Method of manufacturing high-speed connector inserts and cables

• US 8,327,536 B2
• Filed: 02/23/2011
• Issued: 12/11/2012
• Est. Priority Date: 06/30/2010
• Status: Expired due to Fees

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Kim, Min Chul, Yuan, Paul, Pong, Josh, Tang, Joseph
• Primary Examiner(s): Nguyen, Donghai D.
• Application Number:
  US13/033,562
• Publication Number:
  US 20120000703A1
• Time in Patent Office: 657 Days
• Field of Search: 29/33.F, 298/25, 298/57, 29860-864, 298/68, 174/84.R, 174/702.R, 439/98, 439/607.41, 439/607.47, 439/607.5, 439/701
• US Class Current: 29/861
• CPC Class Codes: H01R 12/53 connecting to cables except for flat or ribbon cables
• CPC Class Codes: H01R 13/6463 using twisted pairs of wires
• CPC Class Codes: H01R 13/6471 by special arrangement of ground and signal conductors, e.g. GSGS [Ground-Signal-Ground-Signal]
• CPC Class Codes: H01R 13/65915 Twisted pair of conductors surrounded by shield
• CPC Class Codes: H01R 13/6592 the conductive member being a shielded cable
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 2107/00 Four or more poles
• CPC Class Codes: H01R 4/02 Soldered or welded connections H01R4/625, H01R4/723, H01R12/59 take precedence
• CPC Class Codes: H01R 4/023 between cables or wires and terminals
• CPC Class Codes: H01R 43/0249 for simultaneous welding or soldering of a plurality of wires to contact elements
• CPC Class Codes: H01R 43/048 Crimping apparatus or processes H01R43/042 takes precedence
• CPC Class Codes: H02G 15/08 Cable junctions for gas or oil filled cables H02G15/24
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49179 by metal fusion bonding
• CPC Class Codes: Y10T 29/49181 by deforming
• CPC Class Codes: Y10T 29/49213 Metal

Abstract

High speed connector inserts and cables having improved heat conduction, high strength, and may be manufactured in a reliable manner. One example may provide a connector insert having several paths by which heat may be removed from circuitry in the cable insert. In one example, heat may be removed from one or more circuits by forming a thermal path between a circuit and a shield of the connector insert. Another path may include one or more pads on a side of an integrated circuit board that are soldered directly to the shield. A braiding surrounding a cable may be soldered or otherwise thermally connected to the shield. Another example may provide a cable having a braiding that includes one or more types of fibers, such as aramid fibers. Another example may provide for increased manufacturability by using a wire comb and a solder bar.

Claims

1. A method of manufacturing a cable assembly, the cable assembly comprising a connector insert and a cable, the method comprising:

separating a plurality of fibers in a shield layer of the cable from a plurality of metallic wires in the shield layer of the cable;

forming a solder connection between the plurality of metallic wires to a shield of the connector insert;

placing a cap over the solder connection; and

crimping the cap.

2. The method of claim 1 wherein the plurality of fibers are aramid fibers.

3. The method of claim 1 wherein the shield layer of the cable is a braided layer.

4. The method of claim 1 wherein the shield layer of the cable is formed of a plurality of counter-rotating spirals.

5. The method of claim 1 further comprising:

soldering the cap to the connector insert.

6. The method of claim 1 further comprising:

soldering a conductive pad on a printed circuit board to an inside wall of the connector insert.

7. The method of claim 6 wherein the conductive pad is on an edge of the printed circuit board.

8. The method of claim 6 further comprising:

thermally coupling an active device on the printed circuit board to the shield.