Type III PCMCIA card with integrated receptacles for receiving standard communications plugs

• US 6,116,962 A
• Filed: 03/25/1998
• Issued: 09/12/2000
• Est. Priority Date: 11/17/1997
• Status: Expired due to Term

• Current Assignee: Intel Corporation
• Original Assignee: Xircom Incorporated (Intel Corporation)
• Inventors: Laity, Ian A.
• Primary Examiner(s): Bradley, Paula
• Assistant Examiner(s): TA, THO DAC
• Application Number:
  US09/048,143
• Time in Patent Office: 902 Days
• Field of Search: 439/676, 439/76.1, 439/946, 439/946.2, 439/638, 439/344, 361/737, 361/686, 361/785
• US Class Current: 439/676
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 24/64 for high frequency, e.g. RJ 45
• CPC Class Codes: H01R 27/00 Coupling parts adapted for co-operation with two or more dissimilar counterparts for dissimilar contact members H01R13/35; supported only by co-operation with a counterpart H01R31/00; with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/90
• CPC Class Codes: H01R 27/02 for simultaneous co-operation with two or more dissimilar counterparts
• CPC Class Codes: H01R 31/06 Intermediate parts for linking two coupling parts, e.g. adapter with a holder adapted for supporting apparatus to which its counterpart is attached H01R33/94
• CPC Class Codes: H05K 5/0273 having extensions for peripherals, e.g. LAN, antennas details of antennas H01Q1/2275
• CPC Class Codes: Y10S 439/946 Memory card cartridge

Abstract

A Type III PCMCIA communications card for insertion in a slot in a host computer comprises a housing including a top wall and longitudinal, parallel side walls depending from the top wall, the longitudinal side walls and top wall defining an internal cavity enclosed by a bottom cover panel. The housing further has a forward end, a rear margin and a rear end surface, the rear margin of the housing defining at least one substantially longitudinally oriented receptacle extending forwardly from the rear end surface and sized and configured to receive a standard RJ-type modular plug. A substrate, mounted within the cavity of the housing, supports electronic components for carrying out the communications function. The substrate has a rear margin carrying a contact block including a plurality of contact wires, each contact wire having a first portion connected to components on the substrate, and a second portion extending into the at least one receptacle, the second portion of the contact wire being shaped and positioned for engagement with a corresponding contact on the connector plug. A connector provided at the forward end of the housing is adapted to be received by a corresponding connector within the slot of the host computer. The card has an overall height not exceeding approximately 10.5 mm, the communications card being directly connectable to a digital information system such as a LAN or a telephone line system utilizing standard RJ-type connectors.

Claims

1. A device for use in a host system having a PCMCIA Type III standard slot, the device being adapted to connect the host system to an information transfer system, the device comprising:

a housing having longitudinal sides, a transverse front end and a rear portion, at least the rear portion of the housing having a thickness conforming substantially to the PCMCIA Type III standard;

a substrate enclosed within the housing, the substrate carrying circuit elements and including a rear margin within the rear portion of the housing;

a connector at the front end of the housing connected to circuit elements on the substrate and adapted to mate with a corresponding connector within the slot of the host system;

a contact block mounted on the rear margin of the substrate, the contact block having an overall height within the thickness confines of the rear portion of the housing, the contact block having a plurality of side-by-side contact wire sections, each section being adapted to carry a plurality of contact wires; and

a forwardly extending receptacle defined by the rear portion of the housing, the receptacle being sized and configured to receive an RJ-type standard connector plug having a plurality of contacts, the receptacle being in longitudinal alignment with one of the contact wire sections of the contact block, at least the one contact wire section carrying a plurality of contact wires, each of said contact wires having a first portion connected to circuit elements on the substrate and a second portion extending into the receptacle, the second portion of each contact wire being shaped and positioned for engagement with a corresponding contact on the connector plug, the contacts on the plug being adapted to engage the second portions of the contact wires in the receptacle when the plug is inserted in the receptacle, wherein the device is adapted to be directly connectable to the information transfer system utilizing the standard connector plug.

2. A device, as defined in claim 1, in which:

the second terminal portion of each contact wire forms an angled, spring biased contact for engagement by a corresponding contact on the modular plug.

3. A device, as defined in claim 1, in which:

the contact wire retaining surfaces define a plurality of spaced apart, parallel, vertical slots formed in the front and rear faces of the wall, the second terminal portion of each contact wire being bent so as to define a forwardly extending extremity received by a corresponding slot in the rear face of the wall.

4. A device, as defined in claim 1, in which:

the RJ-type modular plug has a resilient biasing clip including retention surfaces, the rear portion of the housing including opposed, parallel outer walls defining the at least one receptacle, one of the outer walls having surfaces defining a cutout through which the biasing clip is adapted to project when the plug is fully inserted, the surfaces of the cutout being configured to be engaged by the retention surfaces of the biasing clip.

5. A device, as defined in claim 1, in which:

the second portion of each contact wire includes an end; and

the at least one receptacle has a top wall having an interior surface, the interior surface including a plurality of longitudinally extending grooves, each groove receiving the end of one of the contact wires.

6. A device, as defined in claim 1, in which:

the contact block includes a plurality of longitudinally extending slots, each slot being in longitudinal alignment with a corresponding groove in the interior surface of the top wall of the at least one receptacle, the second portion of each contact wire being retained within one of the slots.

7. A device, as defined in claim 1, in which:

the contact block defines a recess overlying the rear margin of the substrate, at least part of the first portion of each contact wire being disposed within the confines of the recess.

8. A device, as defined in claim 1, in which:

the housing and the rear portion thereof are formed as a one-piece, unitary structure.

9. A device, as defined in claim 1, in which:

the rear portion of the housing includes a receptacle body defining the at least one receptacle, the receptacle body and the remainder of the housing comprising separately formed structures having joinder surfaces for bonding the receptacle body and the remainder of the housing.

10. A device, as defined in claims 1, in which:

the rear portion of the housing defines a cellular communications connector receptacle, the cellular communications connector receptacle including electrical contacts connected to circuit elements on the substrate.

11. A device, as defined in claim 1, in which the contact block comprises:

a base;

a transversely extending, vertical wall mounted on the base, the wall having a front face, a rear face and a bottom face, the wall further including the contact wire sections, at least the one contact wire section of the wall including surfaces for retaining the plurality of contact wires against lateral displacement and further including a recess in the bottom face; and

each contact wire of the plurality of contact wires including a portion engaging associated ones of the contact wire retaining surfaces, each said contact wire further including a first terminal portion extending into the recess and a second terminal portion extending from the rear face of the wall, the second terminal portion being adapted to be engaged by a corresponding contact on the connector plug.

12. A device, as defined in claim 11, in which:

the first terminal portion extends rearwardly within said recess; and

a portion of the rear face of the vertical wall of the contact block is shaped to facilitate access to each first terminal portion of the contact wire.

13. A device, as defined in claim 12, in which:

the shaped portion of the rear face of the vertical wall comprises a beveled surface.

14. A device, as defined in claim 1, in which:

the contact wire retaining surfaces define a plurality of spaced apart, parallel, vertical slots extending between the front and rear faces of the wall, each slot in the front wall communicating with the recess.

15. A device, as defined in claim 14, in which:

the wall includes a contact wire retention aperture extending between each slot and the recess.

16. A device, as defined in claim 1, in which:

the contact block comprises three contact wire sections.

17. A device, as defined in claim 16, in which:

the receptacle is sized and configured to receive an RJ-45 connector plug.

18. A device, as defined in claim 17, in which:

the rear portion of the housing defines a second forwardly extending receptacle in side-by-side relationship with the first mentioned receptacle, the second receptacle being sized and configured to receive an RJ-11 connector plug and disposed in longitudinal alignment with a second contact wire section of the contact block, the second contact wire section of the contact block carrying a plurality of contact wires each having a first portion connected to circuit elements on the substrate and a second portion extending into the second receptacle for engagement with a corresponding contact on the RJ-11 connector plug.

19. A device, as defined in claim 18, in which:

the rear portion of the housing defines a third forwardly extending receptacle in side-by-side relationship with the first and second receptacles, the third receptacle being sized and configured to receive a second RJ-11 connector plug and disposed in longitudinal alignment with the third contact wire section of the contact block, the third contact wire section carrying a plurality of contact wires each having a first portion connected to circuit elements on the substrate and a second portion extending into the third receptacle for engagement with a corresponding contact on the second RJ-11 connector plug.

20. A device, as defined in claim 19, in which:

the rear portion of the housing further defines a fourth forwardly extending receptacle in side-by-side relationship with the first, second and third receptacles, the fourth receptacle being adapted to receive a cellular communications connector, the fourth receptacle including electrical contacts connected to circuit elements on the substrate.

21. An enclosure for a device adapted to be received by a PCMCIA Type III standard slot in a host system, the enclosure comprising:

a molded plastic housing including a top wall and longitudinal, parallel side walls depending from the top wall, the longitudinal side walls and top wall defining an internal cavity for receiving a substrate carrying electronic components, the housing further having a forward end, a rear portion and a rear end surface, the rear portion defining at least one receptacle extending forwardly from the rear end surface, the at least one receptacle being sized and configured to closely receive a standard RJ-type modular plug, at least the rear portion of the housing conforming substantially to the PCMCIA Type III thickness standard; and

a bottom metal cover panel enclosing the cavity, the bottom cover panel including parallel, upwardly extending side flanges configured to nest within the side walls of the housing, the longitudinal side walls of the housing and the upwardly extending side flanges of the bottom cover panel being adapted to receive and retain the substrate between them.

22. An enclosure, as defined in claim 21, in which:

the housing comprises a one-piece, unitary molded plastic structure.

23. An enclosure, as defined in claim 21, in which:

the rear portion of the housing includes a receptacle body defining the at least one receptacle, and, wherein the receptacle body and the remainder of the housing comprise separate, molded plastic structures, the receptacle body and the remainder of the housing being bonded along joinder surfaces.

24. An enclosure, as defined in claim 21, in which:

the at least one receptacle is sized and configured to receive an RJ-45 type modular plug.

25. An enclosure, as defined in claim 21, in which:

the rear portion of the housing defines a plurality of side-by-side forwardly extending receptacles, each of said plurality of receptacles being sized and configured to receive an RJ-type modular plug.

26. An enclosure, as defined in claim 25, in which:

said plurality of receptacles includes two receptacles each of which is sized and configured to receive an RJ-11 type modular plug.

27. An enclosure, as defined in claim 26, in which:

said rear portion of the housing further defines a forwardly extending receptacle for receiving a cellular communications plug.

28. An enclosure, as defined in claim 26, in which:

said plurality of receptacles further includes a receptacle sized and configured to receive an RJ-45 type modular plug.

29. An enclosure, as defined in claim 28, in which:

said rear portion of the housing further defines a forwardly extending receptacle for receiving a cellular communications plug.

30. A contact block adapted to make electrical connection with at least one RJ-type modular plug, the contact block comprising:

a base;

a transversely extending, vertical wall mounted on the base, the wall having a front face, a rear face and a bottom face, the wall further including a plurality of contact wire sections, each of said contact wire sections including surfaces for retaining contact wires against lateral displacement and further including a recess in the bottom face; and

a plurality of shaped contact wires carried by at least one of the plurality of contact wire sections, each of the shaped contact wires including a portion engaging associated ones of the contact wire retaining surfaces, each said contact wire further including a first terminal portion extending into the recess and a second terminal portion extending from the rear face of the wall, the second terminal portion being adapted to be engaged by a corresponding contact on the at least one RJ-type modular plug, the contact block having an overall height less than the PCMCIA Type III standard thickness dimension.

31. A contact block, as defined in claim 30, in which:

the second terminal portion of each contact wire forms an angled, spring biased contact for engagement by a corresponding contact on the modular plug.

32. A contact block, as defined in claim 30, in which:

the contact wire retaining surfaces define a plurality of spaced apart, parallel, vertical slots formed in the front and rear faces of the wall, the second terminal portion of each contact wire being bent so as to define a forwardly extending extremity received by a corresponding slot in the rear face of the wall.

33. A device, as defined in claim 30, in which:

the first terminal portion extends rearwardly within said recess; and

a

portion of the rear face of the vertical wall of the contact block is shaped to facilitate access to each first terminal portion of the contact wire.

34. A device, as defined in claim 33, in which:

the shaped portion of the rear face of the vertical wall comprises a beveled surface.

35. A contact block, as defined in claim 30, in which:

the contact wire retaining surfaces define a plurality of spaced apart, parallel, vertical slots extending between the front and rear faces of the wall, each slot in the front wall communicating with the recess.

36. A contact block, as defined in claim 35, in which:

the wall includes a contact wire retention aperture extending between each slot and the recess.

37. A contact block for mounting on the substrate of a device adapted to be received by a PCMCIA Type III standard slot in a host system, the device including at least one receptacle configured to receive an RJ-type modular plug for connection to the contact block, the contact block comprising:

a base;

a wall mounted on the base, the wall having a substrate-engaging surface, a plurality of spaced apart, parallel slots, and a recess extending from the substrate-engaging surface, each slot communicating with the recess through a contact wire retention aperture; and

a plurality of contact wires carried by the contact block, each contact wire being carried by one of said retention apertures and having a first portion extending into the recess and adapted to be connected to the substrate, and a second portion extending from one of the slots in the wall of the contact block and adapted to be engaged by a corresponding contact on the modular plug, the contact block having an overall height less than the PCMCI Type III standard thickness dimension.

38. A device for use in a host system having a PCMCIA Type III standard slot, the device being adapted to connect the host system to an information transfer system, the device comprising:

a housing having longitudinal sides, a transverse front end and a rear portion, at least the rear portion of the housing having a thickness conforming substantially to the PCMCIA Type III standard;

a substrate enclosed within the housing, the substrate carrying circuit elements;

a connector at the front end of the housing connected to said circuit elements on the substrate and adapted to mate with a corresponding connector within the slot of the host system;

a transversely extending contact block disposed within the rear portion of the housing and having an overall height within the thickness confines of the rear portion of the housing, the contact block having a plurality of side-by-side contact wire sections, at least one of the contact wire sections carrying a plurality of contact wires, each of said contact wires having a first portion connected to circuit elements on the substrate; and

a forwardly extending receptacle defined by the rear portion of the housing, the receptacle being sized and configured to receive an RJ-type standard connector plug having a plurality of contacts, the receptacle being in longitudinal alignment with the at least one contact wire section of the contact block, each of the plurality of contact wires of the at least one contact wire section having a second portion extending into the receptacle, the second portion of each contact wire being shaped and positioned for engagement with a corresponding contact on the connector plug, the contacts on the plug being adapted to engage the second portions of the contact wires in the receptacle when the plug is inserted in the receptacle, wherein the device is adapted to be directly connectable to the information transfer system utilizing the standard connector plug.

39. A device, as defined in claims 38, in which:

the rear portion of the housing defines a cellular communications connector receptacle, the cellular communications connector receptacle including electrical contacts connected to circuit elements on the substrate.

40. A device as defined in claim 38, in which:

the contact block comprises a one-piece, unitary, molded plastic structure.

41. A device, as defined in claim 40, in which:

the contact block comprises three contact wire sections.

42. A device, as defined in claim 38, in which:

the receptacle is sized and configured to receive an RJ-45 connector plug.

43. A device, as defined in claim 42, in which:

the rear portion of the housing defines a second forwardly extending receptacle in side-by-side relationship with the first mentioned receptacle, the second receptacle being sized and configured to receive an RJ-11 connector plug and disposed in longitudinal alignment with a second contact wire section of the contact block, the second contact wire section of the contact block carrying a plurality of contact wires each having a first portion connected to circuit elements on the substrate and a second portion extending into the second receptacle for engagement with a corresponding contact on the RJ-11 connector plug.

44. A device, as defined in claim 43, in which:

the rear portion of the housing defines a third forwardly extending receptacle in side-by-side relationship with the first and second receptacles, the third receptacle being sized and configured to receive a second RJ-11 connector plug and disposed in longitudinal alignment with the third contact wire section of the contact block, the third contact wire section carrying a plurality of contact wires each having a first portion connected to circuit elements on the substrate and a second portion extending into the third receptacle for engagement with a corresponding contact on the second RJ-11 connector plug.

45. A device, as defined in claim 44, in which:

the rear portion of the housing further defines a fourth forwardly extending receptacle in side-by-side relationship with the first, second and third receptacles, the fourth receptacle being adapted to receive a cellular communications connector, the fourth receptacle including electrical contacts connected to circuit elements on the substrate.