High-speed connector inserts and cables

• US 9,385,478 B2
• Filed: 02/24/2012
• Issued: 07/05/2016
• Est. Priority Date: 06/30/2010
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Kim, Min Chul, Yuan, Paul, Pong, Josh, Tang, Joseph
• Primary Examiner(s): Leon, Edwin A.
• Application Number:
  US13/404,949
• Publication Number:
  US 20120152613A1
• Time in Patent Office: 1,593 Days
• Field of Search: 439/607.41, 174/88.C
• US Class Current: 1/1
• 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 connector insert and cable apparatus comprising:

an insert shield;

a cable comprising a plurality of twisted pairs, a plurality of wires, and a shield layer electrically connected to the insert shield;

a block having a plurality of non-circular openings for the twisted pairs and a plurality of approximately circular openings for the wires, wherein the plurality of twisted pairs and a plurality of wires pass through the block using the openings;

a printed circuit board coupled to at least one of the twisted pairs, the printed circuit board having a pad connected to the insert shield; and

an active device fixed to the printed circuit board and thermally coupled to the insert shield.

2. The connector insert and cable apparatus of claim 1 wherein the cable shield layer is soldered to the insert shield.

3. The connector insert and cable apparatus of claim 1 wherein each of the plurality of non-circular openings are approximately elliptical.

4. The connector insert and cable apparatus of claim 1 wherein the pad is located on a side of the printed circuit board.

5. The connector insert and cable apparatus of claim 1 wherein a cap is crimped over the connection between the shield layer and the insert shield.

6. The connector insert and cable apparatus of claim 5 wherein the cap is soldered to the connector insert.

7. The connector insert and cable apparatus of claim 1 further comprising:

a plastic housing covering a portion of the insert shield.

8. The connector insert and cable apparatus of claim 1 wherein the cable shield layer comprises a plurality of fibers.

9. The connector insert and cable apparatus of claim 5 wherein the plurality of fibers comprises aramid fibers.

10. A connector insert and cable apparatus comprising:

a cable having a shield layer; and

a connector insert comprising;

a printed circuit board having a first side ground contact formed on a first side of the printed circuit board;

an integrated circuit on the printed circuit board; and

a shield around the printed circuit board,

wherein the integrated circuit is thermally connected to the shield,

wherein the first side ground contact on the printed circuit board is attached to the shield, and

wherein the shield layer is electrically connected to the shield.

11. The connector insert and cable apparatus of claim 10 wherein the printed circuit board further comprises a second ground contact on a second side, the second ground contact attached to the shield.

12. The connector insert and cable apparatus of claim 11 wherein the first side ground contact and the second side ground contact are soldered to the shield.

13. The connector insert and cable apparatus of claim 10 wherein the integrated circuit is thermally connected to the shield using a thermally conductive material.

14. The connector insert and cable apparatus of claim 10 further comprising a housing around at least a portion of the shield.

15. A connector insert and cable apparatus comprising:

a cable having a shield layer and a plurality of conductors; and

a connector insert comprising;

a printed circuit board having a first side ground contact formed on a first side of the printed circuit board;

an integrated circuit on the printed circuit board and coupled to the plurality of conductors;

a plurality of contacts;

a housing supporting the plurality of contacts and attached to the printed circuit board; and

a shield around the printed circuit board and electrically connected to the shield layer and the first side ground contact.

16. The connector insert and cable apparatus of claim 15 wherein the printed circuit board further comprises a second ground contact on a second side, the second ground contact attached to the shield.

17. The connector insert and cable apparatus of claim 16 wherein the first side ground contact and the second side ground contact are soldered to the shield.

18. The connector insert and cable apparatus of claim 15 further comprising a block having passages, each passage for one of the plurality of conductors.

19. The connector insert and cable apparatus of claim 15 wherein the integrated circuit is thermally connected to the shield using a thermally conductive material.

20. The connector insert and cable apparatus of claim 15 further comprising a housing around at least a portion of the shield.