Backward compatible connector system

• US 7,540,788 B2
• Filed: 01/05/2007
• Issued: 06/02/2009
• Est. Priority Date: 01/05/2007
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Howarth, Richard, Stringer, Christopher, Crooijmans, Wim, Murphy, R. Sean
• Primary Examiner(s): Duverne; Jean F
• Application Number:
  US11/650,330
• Publication Number:
  US 20080166905A1
• Time in Patent Office: 879 Days
• Field of Search: 439/676, 439/941, 439/620
• US Class Current: 439/676
• CPC Class Codes: H01R 12/7076 for connection between PCB and component, e.g. display
• CPC Class Codes: H01R 12/716 Coupling device provided on the PCB
• CPC Class Codes: H01R 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• CPC Class Codes: H01R 13/64 Means for preventing incorrect coupling
• CPC Class Codes: H01R 13/6658 on printed circuit board H01R13/6666 - H01R13/6691 take precedence
• CPC Class Codes: H01R 13/74 Means for mounting coupling parts in openings of a panel

Abstract

Various embodiments of connectors and connector assemblies provide modified structural features to meet evolving industrial design requirements while maintaining backward compatibility. In one embodiment, alignment posts on the two sides of a plug connector are substantially removed and the remaining connector shell reshaped so as to preserve alignment capability. Other pre-existing features such as alignment grooves and some or all springy raised tabs can be eliminated resulting in a more compact and monolithic structure for the connector without impacting functionality or backward compatibility. In another embodiment, a trim ring is molded to the base of the connector to form an integrated unit. The integrated unit results in a reduced size of the connector when it is incorporated into other devices such as a docking station. In yet another embodiment, a printed circuit board is integrated into the boot of a connector assembly to act as an intermediate connection mechanism between the cable wires and the connector pins. Other functionality such as identification circuitry or electrostatic discharge protection circuitry can be incorporated on to the integrated printed circuit board.

Claims

1. A plug connector for use in a connector system having a receptacle connector, the receptacle connector having alignment projections projecting toward an interior of a box shaped housing of the receptacle connector, the plug connector comprising:

a body having a bottom plate with a width W, a top plate with a width W′

that is smaller than W, a first side plate and a second side plate each having a step to accommodate the width differential between the top and bottom plates, wherein the first and second side plates are smaller relative to the top and bottom plate providing a substantially flat body; and

an array of electrodes extending in the direction of the depth of the body and being positionally secured by insulating material to an interior surface of the bottom plate of the body leaving an insertion cavity in the interior of the body between the array of electrodes and the top plate,

wherein the steps in the first and second side plates are aligned with the alignment projections of the receptacle connector to guide insertion of the plug connector into the receptacle connector housing.

2. The plug connector of claim 1 further comprising a shell that is made of a single sheet of conductive material wrapped around the plug connector.

3. The plug connector of claim 1 wherein the steps on each side plate of the plug connector have curved edges.

4. The plug connector of claim 1 wherein the array of electrodes can have up to 30 pins.

5. The plug connector of claim 1 further comprising an integrated trim ring molded to a base of the plug connector.

6. The plug connector of claim 5 wherein the trim ring is made of high temperature resilient material such as glass reinforced nylon.

7. The plug connector of claim 5 wherein the plug connector with the integrated trim ring is disposed on a printed circuit board at a predetermined angle from the vertical axis.

8. The plug connector of claim 7 wherein the predetermined angle is approximately 10 degrees from the vertical axis.

9. A cable connector assembly including the plug connector of claim 1, further comprising:

a cable housing a plurality of wires;

a boot connecting a first end of the cable to the plug connector, wherein electrical coupling between the plurality of wires inside the cable and the array of electrodes inside the plug connector is made via a printed circuit board integrated into the boot; and

a resistor disposed on the printed circuit board and electrically coupled to a predetermined electrode of the plug connector.

10. The cable connector assembly of claim 9 wherein the printed circuit board comprises a plurality of solder pads adapted to receive a corresponding plurality of wires from the cable.

11. The cable connector assembly of claim 10 wherein the printed circuit board further comprises a plurality of conductive traces electrically coupling the plurality of solder pads to a corresponding plurality of contacts for the array of electrodes.

12. The cable connector assembly of claim 9 further comprising one or more electronic components placed on the printed circuit board and configured to perform one or more predetermined functions.

13. The cable connector assembly of claim 9 wherein the resistor disposed on the printed circuit board identifies a type of the cable connector.

14. The cable connector assembly of claim 12 wherein electrostatic discharge protection circuitry is disposed on the printed circuit board and is electrically coupled to one or more predetermined electrodes of the plug connector.

15. The cable connector assembly of claim 9 wherein the second end of the cable is coupled to a universal serial bus connector.

16. The cable connector assembly of claim 13 wherein the resistor is coupled between two predetermined electrodes.

17. The cable connector assembly of claim 16 wherein the array of electrodes comprises at least 30 pins disposed in a row and wherein the resistor is coupled between electrode number 15 and a ground electrode.

18. The cable connector assembly of claim 9 wherein the plurality of wires comprises four wires for universal serial bus (USB) connection.

19. The cable connector assembly of claim 9 wherein the cable comprises one or more mesh braids configured to provide electrical shielding.

20. The cable connector assembly of claim 9 wherein the printed circuit board is in the shape of a bracket with its opening adapted to receive the cable.

21. The cable connector assembly of claim 12 wherein EMI containment means are disposed on the printed circuit board.

22. The cable connector assembly of claim 9 wherein the cable comprises a Ferrite wrap adapted to increase EMI absorption.