Magnetic connector having a unitary housing

• US 8,535,088 B2
• Filed: 10/20/2009
• Issued: 09/17/2013
• Est. Priority Date: 10/20/2009
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Gao, Zheng, DiFonzo, John C., Banko, Joshua, Kim, Min Chul
• Primary Examiner(s): NGUYEN, TRUC T
• Application Number:
  US12/582,308
• Publication Number:
  US 20110092081A1
• Time in Patent Office: 1,428 Days
• Field of Search: 439/638
• US Class Current: 439/490
• CPC Class Codes: B32B 2250/02 2 layers
• CPC Class Codes: B32B 2250/24 All layers being polymeric
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2457/00 Electrical equipment
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/365 comprising polycarbonates
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: H01B 7/29 Protection against damage caused by extremes of temperature or by flame heat dissipation or conduction H01B7/42
• CPC Class Codes: H01R 13/24 resilient; resiliently-mounted
• CPC Class Codes: H01R 13/5816 for cables passing through an aperture in a housing wall, the separate part being captured between cable and contour of aperture
• CPC Class Codes: H01R 13/5845 the strain relief being achieved by molding parts around cable and connections
• CPC Class Codes: H01R 13/6205 Two-part coupling devices held in engagement by a magnet
• CPC Class Codes: H01R 13/7175 Light emitting diodes (LEDs)
• CPC Class Codes: H01R 2201/06 for computer periphery
• CPC Class Codes: H01R 9/03 Connectors arranged to contact a plurality of the conductors of a multiconductor cable , e.g. tapping connections

Abstract

Power cables that include plug housings having an improved appearance as well as employ a halogen-free cable while providing adequate fire resistance. One example provides a power cable having cable plug with a substantially unitary body. Another example provides a power cable that is formed using halogen-free materials. To provide adequate fire protection, a strain relief formed using multiple materials is used.

Claims

1. A cable plug comprising:

a strain relief that allows passage of a cable;

an assembly comprising a nonconductive insulative housing and power and ground conductors, the assembly further comprising passages, the passages connected to the conductors;

a plurality of contact pins located in passages in the assembly and having a contact portion extending beyond the assembly such that contact may be made with opposing contacts in a compatible connector receptacle;

a circuit board fixed to the assembly and contact pins;

a light-emitting diode fixed to the circuit board;

a magnetic attraction plate positioned around the contact portion of the contact pins; and

a cylindrical unitary housing made from a single piece of material and having a first opening for the cable and a second opening for the attraction plate, the attraction plate and cylindrical unitary housing enclosing the assembly, the plurality of contacts, the circuit board, and the light-emitting diode,

wherein the magnet attraction plate and the contact portion protrude through a second opening in the unitary housing.

2. The cable plug of claim 1 wherein the assembly further comprises a metal tab formed from an end of the ground conductor.

3. The cable plug of claim 1 wherein the contact pins comprise spring-biased pins.

4. The cable plug of claim 1 wherein the contact pins comprise a center pin, two ground contact pins, and two power supply contact pins.

5. The cable plug of claim 1 further comprising a dust cover over the attraction plate.

6. The cable plug of claim 1 further comprising exit holes in the housing, wherein the exit holes are filled with an adhesive.

7. The cable plug of claim 4 wherein the power supply contact pins are on each side of the center pin, and the ground contact pins are on each side of the power supply pins away from the center pin.

8. The cable plug of claim 5 further comprising a front plate between the assembly and a front portion of the cable plug.

9. A cable plug comprising:

a unitary housing made from a single piece of material and having a cylindrical shape and having a first opening at an end to accept a cable;

an assembly housed in the unitary housing and comprising a nonconductive housing and power and ground conductors, the power and ground conductors coupled to the cable;

a circuit board coupled to the assembly;

a plurality of contacts coupled to the circuit board;

a magnetic attraction plate positioned around the plurality of contacts, the attraction plate and the plurality of contacts protruding through a second opening in the unitary housing;

a first light-emitting diode coupled to the circuit board;

a first light pipe over the first light-emitting diode; and

a first light insulator surrounding the first light-emitting diode and the first light pipe to limit illumination in a first and second direction and to allow illumination in a third direction,

wherein a third opening in the unitary housing is aligned with the first light-emitting diode in the third direction.

10. The cable plug of claim 9 further comprising a second light pipe in the third opening in the unitary housing.

11. The cable plug of claim 9 further comprising:

a second light-emitting diode coupled to the circuit board;

a second light pipe over the second light-emitting diode; and

a second light insulator surrounding the second light-emitting diode and the second light pipe to limit illumination in the first and second direction and to allow illumination in a fourth direction, the fourth direction the opposite direction as the third direction,

wherein a fourth opening in the unitary housing is aligned with the second light-emitting diode in the fourth direct ion.

12. The cable plug of claim 9 wherein the unitary housing is formed of aluminum.

13. The cable plug of claim 9 wherein the circuit board is a flexible circuit board.

14. The cable plug of claim 9 wherein the unitary housing and the attraction plate form an enclosure that encloses the assembly, the circuit board, the plurality of contacts, the first light-emitting diode, and the first light insulator.

15. The cable plug of claim 10 wherein the second light pipe is formed using an adhesive.

16. A cable plug comprising:

a unitary housing made from a single piece of material and having a cylindrical shape and having a first opening at an end to accept a cable in a first direction;

an assembly housed in the unitary housing and comprising a nonconductive housing and power and ground conductors, the power and ground conductors coupled to the cable;

a circuit board coupled to the assembly;

a plurality of contacts coupled to the circuit board;

a magnetic attraction plate positioned around the plurality of contacts, the attraction plate and the plurality of contacts protruding through a second opening in the unitary housing in a second direction, the second direction orthogonal to the first direction;

a first light-emitting diode coupled to the circuit board;

a first light pipe over the first light-emitting diode; and

a first light insulator around the first light-emitting diode and the first light pipe, the first light insulator to limit stray illumination and to allow illumination through a third opening in the unitary housing.

17. The cable plug of claim 16 further comprising a second light pipe in the third opening in the unitary housing.

18. The cable plug of claim 17 wherein the second light pipe is formed using an adhesive.

19. The cable plug of claim 16 further comprising:

a second light-emitting diode on the circuit board;

a second light pipe over the second light-emitting diode; and

a second light insulator around the second light-emitting diode and the second light pipe, the second light insulator to limit stray illumination and to allow illumination through a fourth opening in the unitary housing.

20. The cable plug of claim 16 wherein the unitary housing is formed of aluminum.

21. The cable plug of claim 16 wherein the circuit board is a flexible circuit board.

22. The cable plug of claim 16 wherein the first light insulator is formed using foam.

23. The cable plug of claim 16 wherein the unitary housing and the attraction plate form an enclosure that encloses the assembly, the circuit board, the plurality of contacts, the first light-emitting diode, and the first light insulator.