Dual Orientation Plug Connector with External Contacts

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Solution Overview

Problem

The thickness of electronic devices is limited by the size of connectors, particularly receptacle connectors, which can be bulky due to internal contacts that collect debris, and there is a need for smaller, thinner plug connectors with improved manufacturing tolerances and durability for multiple use cycles.

Innovation Solution

The development of dual orientation plug connectors with external contacts on a symmetrical connector tab and a U-shaped metallic band, featuring retention features and a contact assembly overmolded within the metallic band, allowing for reduced size, cost, and intuitive insertion orientation, and eliminating internal contacts prone to debris collection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If internal contacts are used in the receptacle connector, then electrical connection is achieved, but the connector becomes bulky and collects debris

Engineering Contradiction:

Improveelectrical connectionVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The patent inverts the traditional connector design by using external contacts instead of internal contacts. The receptacle connector features contacts that extend outward from the housing rather than being enclosed within an insertion cavity, eliminating the bulky cavity structure while maintaining electrical connection functionality.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent extracts the contacts from the internal cavity and positions them externally on the connector housing. This removal of internal contacts eliminates the insertion cavity that would otherwise be required, reducing the overall connector volume and preventing debris accumulation.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-affected harmful factors

If a metal shield surrounds the plug connector contacts, then protection against electrical interference is provided, but the plug connector thickness increases

Engineering Contradiction:

Improveelectrical interference protectionVSAvoidplug connector thickness

Core Design Contradiction:

Object-affected harmful factorsVSLength of stationary object

Solution Approach 1:

The patent eliminates the traditional metal shield that surrounds contacts in a cavity. Instead, contacts are positioned externally without requiring a enclosing shield structure, thereby reducing the plug connector thickness while maintaining electrical connection functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Rather than enclosing contacts within a shielded cavity, the patent inverts the approach by exposing contacts externally without a surrounding shield, achieving the same electrical connection function with reduced thickness.

Inventive Principle:

Principle #13The other way round (Inversion)

3Length of stationary object

If receptacle connectors are made smaller and thinner, then device thickness is reduced, but manufacturing tolerances become more difficult to achieve

Engineering Contradiction:

Improvereceptacle connector thicknessVSAvoidtolerance achievement

Core Design Contradiction:

Length of stationary objectVSManufacturing precision

Solution Approach 1:

The patent segments the connector into distinct functional elements: external contacts mounted on the housing surface, a simplified body structure, and separate retention features. This segmentation allows each component to be manufactured and assembled independently, making it easier to achieve precise tolerances in smaller, thinner connectors.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By inverting the design to use external contacts rather than internal contacts, the patent simplifies the overall structure, reducing the number of manufacturing steps and tolerance-critical features required, thereby facilitating easier manufacturing of smaller connectors.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If internal contacts are used, then electrical connection is achieved, but debris collection and trapping occurs

Engineering Contradiction:

Improveelectrical connectionVSAvoiddebris collection

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent extracts contacts from the internal insertion cavity and positions them externally on the connector housing. This eliminates the enclosed cavity that would otherwise trap debris, allowing debris to be easily removed or prevented from accumulating while maintaining electrical connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of enclosing contacts within a cavity that traps debris, the patent inverts the design by exposing contacts externally, preventing debris accumulation while maintaining the same electrical connection function.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS9153920B2Plug connector having an over-molded contact assembly with a conductive plate between two sets of electrical contacts

Publication Date: 2015.10.06 APPLE INC

AI summary

A dual orientation plug connector having a tab portion with first and second opposing exterior surfaces that are substantially identical, parallel and opposite each other. Each exterior surface may have a plurality of electrical contacts. A substantially u-shaped metallic band surrounds a portion of the periphery of the plug connector. A contact assembly having an upper contact carrier, intermediate conductive plate and lower contact carrier may be disposed within the tab portion of the plug connector. A circuit assembly may be disposed within a body portion of the plug connector and electrically coupled to the plurality of electrical contacts.