PATENT DOCUMENT

Publication Number: US-7544066-B1
Application Number: US-13501308-A
Country: US
Kind Code: B1

Title: Electrical connector with flexible interconnect

Abstract:
An electrical connector that utilizes a flexible substrate for providing electrical contact surfaces within the electrical connector is disclosed. Advantageously, the electrical contact surfaces can be precisely formed on the flexible substrate such that manual assembly of individual contacts (e.g., pins) for a connector can be avoided. In one embodiment, the flexible substrate also facilitates connection of the electrical connector to other electrical components, such as other substrates, integrated circuits, etc., without having to solder leads or pins of a connector to a printed circuit board. In one implementation, the flexible substrate can be integrally formed with a system substrate.

Claims:
1. An electrical connector, comprising:
 a metal shield forming an interior cavity of said electrical connector; 
 a molded internal structure that is electrically insulative, said molded internal structure including a contact support protrusion and an opening, the contact support protrusion extending laterally from the opening into the interior cavity of said electrical connector; and 
 a flexible electrical substrate having a plurality electrical contacts formed thereon, said flexible electrical substrate being secured to the contact support protrusion, 
 wherein the electrical contacts of said flexible electrical substrate form electrical contacts for said electrical connector. 
 
   
   
     2. An electrical connector as recited in  claim 1 , wherein the said electrical connector includes at least thirty electrical contacts all supported by the electrical contacts of said flexible electrical substrate. 
   
   
     3. An electrical connector as recited in  claim 1 , wherein said flexible electrical substrate comprises a film. 
   
   
     4. An electrical connector as recited in  claim 1 , wherein said flexible electrical substrate comprises a plurality of thin layers, at least one layer including metal and at least another later including polyimide. 
   
   
     5. An electrical connector, comprising:
 a metal shield forming an interior cavity of said electrical connector; 
 a molded internal structure that is electrically insulative, said molded internal structure including a contact support protrusion; and 
 an opening in said internal structure to receive a flexible electrical substrate having a plurality electrical contacts formed thereon, whereby the electrical contacts of said flexible electrical substrate form electrical contacts for said electrical connector, 
 wherein the contact support protrusion extends laterally from the opening into the interior cavity of said electrical connector. 
 
   
   
     6. An electrical connector as recited in  claim 5 , wherein said flexible electrical substrate comprises a film. 
   
   
     7. An electrical system assembly, comprising:
 a substrate for electrical interconnections, said substrate having a system portion and a flexible connector portion; 
 a connector housing having a grounding shield; and 
 a molded internal structure housed within said connector housing including a contact support protrusion and an opening, wherein the contact support protrusion extends laterally from the opening into an interior cavity of said connector housing, 
 wherein the flexible connector portion of said substrate is provided internal to said connector housing so as to provide electrical conductors within said connector housing. 
 
   
   
     8. An electrical system assembly as recited in  claim 7 , wherein a complementary connector can electrically couple with the electrical conductors within said connector. 
   
   
     9. An electrical system assembly as recited in  claim 7 , wherein said connector housing further including an insulator, the flexible connector portion of said substrate is provided on a surface of the insulator. 
   
   
     10. An electrical system assembly as recited in  claim 9 , wherein the flexible connector portion of said substrate is attached to the surface of the insulator. 
   
   
     11. An electrical system assembly as recited in  claim 10 , wherein the flexible connector portion of said substrate has a plurality of metal traces disposed thereon. 
   
   
     12. An electrical system assembly as recited in  claim 7 , wherein the system portion of said substrate is less flexible than the flexible connector portion. 
   
   
     13. An electrical system assembly as recited in  claim 7 , wherein the electrical conductors of the flexible connector portion are provided internal to said connector housing and electrically coupled to the system portion without use of solder or additional metal components. 
   
   
     14. An electrical system assembly as recited in  claim 7 , wherein the system portion of said substrate includes bonding regions for receiving electronic components. 
   
   
     15. A consumer electronic product, comprising:
 a substrate for electrical components; 
 a housing for said consumer electronic product, said housing encloses said substrate and at least a portion of at least one electrical connector; 
 a flexible interconnect configured to electrically connect the at least one electrical connector to said substrate; and 
 a molded internal structure housed within the at least one electrical connector including a contact support protrusion and an opening, the contact support protrusion and opening configured to receive one end of said flexible interconnect, 
 wherein the contact support protrusion extends laterally from the opening into an interior cavity of the at least one electrical connector, and 
 wherein the at least one electrical connector is secured to said housing yet remains exposed and accessible from outside of said housing. 
 
   
   
     16. A consumer electronic product as recited in  claim 15 , wherein the at least one electrical connector is mechanically supported by said housing, and wherein the at least one electrical connector is not mechanically supported by said substrate. 
   
   
     17. A consumer electronic product as recited in  claim 15 , wherein the flexible interconnect is a contiguous extension of said substrate. 
   
   
     18. A consumer electronic product as recited in  claim 17 , wherein the flexible interconnect comprises a plurality of thin layers, at least one layer including metal and at least another later including polyimide. 
   
   
     19. A consumer electronic product as recited in  claim 15 , wherein the flexible interconnect comprises a plurality of thin layers, at least one layer including metal and at least another later including polyimide. 
   
   
     20. A method for assembling a connector, said method comprising:
 providing an internal molded structure that is electrically insulative, the internal structure including a contact support protrusion and an opening, 
 molding the contact support protrusion to extend laterally from the opening into an interior cavity of the connector; 
 placing an end of a flexible electrical substrate proximate to the contact support protrusion of the internal structure, the end of the flexible electrical substrate having a plurality of exposed electrical contacts; and 
 securing the end of the flexible electrical substrate to the internal structure. 
 
   
   
     21. A method as recited in  claim 20 , wherein said method further comprises:
 providing an outer structure that is electrically conductive, 
 wherein the outer structure is provided or placed around the inner structure. 
 
   
   
     22. A method as recited in  claim 20 , wherein said providing of the internal structure comprises injection molding.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims priority to U.S. Provisional Patent Application No. 61/035,320, filed Mar. 10, 2008, entitled “ELECTRICAL CONNECTOR WITH FLEXIBLE INTERCONNECT”, which is herein incorporated herein by reference. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The invention relates to connectors for electronic devices. 
   2. Description of the Related Art 
   Today, consumer electronic devices, such as personal computers, personal digital assistants, mobile telephones, and portable media players, often utilize one or more electrical connectors. These electrical connectors facilitate electrical connection with other devices, such as host computers, accessory devices, data networks, etc. 
   Since many consumer electronic device are portable and small, there is a desire to make the electrical connectors small. Unfortunately, in many cases, these electrical connectors are required to support a substantial number electrical contacts (e.g., 30 pins) within a constrained space. Moreover, conventional techniques for assembly of electrical connectors, particularly those having a substantial number of electrical contacts, is tedious, error prone and time consuming. Assembly of a system having such an electrical connector is also problematic because the electrical connector is manually attached (e.g., soldered) to the system&#39;s circuit board during assembly, which can require each of the substantial number of electrical contacts be individually soldered to the system&#39;s circuit board. 
   Thus, there is a need for improved approaches to assembling connectors and/or systems using connectors. 
   SUMMARY OF THE INVENTION 
   The invention pertains to an electrical connector that utilizes a flexible substrate for providing electrical contact surfaces within the electrical connector. Advantageously, the electrical contact surfaces can be precisely formed on the flexible substrate such that manual assembly of individual contacts (e.g., pins) for a connector can be avoided. In one embodiment, the flexible substrate also facilitates connection of the electrical connector to other electrical components, such as other substrates, integrated circuits, etc., without having to solder leads or pins of a connector to a printed circuit board. In one implementation, the flexible substrate can be integrally formed with a system substrate. 
   The invention may be implemented in numerous ways, including, but not limited to, as a method, system, device, or apparatus. Some exemplary embodiments of the invention are discussed below. 
   As an electrical connector, one embodiment of the invention can, for example, include at least: a metal shield, a molded internal structure that is electrically insulative and that includes a contact support protrusion, and a flexible electrical substrate having a plurality electrical contacts formed thereon. The flexible electrical substrate can be secured to the contact support protrusion, and the electrical contacts of the flexible electrical substrate can form electrical contacts for the electrical connector. 
   As an electrical connector, another embodiment of the invention can, for example, include at least: a metal shield, an internal structure that is electrically insulative and that includes a contact support protrusion, and an opening in the internal structure to receive a flexible electrical substrate having a plurality electrical contacts formed thereon, whereby the electrical contacts of the flexible electrical substrate form electrical contacts for the electrical connector. 
   As an electrical system assembly, one embodiment of the invention can, for example, include at least: a substrate for electrical interconnections, the substrate having a system portion and a flexible connector portion; and a connector housing having a grounding shield. The flexible connector portion of the substrate can be provided internal to the connector housing so as to provide electrical conductors within the connector housing. 
   As a consumer electronic product, one embodiment of the invention can, for example, include at least: a substrate for electrical components; and a housing for the consumer electronic product. The housing for the consumer electronic product can enclose the substrate and at least a portion of at least one electrical connector. The at least one electrical connector can be secured to the housing yet remain exposed and accessible from outside of the housing. 
   As a method for assembling a connector, one embodiment of the invention can, for example, include at least the acts of: providing an internal structure that is electrically insulative, the internal structure including a contact support protrusion; placing an end of a flexible electrical substrate proximate to the contact support protrusion of the internal structure, the end of the flexible electrical substrate having a plurality of exposed electrical contacts; and securing the end of the flexible electrical substrate to the internal structure. 
   Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
       FIG. 1  is a cross-sectional view of an electrical connector according to one embodiment of the invention. 
       FIG. 2  is perspective view of an electrical connector assembly according to one embodiment of the invention. 
       FIGS. 3A-3C  are views of an electrical connector according to one embodiment of the invention. 
       FIG. 4  is a flow diagram of a connector assembly process according to one embodiment of the invention. 
       FIG. 5  is a cross-sectional view of an exemplary consumer electronic device according to one embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The invention pertains to an electrical connector that utilizes a flexible substrate for providing electrical contact surfaces within the electrical connector. Advantageously, the electrical contact surfaces can be precisely formed on the flexible substrate such that manual assembly of individual contacts (e.g., pins) for a connector can be avoided. In one embodiment, the flexible substrate also facilitates connection of the electrical connector to other electrical components, such as other substrates (e.g., printed circuit board, flex circuit, rigid-flex circuit), integrated circuits, etc., without having to solder leads or pins of a connector to a printed circuit board. In one implementation, the flexible substrate can be integrally formed with a system substrate (e.g., flex circuit, rigid-flex circuit). 
   Exemplary embodiments of the invention are discussed below with reference to the various figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes, as the invention extends beyond these embodiments. 
     FIG. 1  is a cross-sectional view of an electrical connector  100  according to one embodiment of the invention. The electrical connector  100  includes an outer housing  116  and an inner structure  102  that serves as an inner housing for the electrical connector  100 . The inner structure  102  includes a contact support protrusion  104 . The contact support protrusion  104  serves to provide a support structure for electrical contacts that are used by the electrical connector  100 . The electrical connector  100  has at least one opening  106  in the inner structure  102  to receive a contact end  108  of a flexible substrate  110 . For example, the flexible substrate  110  can be a flexible printed circuit product, such as a flexible product (e.g., flex circuit or flexible printed circuit). The contact end  108  has a plurality of exposed contacts  112  on an upper surface. The contact end  108  can also be secured to the inner structure, such as the contact support protrusion  104  by any of a variety of different means, including adhesive, heat-steaks, rails/guides, recesses, or other mechanical means. 
   The electrical connector  100  provides an opening  114  for receiving a counterpart connector. When a counterpart connector connects with the electrical connector  100  via the opening  114 , corresponding metal components within the counterpart connector make electrical connections with the corresponding exposed contacts  112 , thereby making an electrical connection. 
   The use of the flexible substrate  110  to provide the exposed contacts  112  makes construction and assembly of the electrical connector  100  substantially less difficult than conventional approaches. Given that electrical connectors often support a plurality of contacts (e.g., pins), the ability to provide the contact surface in a single fabricated flexible substrate is a distinct improvement over the tedious manual process of assembling electrical contacts. 
     FIG. 2  is perspective view of an electrical system assembly  200  according to one embodiment of the invention. The electrical system assembly  200  couples a substrate for electrical circuitry to a connector using a flexible portion of the substrate. The electrical system assembly  200  can also be referred to as an electrical connector assembly. 
   As illustrated in  FIG. 2 , the electrical system assembly  200  can include a system substrate  202  that includes electrical interconnections and bonding regions. Electrical components  204 , such as integrated circuit chips, can be bonded (e.g., soldered) to the bonding regions of the system substrate  202 . The system substrate  202  with the electrical components  202  can provide a system function for a consumer electronic device (see, e.g.,  FIG. 5 ). In order to support input/output operations, the system substrate  202  can include a flexible portion  206 . In one embodiment, the flexible portion  206  is integral with the system substrate  202 . The flexible portion  206  can include a plurality of interconnection traces that are provided to a connector  208 . The connector  208  provides a physical input/output interface for the consumer electronic device. In one embodiment, an end of the flexible portion  206  can have exposed traces that are provided within the connector  208  and serve as electrical contact points or pins for the connector  208 . The electrical connector  100  illustrated in  FIG. 1  illustrates one implementation of such an embodiment. As an example, the flexible portion  206  can be a flexible printed circuit product. 
     FIGS. 3A-3C  are views of an electrical connector  300  according to one embodiment of the invention.  FIG. 3A  is a front view of the electrical connector  300 ,  FIG. 3B  is a rear view of the electrical connector  300 , and  FIG. 3C  is a side view of the electrical connector  300 . 
   As shown in  FIG. 3A , the electrical connector  300  can have an outer housing  302 . In one implementation, the outer housing  302  can formed of an electrically conductive material, such as a metal. The electrical connector  300  can also have an inner housing  304 . In one implementation, the inner housing  304  can be formed of an electrically insulative material, such as plastic or resin. The inner housing  304  can form an extended central portion  306  and a cavity  307  within the electrical connector  300 . A polyimide film  308  having exposed electrical contacts can be provided on the extended central portion  306 . The polyimide film  308  can be used to electrically connect the electrical connector  300  to an external electronic component, such a flexible (system) circuit, semi-flexible (e.g., rigid-flex) circuit, printed circuit board, integrated circuit, etc. The rear view of the electrical connector  300 , as shown in  FIG. 3B , illustrates an opening  310  in the inner housing  304  that enables the polyimide film  308  to be supplied to the cavity  307  and provided on the extended central portion  306 . However, it should be noted that, for ease of illustration,  FIG. 3B  does not depict the polyimide film  308 . However,  FIGS. 3A and 3C  illustrate the polyimide film  308  provided on the extended central portion  306 . More generally, the polyimide file  308  can be considered a flexible printed circuit product. 
   The cavity  307  allows a counterpart connector  312  to be inserted. When the counterpart connector  312  is inserted into the cavity  307  of the electrical connector  300 , counterpart electrical contacts of the counterpart connector  312  can physically and electrically contact the exposed electrical contacts of the polyimide film  308 . For example, the counterpart electrical contacts of the counterpart connector  312  can press against the exposed electrical contacts of the polyimide film  308  with a small bias force to ensure a stable and reliable electrical connection. In one embodiment, the polyimide film  308  can be Kapton® which is available from E. I. du Pont de Nemours and Company (DuPont). 
     FIG. 4  is a flow diagram of a connector assembly process  400  according to one embodiment of the invention. The connector assembly process  400  can be used to form an electrical connector, such as the electrical connector  100  illustrated in  FIG. 1 . 
   The connector assembly process  400  can begin by providing  402  an internal structure that is electrically insulative. The internal structure can be molded, such as injection molded, or otherwise formed. In one embodiment, the internal structure is formed to include a contact support protrusion (or extended central portion). Next, an end of a flexible substrate having exposed contacts can be placed on the contact support protrusion of the internal structure. The end of the flexible substrate can then be secured  406  to the internal structure. 
   In some embodiments, the electrical connector also has an outer structure. Typically, the outer structure is a conductive outer casing for the electrical connector. The conductive outer casing can, for example, surround the inner housing along one axis. The conductive outer casing can provide Electro-Static Discharge (ESD) protection to the electrical connector. In one implementation, the conductive outer casing is metal. Hence, in such embodiments, the connector assembly process  400  can further operate to provide the outer structure for the electrical connector. For example, the outer structure can be provided already attached with the internal structure at the block  402 . In an alternative example, the outer structure can be provided and attached to the internal structure after any of the blocks  402 ,  404  or  406  of  FIG. 4 . 
   In some embodiments, an electrical connector can be integral with or secured to a housing of a consumer electronic product. By integrating or securing the electrical connector with or to a housing, the electrical connector can be firmly coupled to the housing such that external forces applied to the connector are transferred to the housing and not to other internal components, such as a solder connections. Since the housing has greater mass and structural integrity, external forces applied to the connector can thus be better absorbed by the housing. 
     FIG. 5  is a cross-sectional view of an exemplary consumer electronic device  500  according to one embodiment of the invention. The consumer electronic device  500  has a housing  502 . An electrical connector  504  is provided at an opening  506  in the housing  502 . The electrical connector  504  is also secured to the housing  502 . The housing  502  serves to encompass electrical components of the consumer electronic device  500 . The electrical components can be different for different electronic devices. For example, the consumer electronic device  500  can pertain to a personal computer, a personal digital assistant, a portable media player, a mobile telephone, etc. As shown in  FIG. 5 , the electrical components can include a system board  508  that includes various components  510 - 516  mounted thereon. A flexible extension  518  of the system board  508  is also provided within the housing  502  and serves to electrically connect the system board  508  to the connector  504 . In particular, as noted above, the flexible extension  518  (e.g., flexible substrate) can provide (i) electrical connection from the connector  504  and the system board  508 , and (ii) conductive traces at the connector  504  that service to permit electrical interconnection with a counterpart connector (when the connectors are connected). Further, since the electrical connector  504  is secured to the housing  502 , mechanical forces induced on the electrical connector  504  can be imposed on and absorbed by the housing  502 , thereby isolating the system board  508  from such forces where they would be problematic. 
   In one embodiment, the flexible extension  518  is flexible printed circuit product, such as a flex circuit. In one implementation, these flexible printed circuit products utilize a polyimide film, such as Kapton®. The system board  508  can be a flexible substrate (e.g., flex circuit) or a semi-rigid substrate (e.g., rigid-flex circuit). 
   The invention can be utilized in a variety of different devices (e.g., electronic devices) including, but not limited to including, portable and highly compact electronic devices (i.e., portable electronic devices) with limited dimensions and space. In one embodiment, a device may be a laptop computer, a tablet computer, a media player, a mobile phone (e.g., cellular phone), a personal digital assistant (PDA), substantially any handheld electronic device, a computer mouse, a keyboard, a remote control, substantially any computer accessory, and/or substantially any computer peripheral. Typically, the electronic devices include at least one electrical component inside its housing. The electrical component can, for example, be an integrated circuit or circuit board. Examples of integrated circuits include memory, processor (microprocessor or controller), ASIC, and various others. 
   The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
   The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20080606
Publication Date: 20090609
Grant Date: 20090609
Priority Date: 20080310
Inventors: LYNCH STEPHEN BRIAN
SLOEY JASON
FRAZIER CAMERON
SCHMIDT MATHIAS
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R12/592", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R12/721", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/721", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40688643