Connector Devices Having a Flushed and Zero Gap Finish and Methods of Manufacture

• US 20130084745A1
• Filed: 10/04/2011
• Published: 04/04/2013
• Est. Priority Date: 10/04/2011
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Siahaan, Edward, Ardisana, John B. II, Golko, Albert J.
• Granted Patent: US 8,784,136 B2
• Time in Patent Office: Days
• US Class Current: 439/607.41
• CPC Class Codes: H01R 13/50 formed as an integral body H01R13/514 takes precedence
• CPC Class Codes: H01R 13/6581 Shield structure
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor

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.

Claims

1. A cable connector comprising:

a shield having a distal portion and a stepped-down proximal portion, wherein the stepped-down proximal portion has a reduced profile relative to the distal 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 about 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.

2. The connector of claim 1 wherein the shield shell is dimensioned such that when the proximal portion is fittingly received within the distal cavity of the boot member a distal edge of the boot member abuts against a proximal edge of the distal portion of the shield shell.

3. The connector of claim 1 wherein the shield shell comprises

a front shield shell corresponding to the distal portion, and

a rear shield shell corresponding to the stepped-down proximal portion,

wherein the front shield shell and the rear shield shell are fixedly attached.

4. The connector of claim 3 wherein the shield shell and boot member are dimensioned so that when the proximal portion is fittingly received within the distal cavity of the boot member a distal edge of the boot member abuts against a proximal edge of the distal portion of the shield shell.

5. The connector of claim 4 wherein the distal edge and proximal edge are in direct contact around substantially the entire distal opening so as to inhibit space between the distal edge and proximal edge.

6. The connector of claim 1, wherein

the front shield shell has an outer surface and an inner surface defining an axial passageway extending therethrough,

the rear shield shell includes an axial passageway extending therethrough from a proximal opening to a distal opening and a plurality of deflectable tabs disposed near the distal opening, the deflectable tabs extending radially outward so as to be fittingly receivable within the axial passageway of the front shield shell, the tabs being deflected and in contact with the inner surface of the front shield shell when received therein, and

the distal cavity is disposed at a distal opening of an axial passageway extending through the boot member.

7. The connector of claim 6 wherein the deflectable tabs extend distal of the distal opening of the rear shield shell.

8. The connector of claim 6 wherein contact between each of the deflectable tabs and the inner surface of the front shield shell is line-to-line contact sufficient for welding of each of the tabs to the front shield shell.

9. The connector of claim 6 wherein the deflectable tabs are distributed about the distal opening of the rear shield shell so as to distribute stresses when coupled to the inner surface of the front shield shell.

10. The connector of claim 6 wherein each of the front shield shell and the rear shield shell has four sides.

11. The connector of claim 10 wherein the plurality of deflectable tabs comprises at least one tab on each of the four sides of the rear shield shell corresponding to the four sides of the front shield shell.

12. The connector of claim 10 wherein the boot member has four sides corresponding to the four sides of the front shield shell and the rear shield shell.

13. A method of making a connector, the method comprising:

providing a shield shell having an axial passageway extending therethrough, a distal portion, and a proximal portion stepped-down toward the passageway axis such that the stepped-down proximal portion has a reduced profile relative to the distal portion;

inserting a plurality of terminals into the front shield shell;

electrically coupling a plurality of wires extending through a cable to each of the plurality of terminals; and

distally advancing a boot having a distal cavity to fittingly receive the stepped-down proximal portion within the distal cavity so that the outer surface of the boot is about flush with an outer surface of the distal portion of the shield shell.

14. The method of claim 13, further comprising:

forming the stepped-down proximal portion by bending one or more sidewalls of the proximal portion toward the axis extending therethrough.

15. The method of claim 14, wherein the shield shell has four sides and bending the proximal portion comprises bending each side of a proximal portion toward the axis.

16. The method of claim 13, further comprising:

forming the stepped-down proximal portion by half-shearing one or more sidewalls of the proximal portion toward the axis extending therethrough.

17. The method of claim 16 wherein the shield shell has four sides and half-shearing comprises half-shearing each of the four sides toward the axis.

18. The method of claim 13 wherein the shield shell comprises a front shield shell and a rear shield shell, the method further comprising:

inserting the rear shield shell into an axial passageway of the front shield shell so that a plurality of deflectable tabs near a distal portion of the rear shield shell contact an inner surface of the front shield shell;

positioning the rear shield shell so that a proximal portion of the rear shield shell extends outside of the front shield shell while the deflectable tabs are in direct contact with the inner surface of the front shield shell;

coupling the rear shield shell to the front shield shell by fixedly attaching the deflectable tabs to the inner surface of the front shield shell;

distally advancing a boot relative the rear shield shell to fittingly receive the proximal portion of the rear shield shell within a cavity at a distal opening of the boot until a distal edge of the boot abuts against a proximal edge of the front shield shell.

19. The method of claim 18 wherein fixedly attaching the deflectable tabs to the inner surface of the front shield shell comprises applying adhesive to the deflectable tabs.

20. The method of claim 18 wherein fixedly attaching the deflectable tabs to the inner surface of the front shield shell comprises welding the deflectable tabs in contact with the inner surface of the front shield shell.

21. The method of claim 20 wherein welding comprises laser welding through a distal opening of the front shield shell.

22. The method of claim 18 wherein inserting the rear shield shell into the axial passageway of the front shield shell comprises inserting the proximal portion of the rear shield shell through a distal opening of the front shield shell so as to deflect the tabs inward during insertion.

23. The method of claim 18 wherein the method further comprises:

inserting a plurality of terminals into the front shield shell.

24. The method of claim 23, the method further comprising:

electrically coupling a plurality of wires extending through a cable to each of the plurality of terminals.

25. The method of claim 18 wherein the cable extends through the boot member, and wherein distally advancing the boot member comprises sliding the boot member along the cable.

26. A USB cable connector comprising:

a connector end having a plurality of contacts positioned within a first housing;

a cable having a plurality of wires;

a connector body coupled inline between the cable and the connector end, the connector body having a second 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;

wherein 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.

27. The USB cable connector of claim 26, wherein the first housing of the connector end comprises at least a distal portion of a shield shell and the connector body includes an external boot member such that the outer surface of the shield shell is flush with the outer surface of the boot member.

28. The USB cable connector of claim 27, wherein each of the distal portion of the shield shell and the boot member has a substantially rectangular cross-section such that the outer surface of the distal portion of the shield shell is flush with the boot member along each side of the respective rectangular boot member.