WO2008065659A2

WO2008065659A2 - Male data communication connector having contacts of different height

Info

Publication number: WO2008065659A2
Application number: PCT/IL2007/001470
Authority: WO
Inventors: Yohan Cohen
Original assignee: Walletex Microelectronics Ltd.
Priority date: 2006-11-29
Filing date: 2007-11-28
Publication date: 2008-06-05
Also published as: WO2008065659A3

Abstract

A multi-contact connector (100) having a set of contacts (110, 120) supported on a planar substrate (130) in proper spatial alignment for engaging corresponding contacts (420) of a female receptacle (400) having an internal shield (410). At least one contact in the contact set has an active surface that is offset relative to the planar substrate by a greater distance than the respective active surfaces of other contacts in the contact set so as to mechanically create a space between the shield and the other contacts of the contact set when the connector is inserted within the receptacle. A pair of contact sets may also be provided, each on an opposite surface of the planar substrate.

Description

Male data communication connector having contacts of different height

FIELD OF THE INVENTION

This invention relates generally to the field of data connectors.

BACKGROUND OF THE INVENTION

Data connectors are well known and include USB connectors, IEEE 1394 connectors, cellular phone connectors and so on. Advances in technology have increased the data transfer rate of the devices using such connectors.

The USB connector is also common and is used for peripheral devices such as a computer mouse, a keypad, a printer and similar devices. Current methods for USB connection, for example, use a housing supporting only four contacts pads (VCC, D-, D+, GND) as needed for USB communication. The contacts are implemented on a substrate and are of the same height in order to connect to complementary resilient contacts of the USB female connector. Over the last ten years, the size of some USB devices has been reduced to fit inside a user's wallet or pocket, thus requiring the provision of a thin USB connector that uses only the inner space of the USB host connector to effect connection. This has been achieved in part by suppressing the outer shield provided in conventional male USB connectors in order to reduce the thickness of the male connector. This is not an entirely satisfactory solution since the shield is used to reduce electromagnetic radiation and its elimination is therefore not desirable.

USB connectors currently have a housing supporting only four contacts (VCC, D-, D+, GND) as needed for USB communication, and are designed to avoid contact with the host device shield.

WO2005/124932 published December 29, 2005 and entitled "Improved connector and device for flexibly connectable computer systems" discloses a double- sided male USB connector and various card-shaped devices having one or more male USB connectors, which may be single-sided or double-sided and are dimensioned to fit into a USB receptacle. The device can have a rechargeable power source that is fed power via the connector's power lines. The device can be manufactured from flexible material using a lamination process and may be configured to communicate with a broad- variety of other electronic devices. The full contents of WO2005/124932 are incorporated herein by reference. When the double-sided male USB connector described in WO2005/124932 is inserted into a female receptacle having only a single set of contacts, the exposed contacts on an inactive surface of the connector that is disposed so as not to make contact with the contacts in the female receptacle will lie proximate the outer shielding of the receptacle. Since these contacts are electrically coupled to the contacts on the active surface, which engage the contacts of the receptacle, there is the danger that the exposed contacts may touch the outer shielding of the receptacle thereby shorting data to ground. This of course must be avoided. To this end, WO2005/124932 provides short- circuit protection in order that the contacts on the inactive surface of the connector be effectively disconnected from the shielding via reverse biased rectifier diodes that prevent data from flowing into the shield and ensuring operability of the connector even if inactive contacts of the connector touch the shielding of the receptacle.

No such shielding is required if only a single set of contacts is provided since in such case there are no exposed contacts on the inactive surface of the connector that can touch the shielding.

In the case of both single- and double-sided connectors there may be the need to provide a shield contact to engage the shielding of the female receptacle.

BRIEF SUMMARY OF THE INVENTION

In accordance with one embodiment, the invention provides a double-sided connector having at least two contact pads each having contacts of different respective heights and capable of connecting to a host device. In each contact set, at least one contact is elongated so that even when it engages the outer shield of the receptacle, this will leave a sufficiently large between the remaining contacts and the outer shield thus ensuring continuous operability of the connector. In accordance with some embodiments, the electrical signal contacts of each contact pad that can be damaged by, or will suffer from, or will be electrically impaired by such contact with the receptacle shield are elongated.

In accordance with other embodiments, a short-circuit protection device is provided in association with the elongated contacts so that contact with the receptacle shield does not impair operability of the connector.

In accordance with some embodiments, there are electrically coupled to one of the data connector pads additional pads that can effect contact with the receptacle shield in order to create mechanical space between the shield and the other connector pads that must be electrically isolated from the receptacle shield.

According to one embodiment of the invention, there is provided a male multi- contact data connector having two set of contacts supported on opposite surfaces of a planar substrate, respective contacts in each contact set being in proper spatial alignment for engaging corresponding contacts of a female receptacle having an internal shield and a single set of contacts that is compatible with either one of said sets of contacts, wherein: corresponding contacts in each set are spatially aligned in anti-phase relationship so as to allow the connector to be connected in two opposed orientations to said female receptacle; in each contact set there is at least one elongated contact that is permitted to make contact with the shield without impairing operability of the connector; and the at least one elongated contact in each contact set has an active surface that is offset relative to the surface of the planar substrate by a greater distance than the respective active surfaces of other contacts in said set so as to mechanically create a space between the shield and the other contacts of said set when the connector is inserted within the receptacle with the contacts of said set disposed so as not make contact with the contacts in the female receptacle. According to another embodiment of the invention, there is provided a multi-contact male data communication connector having no outer shield and comprising: a body portion for accommodating a planar substrate therein; a set of contacts supported on the planar substrate in proper spatial alignment for engaging corresponding contacts of a female receptacle having an internal shield; and at least one shield contact supported by the body portion and configured to connect electrically to the internal shield of the female receptacle when the connector is inserted into the female receptacle.

According to yet another embodiment of the invention, there is provided a male data communication connector comprising: a body portion supporting at least one set of electrical contacts for engaging corresponding contacts of a receptacle formed at least partially of ferromagnetic material; and a magnet supported by the body portion for securing electrical contact of the connector with the receptacle. BRIEF DESCRIPTION OF THE DRAWINGS

In order to understand the invention and to see how it may be carried out in practice, some embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, wherein: Figs. 1a and 1b show respectively side and plan views of a male data communication connector having contacts of different respective heights in accordance with an embodiment of the invention;

Fig. 2 is a cross-sectional view along the line A-A in Fig 1a;

Figs. 3 is a perspective view of the USB male cbmmunication data connector shown in Figs. 1 and 2;

Fig. 4 is a perspective view of a convention prior art type-A USB host receptacle;

Figs. 5a and 5b show respectively perspective and cross-sectional views of the connector shown in Figs. 1a and 1b, when connected to the USB receptacle shown in Fig. 4; Fig. 6 is an exploded view of a male USB data connector having a PCB and an outer shield in accordance with another embodiment of the invention;

Figs. 7a and 7b show respectively plan and side views of the connector shown in Fig. 6;

Figs. 8a and 8b show respectively plan and side views of a USB male connector according to one embodiment;

Figs. 9a and 9b show respectively plan and 5;ide views of a USB male connector according to another embodiment;

Fig. 10a is a perspective view of an USB receptacle having an outer shield;

Figs. 10b and 10c show respectively connection of shield contacts in the USB male connectors shown in Figs. 8 and 9 to the receptacle shield shown in Fig. 10a;

Figs. 11 to 13 show construction features of the connector according to other embodiments of the invention; and

Figs. 14 and 15 illustrate schematically prior art approaches to preventing electric short circuit between the inactive contacts of a double-sided male connector and the shield of a female receptacle.

The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention. DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of the preferred embodiment are provided herein, it is to be understood, however, that the present invention may be embodied in various forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner. In the following description, identical components that appear in different figures or that serve an identical function will be referenced by the same reference numerals. Figs. 1a and 1b show respectively side and plan views of a male data communication connector 100 having contacts of different respective heights. The connector has two sets of contacts 110 and 120 that protrude from and are supported by opposing surfaces of a planar substrate 130 supported within a body 140 (shown in Fig. 2). Corresponding contacts in each set are spatially aligned in anti-phase relationship allowing the connector to be connected in two opposed orientations to a corresponding female receptacle having only a single set of contacts that is compatible with either one of the contact sets and an internal shield. A suitable receptacle is described below with reference to Figs. 4 and 5 of the drawings. The connector may be a standard type A USB connector although it is not limited thereto. Fig. 2 is a cross-sectional view along the line A-A in Fig 1a showing the internal planar substrate 130 that supports the two sets of contacts 110 and 120. The body 140 envelops the planar substrate 130 and the two sets of contacts 110 and 120 such that at least one contact in each set of contacts is elongated so as to protrude from the body 140, whereby the active surface of the elongated contact or contacts is displaced a greater height from the substrate 130 than the corresponding active surfaces of the remaining contacts that may be substantially flush with the substrate 130. By "active surface" is meant that surface of the contact that engages a complementary contact surface in the female receptacle.

In accordance with one embodiment, only those contacts in each contact set are elongated that may contact the internal shield of the receptacle. For example, the GND contacts may be elongated while the D-, D+ may not be elongated so as to prevent data being shorted to ground via the internal shielding of the receptacle. However, in accordance with another embodiment, short-circuit protection between the two contacts sets is provided in a manner as described in above-referenced WO2005/124932. In this case, any of the contacts may be elongated.

Fig. 3 shows a perspective view of the USB male communication data connector described above with reference to Figs. 1a, 1b and 2 of the drawings. Fig. 4 is a perspective view of a standard type-A USB host receptacle 400 showing an internal surface of a host receptacle shield 410 that engages the active surface of the protruding contacts of either one set of contacts in the male connector. The receptacle has a set of contacts 420 supported on a block 430 and configured to engage either set of contacts of the male connector 100. Fig. 5a is a perspective view of the male data communication connector 100 shown in Figs. 1a and 1b, when connected to the host female USB receptacle 400.

Fig. 5b is a cross-sectional view along the line B-B in Fig. 5a showing the connection between the contacts 420 in the host female USB connector and either the first or second sets of contacts 110 and 120, respectively, of the male connector 100. It is seen that the contacts 110 on the upper surface of the connector 100 are "inactive" in that they do not make contact with the contacts 420 in the female receptacle 400. In contrast, the contacts 120 may be said to be "active".

Fig. 6 is an exploded view of a male USB data connector 600 according to another embodiment of the invention. The connector 600 comprises a PCB 601 and at least one shield contact 602 that serves to connect to a connector shield in a host device. The PCB 601 also integrates a set of USB contacts 603 comprising four contacts GND, D+, D-, Vbus as needed for USB connection. In the figure, two shield contacts 602 are provided each in the form of a metal band whose ends engage metal shielding pads 604 on the PCB. However, this is illustrative¹ only and any other suitable manner for connecting the shield contacts may be employed, some of which will be described albeit by way of non-limiting example with reference to Figs 8 and 9 below.

Figs. 7a and 7b show respectively plan and side views of the connector 600 according to one embodiment wherein the shield contacts 602 are disposed along side edges of the PCB 601 and extend at least along a major dimension of the connector. Figs. 8a and 8b show respectively plan and side views of the connector according to one embodiment assembled in a plastic body portion 605 dimensioned for proper insertion into a female USB receptacle. The shield contact 602 extends along a side edge of the body portion 605, which supports respective USB contacts 603 on opposing surfaces thereof. Figs. 9a and 9b show respectively plan and side views of an assembled connector according to another embodiment, whose body portion 605 supports at least two shield contacts 602 each on a respective opposing major planar surface thereof and serving for contact with a connector shield in a host device. The body portion 605 further comprises opposing sets of USB contacts 603 also supported on opposing major planar surfaces of the connector.

Fig. 10a is a perspective view of a USB host receptacle 650 showing a host receptacle shield 651 formed at least partially of ferromagnetic material and having an internal surface 652 that effects electrical contact with one of the dedicated shield contacts 602 of the connector as shown in Fig. 9b.

Fig. 10b is a perspective view of the male connector 600 shown in Figs. 8a and 8b when connected to the host female USB connector 650 and showing contact between the host connector shield 651 and the shield contact 602 of the male data connector. By way of example only, the connector 600 is double-sided, there being also shown the inactive contact set on the upper (inactive) surface of the connector.

Fig. 10c is a perspective view of the connector shown in Figs. 9a and 9b when connected to a host female USB connector 650 and showing contact between the host connector shield 651 and the shield contact 602 of the male data connector.

Fig. 11 is a plan view of a male USB connector having a body portion 605 supporting on opposite major planar surfaces thereof respective shield contacts 602 serving to make contact with the host connector shield. The same planar surfaces support opposed sets of USB contacts as described above with reference to Fig. 9a. The connector is further provided with one or more magnets 660 fixed to both major surfaces of the connector for securing connection of the shield contacts 602 with the complementary metal shield 651 of a host female USB connector by virtue of the resulting magnetic attraction between the magnets 602 and the metal shield.

Fig. 12 is a perspective view of an USB data connector 600 comprising a set of USB-compatible contacts 603 and having a peripheral shield contact 602 supported on side edges of the PCB so as to engage the host connector shield during connection. The connector 600 is integrated within a device having a body portion 670; the shield contact 602 having an elongated portion 671 that extends into the body portion 670 to reinforce the mechanical connection strength of the USB data connector to the body portion. This reduces the risk fracture at the junction 672 between the connector 600 and the body 670, the junction being shown by the dashed line in the drawing. Fig. 13 is a plan view of a PCB 601 having a peripheral shield contact 602 and supporting a set of USB contacts 603 on a surface of the PCB. The peripheral shield contact 602 is shaped to protrude from the edges of the PCB 601 that are exposed to the host connector shield. As noted above, in accordance with one aspect of the invention, some elongated contacts in a double-sided male connector may be able to contact the internal shielding of the receptacle without impairing the operability thereof. In other situations, such as when the data contact D+ or D- is elongated, short circuit protection must be provided. Figs. 14 and 15 illustrate schematically prior art approaches to preventing electric short circuit between the inactive contacts of a double-sided male USB connector 100 and the grounded shield of a female USB receptacle as described in WO 2005/124932. The two contacts sets 110 and 120 comprise complementary pairs of anti-phase contacts (c1 , cδ), (c2, c7), (c3, c6), and (c4, c5), respectively. Contacts c1 and c8 are commonly connected to the GND connection of the receptacle. Likewise, contacts c4 and c5 are commonly connected to the VBUS connection of the receptacle. Each of the contacts c4 and c5 in the male USB connector 100 is connected to the anode of a respective diode D1 and D2. When contact c4 engages the VBUS contact of the USB receptacle and is thus at positive potential, the diode D1 conducts but since the contact c5 on the opposite surface of the USB male connector engages the internal shield 651 of the receptacle 650 and is therefore connected to GND, the diode D2 is reverse biased and so opposes current flow. The opposite occurs when the male USB connector is inverted such that contact c4 is either at floating potential or is short- circuited to GND via the internal shield 651 of the receptacle 650. By such means, the possibility of a short circuit between VBUS and GND is avoided upon inverting the male USB connector. The VBUS contacts of the male USB connector 100 corresponding to the contacts c4 and c5 are routed via the diodes to a single VBUS contact. Likewise the GND contacts corresponding to the contacts d and cδ are routed to a single GND contact. It will be appreciated that the diodes can be used in such manner to prevent a short circuit with either a double sided USB connector or a single sided USB connector that is inserted such that its contacts face the opposite side of the receptacle USB contacts, thereby risking short circuit with the internal shield 651 of the receptacle 650.

Fig. 15 shows an alternative solution to the short circuit problem, wherein the VBUS and GND contacts of the male connector 100 are connected to a relay 675 that transfers only forward current from the VBUS contacts and does not open the circuit if GND is in contact with one of the VBUS wires. Alternatively, the relay 675 may also be connected to each of the VBUS contacts by itself.

The embodiments shown in Figs. 1b and 6 and their derivatives have been described as though they are mutually independent - as indeed they may be. Thus, the embodiments shown in Figs. 1 to 5 do not need an auxiliary shield contact and the embodiments shown in Figs. 6 to 13 do not need to be double-sided and so have no need for contacts of different effective heights. However, in accordance with another embodiment of the invention, the connector 100 may be provided with an auxiliary shield contact that serves to engage the internal shield of the receptacle. Such an auxiliary contact may be as described above with reference to Figs. 6 to 13.

While the invention has been described in connection with a number of embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.

Specifically, while a preferred embodiment has been described with regard to a male data connector having two sets of contacts on opposing surfaces of the connector, it will be appreciated that the invention is equally applicable to connectors having only a single set of contacts on a single surface of the connector. USB is an acronym for Universal Serial Bus, which has been become the universal standard for connecting peripherals to computer motherboards. Although some embodiments of the invention have been described with particular reference to the USB standard, it is to be understood that the principles of the invention are equally applicable to other standards and particularly to connectors having different contact arrangements than the USB standard. It is therefore to be understood thatthe invention both as described and as claimed is not intended to be limited to any specific standard and the more generic term "flexibly connectable computer systems" abbreviated as FCCS will be used to denote any interface standard for allowing devices to be connected to a computer. Specifically, the connector can be any other connector type having an outer shield such as MiniUSB, MicroUSB, cellular phones, etc.

It should be also noted that while the use of a magnet for securing contact between a male and female USB connector has been described with particular reference to a planar connector supporting a pair of USB contact sets on opposing surfaces thereof, it is to be noted that a magnetic pull may be used to good effect also with data connectors having only a single contact set. Likewise, although in the described embodiments the magnet serves to exert a magnetic pull on the metal shield of the receptacle, any ferromagnetic material may be attached to the inside of the receptacle to provide the required attractive force. In this case, the host receptacle shield 651 need not necessarily be formed of ferromagnetic material.

Finally it should be noted that, when provided, each elongated contact may be of uniform height over the whole of its surface or, alternatively, may be stepped so long as the active surface of the contact is of uniform height.

Claims

CLAIMS:

1. A male multi-contact data connector (100) having two set of contacts (110, 120) supported on opposite surfaces of a planar substrate (130), respective contacts in each contact set being in proper spatial alignment for engaging corresponding contacts of a female receptacle (400) having an internal shield (410) and a single set of contacts that is compatible with either one of said sets of contacts, wherein: corresponding contacts in each set are spatially aligned in anti-phase relationship so as to allow the connector to be connected in two opposed orientations to said female receptacle; in each contact set there is at least one elongated contact that is permitted to make contact with the shield without impairing operability of the connector; and the at least one elongated contact in each contact set has an active surface that is offset relative to the surface of the planar substrate by a greater distance than the respective active surfaces of other contacts in said set so as to mechanically create a space between the shield and the other contacts of said set when the connector is inserted within the receptacle with the contacts of said set disposed so as not make contact with the contacts in the female receptacle.

2. The connector according to claim 1 , further comprising at least one shield contact (602) disposed on a body portion (605) of the, connector that is electrically connected directly or via electrical components to at least one elongated contact of the first or second set of contacts.

3. The connector according to claim 2, wherein the at least one shield contact is disposed along a side edge of the body portion.

4. The connector according to claim 2 or 3, wherein the at least one shield contact extends along a side edge of the body portion.

5. The connector according to claim 2, wherein the at least one shield contact is disposed on an exposed surface of the body portion.

6. The connector according to any one of claims 1 to 5, wherein the at least one shield contact is configured to reinforce the connector.

7. The connector according to any one of claims 1 to 6, wherein the at least one elongated contact is not a data contact.

8. The connector according to any one of claims 1 to 6, wherein the at least one elongated contact is a data contact and said connector further comprises a short circuit prevention device (D1, D2, 675) to prevent an electric short circuit between inactive contacts of the connector and the shield of the receptacle on inserting the connector therein.

9. The connector according to any one of claims 1 to 8, being an FCCS connector.

10. The connector according to any one of claims 1 to 9, further comprising a magnet (660) disposed on an exposed surface of the connector for securing the connector within a receptacle formed at least partially of ferromagnetic material.

11. A multi-contact male data communication connector having no outer shield and comprising: a body portion (605) for accommodating a planar substrate therein; a set of contacts (110, 120) supported on the planar substrate (130) in proper spatial alignment for engaging corresponding contacts of a female receptacle (400) having an internal shield (410); and at least one shield contact (602) supported by the body portion and configured to connect electrically to the internal shield of the female receptacle when the connector is inserted into the female receptacle.

12. The connector according to claim 11, wherein the at least one shield contact is disposed along a side edge of the body portion.

13. The connector according to claim 11 or 12, wherein the at least one shield contact extends along a side edge of the body portion.

14. The connector according to claim 11, wherein the at least one shield contact is disposed on an exposed surface of the body portion.

15. The connector according to any one of claims 11 to 14, wherein the shield contact is configured to reinforce mechanical strength of the connector.

16. The connector according to any one of claims 11 to 15, further comprising a magnet (660) disposed on an exposed surface of the body portion for securing the connector within the receptacle.

17. The connector according to claim 11 to 16, comprising first and second sets of contacts (110, 120) each supported on a respective opposing surface of the connector, wherein: corresponding contacts in each set are spatially aligned in anti-phase relationship so as to allow the connector to be connected in two opposed orientations to a female receptacle (400) having only a single set of contacts (420) that is compatible with either one of said sets of contacts.

18. The connector according to claim 17, wherein: in each contact set there is at least one elongated contact that is permitted to make contact with the internal shield of the female receptacle without impairing operability of the connector; and the at least one elongated contact in each contact set has an active surface that is offset relative to the surface of the planar substrate by a greater distance than the respective active surfaces of other contacts in said set so as to mechanically create a space between the shield and the other contacts of said set when the connector is inserted within the receptacle with the contacts of said set disposed so as not make contact with the contacts in the female receptacle.

19. The connector according to claim 18, wherein the at least one elongated contact is not a data contact.

20. The connector according to claim 18, wherein the at least one elongated contact is a data contact and said connector further comprises a short circuit prevention device (D1 , D2, 675) to prevent an electric short circuit between inactive contacts of the connector and the shield of the receptacle on inserting the connector therein.

21. The connector according to any one of claims 11 to 20, being an FCCS connector.

22. A male data communication connector comprising: a body portion (605) supporting at least one set of electrical contacts (110, 120) for engaging corresponding contacts (420) of a receptacle (400) formed at least partially of ferromagnetic material; and a magnet (660) supported by the body portion for securing electrical contact of the connector with the receptacle.

23. The data connector according to claim 22, further comprising a shield contact (602) for contacting a metal shield (410) of the receptacle thereby obviating a need for the connector to be provided with its own outer shield and wherein the magnet is adapted to exert a magnetic pull on the metal shield of the receptacle.

24. The connector according to claim 22 or 23, comprising first and second sets of contacts (110, 120) each supported on a respective opposing surface of the connector, wherein: corresponding contacts in each set are spatially aligned in anti-phase relationship so as to allow the connector to be connected in two opposed orientations to a female receptacle (400) having only a single set of contacts (420) that is compatible with either one of said sets of contacts.

25. The connector according to claim 24, wherein: in each contact set there is at least one elongated contact that is permitted to make contact with the internal shield of the female receptacle without impairing operability of the connector; and the at least one elongated contact in each contact set has an active surface that is offset relative to the surface of the planar substrate by a greater distance than the respective active surfaces of other contacts in said set so as to mechanically create a space between the shield and the other contacts of said set when the connector is inserted within the receptacle with the contacts of said set disposed so as not make contact with the contacts in the female receptacle.

26. The connector according to claim 25, wherein the at least one elongated contact is not a data contact.

27. The connector according to claim 25, wherein the at least one elongated contact is a data contact and said connector further comprises a short circuit prevention device (D1 , D2, 675) to prevent an electric short circuit between inactive contacts of the connector and the shield of the receptacle on inserting the connector therein.

28. The connector according to any one of claims 22 to 27, being an FCCS connector.