Connector devices having a flushed and zero gap finish and methods of manufacture
First Claim
1. A cable connector comprising:
- a shield shell having a distal portion and a stepped-down proximal portion, wherein the shield shell comprises a front shield shell and a rear shield shell having a reduced profile relative to the front shield shell, wherein the rear shield has a plurality of deflectable tabs at a distal end thereof, the front shield shell and rear shield shell being separate components that are fixedly attached such that the front shield shell corresponds to the distal portion and the rear shield shell corresponds to the stepped-down proximal portion;
a boot member having a distal cavity dimensioned to fittingly receive the stepped-down proximal portion such that an outer surface of the boot member is flush with an outer surface the distal portion of the shield shell along a length of the connector; and
a plurality of terminals disposed within the shield shell and electrically coupled to a cable through the shield shell and boot member.
1 Assignment
0 Petitions
Accused Products
Abstract
Devices and methods of manufacture for improved connector plugs are provided herein. In one aspect, an exemplary connector plug comprises a shield shell having a proximal stepped-down portion and a boot member that fittingly receives the stepped-down proximal portion so that an outer surface of the distal shield shell and the boot member is about flush with a minimal or negligible space therebetween. In some embodiments, the shield shell comprises a separate front shield shell and a reduced profile rear shield shell welded together so as to provide the advantageous reduced profile and improved aesthetic appearance, while maintaining the structural integrity of the connector. In many embodiments, weld strength of the shield shells is improved by providing line-to-line contact between shield shells by using deflectable tabs and/or utilizing thermal expansion properties of one or both shield shells.
28 Citations
22 Claims
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1. A cable connector comprising:
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a shield shell having a distal portion and a stepped-down proximal portion, wherein the shield shell comprises a front shield shell and a rear shield shell having a reduced profile relative to the front shield shell, wherein the rear shield has a plurality of deflectable tabs at a distal end thereof, the front shield shell and rear shield shell being separate components that are fixedly attached such that the front shield shell corresponds to the distal portion and the rear shield shell corresponds to the stepped-down proximal portion; a boot member having a distal cavity dimensioned to fittingly receive the stepped-down proximal portion such that an outer surface of the boot member is flush with an outer surface the distal portion of the shield shell along a length of the connector; and a plurality of terminals disposed within the shield shell and electrically coupled to a cable through the shield shell and boot member. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of making a connector, the method comprising:
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providing a front shield shell and a rear shield having a reduced profile relative to the front shield shell, the front shield shell and rear shield shell being separate components and the rear shield having a plurality of deflectable tabs at a distal end thereof; positioning the rear shield shell partly within the front shield so that a proximal portion of the rear shield shell extends outside of the front shield shell and the plurality of deflectable tabs engage the front shield shell; and coupling the front shield shell and the rear shield shell to form a shield shell having a distal portion and a stepped-down proximal portion, the distal portion corresponding to the front shield shell and the stepped-down proximal portion corresponding to the proximal portion of the rear shield shell extending outside the front shield shell, wherein the front and rear shield shell are dimensioned so that when distally advancing a boot having a distal cavity to fittingly receive the stepped-down proximal portion of the shield shell within the distal cavity, the outer surface of the boot is flush with an outer surface of the distal portion of the shield shell. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19)
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20. A USB cable connector comprising:
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a connector end having a plurality of contacts positioned within a first shield shell housing; a cable having a plurality of wires; and a connector body coupled inline between the cable and the connector end, the connector body having a second shield shell housing having a reduced profile relative the first shield shell housing and a plurality of bonding pads positioned therein, each of the plurality of bonding pads electrically coupled to one of the plurality of contacts and one of the wires, the second shield shell and first shield shell being separate components that are coupled together, wherein the second shield shell has a plurality of deflectable tabs at a distal end thereof; wherein the first shield shell of the connector end has an outer surface that is flush with an outer surface of the connector body along substantially the entire periphery of the connector when an external boot member is disposed over the second shield shell. - View Dependent Claims (21, 22)
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Specification