is an exploded view of a contact structure according to an embodiment of the present invention. In this example, a flexible circuit board  1550  may include a number of openings for terminals of spring-biased contacts  1420 . Spring-biased contacts  1420  may be attached to flexible circuit board  1550  by inserting terminals of spring-biased contacts  1420  into the openings in flexible circuit board  1550  and soldering. A cap  1410  having openings for contacts  1420  may be placed over contacts  1420 . Cap  1410  may further include gaskets  1520  in openings in cap  1410 . An additional gasket  1530  may be placed or formed between contacts  1420  and inside edges of openings in cap  1410 . Gaskets  1520  and  1530  may be formed of silicone or other sealing material. Cap  1410  may be formed as a two shot injection molded process, where the main part of cap  1410  is formed in a first shot and gaskets  1520  are formed in a second shot. Cap  1410  may be attached to flexible circuit board  1550  using a double-sided adhesive layer  1540 . Adhesive layer  1540  may be a heat activated film or adhesive layer. Bracket  1430  may be attached using a second adhesive layer  1560  to a bottom of flexible circuit board  1550 . Adhesive layer  1560  may also be a heat activated film or adhesive layer. Lid  1510  may be placed over cap  1410 . Lid  1510  may be a portion of a device enclosure for a device housing this contact structure. The enclosure may be conducive or nonconductive. Gasket  1530  may be placed around a raised surface of cap  1410  and be located between cap  1410  and lid  1510 . Threaded inserts  1432  may be press-fit into openings at ends of bracket  1430 . Fasteners, such as screws  1512 , may be inserted into openings at ends of lid  1510  and screwed into threaded inserts  1432  in bracket  1430 . In other embodiments of the present invention, the threaded inserts may be replaced by threaded opening in bracket  1430 . 
     In this example, the contact structure may include three contacts  1420 . In other embodiments of the present invention, the contact structure may include one, two, or more than three contacts  1420 . Also, while in this example each of the contacts  1420  are located in a single raised portion, in other embodiments of the present invention, more than one raised portion may be employed, and one or more contact  1420  may be located in portions of the contact structure other than the one or more raised portions. Also, while the three contacts  1420  are shown as being in a line, in other embodiments of the present invention, contacts  1420  may be arranged in other patterns. 
     Various spring-biased contacts  1420  may be used in contacting structures according to embodiments of the present invention. An example is shown in the following figures. 
       FIG. 16  illustrates a spring-biased contact according to an embodiment of the present invention. This spring-biased contact may include a contacting portion  1420  supported by housing  1610 . Terminal structure  1620  may include legs that may be inserted into openings in a flexible circuit board, printed circuit board, or other appropriate substrate. 
       FIG. 17  is an exploded view of a spring-biased contact of  FIG. 16 . In this example, housing  1610  may include a central opening  1612 . A first end of spring  1710  may be inserted into central opening  1612 . Housing  1610  may further include notches  1616  and  1618 , as well as corner notches  1614 . 
     A contacting portion  1420  may have a backside cavity (not shown.) A second end of spring  1710  may be inserted into the backside cavity of contacting portion  1420 . 
     Terminal structure  1620  may be fit over contacting portion  1420  such that contacting portion  1420  passes through central opening  1622  of terminal structure  1620 . Terminal structure  1620  may include legs which may fit in corner notches  1614 . Tabs  1628  and  1626  may fit in notches  1618  and  1616  in housing  1610  to secure terminal structure  1620  in place relative to housing  1610 . Contacting portion  1420  may include tabs  1422 , which may fit under terminal structure  1620  near portion  1624  to hold contacting portion  1420  in place. Tabs  1628  may include raised portions  1629 , which may fit in the back side cavity of contacting portion  1420 . Tabs  1629  may help to ensure that electrical contact remains between contacting portion  1420  and terminal  1620  as the contacting portion  1420  is depressed towards housing  1610 . 
     In various embodiments of the present invention, different portions of this contact structure and other contact structures may be formed of various materials. For example, cap  1410  and gaskets  1520  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions of spring-biased contacts  1420  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Bracket  1430  may be formed of sheet metal or other material. 
     In various embodiments of the present invention, different portions of this contact structure and other contact structures may be formed in various ways. For example, cap  1410  and gaskets  1520  may be formed using injection or other molding, printing, or other technique. Contact portions and other conductive portions of contacts  1420  may be machined, stamped, coined, forged, printed, or formed in different ways. 
     Embodiments of the present invention may provide contact structures that may be located in 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, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These devices may include contact structures that may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, HDMI, DVI, Ethernet, DisplayPort, Thunderbolt, Lightning, JTAG, TAP, DART, UARTs, clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. In various embodiments of the present invention, the data signal may be unidirectional or bidirectional and the power supply may be unidirectional or bidirectional. 
     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: 20180212
Publication Date: 20180814
Grant Date: 20180814
Priority Date: 20150908
Inventors: WAGMAN, Daniel C.
JOL, ERIC S.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R43/205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/2442", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/2407", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2492", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2478", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/2478", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2478", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/24", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2471", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/41", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/51", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/428", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2421", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R43/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2478", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/16", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/41", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/428", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/2421", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2471", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/506", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 56855295