U.S. patent application number 13/689098 was filed with the patent office on 2013-04-11 for optical connection of devices.
This patent application is currently assigned to Apple Inc.. The applicant listed for this patent is Apple Inc.. Invention is credited to Albert J. Golko, Eric S. Jol, Jason S. Sloey, Ian Spraggs.
Application Number | 20130087690 13/689098 |
Document ID | / |
Family ID | 44279865 |
Filed Date | 2013-04-11 |
United States Patent
Application |
20130087690 |
Kind Code |
A1 |
Sloey; Jason S. ; et
al. |
April 11, 2013 |
OPTICAL CONNECTION OF DEVICES
Abstract
Optical connectors, adapters, and devices with such are
provided. Optical connectors can have a relatively large diameter
for the optical interface. For example, optical connectors can
include a collector for receiving optical signals at a large
opening and providing signals to a photodiode at a small opening of
the collector. Such optical connectors with a large diameter for an
optical interface can advantageously provide reduced alignment
tolerances and/or provide high data rates. Adapters can use a
collector to convert optical data signals from a large width fiber
to a smaller width fiber. An optical connector can be in a docking
station, and lie underneath a bottom surface of a recess in the
docking station.
Inventors: |
Sloey; Jason S.; (Cedar
Park, TX) ; Golko; Albert J.; (Saratoga, CA) ;
Jol; Eric S.; (San Jose, CA) ; Spraggs; Ian;
(San Francisco, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Apple Inc.; |
Cupertino |
CA |
US |
|
|
Assignee: |
Apple Inc.
Cupertino
CA
|
Family ID: |
44279865 |
Appl. No.: |
13/689098 |
Filed: |
November 29, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US11/38533 |
May 31, 2011 |
|
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|
13689098 |
|
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|
61350430 |
Jun 1, 2010 |
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61379335 |
Sep 1, 2010 |
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Current U.S.
Class: |
250/216 ; 385/31;
385/93 |
Current CPC
Class: |
H01L 31/0232 20130101;
G02B 6/389 20130101; G02B 6/4292 20130101; G02B 6/3817 20130101;
G02B 6/4204 20130101; G02B 6/4246 20130101; G02B 6/262
20130101 |
Class at
Publication: |
250/216 ; 385/31;
385/93 |
International
Class: |
G02B 6/42 20060101
G02B006/42; G02B 6/26 20060101 G02B006/26; H01L 31/0232 20060101
H01L031/0232 |
Claims
1. A connector that connects with a corresponding connector, the
connector comprising: a light collector having a first opening and
a second opening opposite the first opening, the first opening for
receiving optical data signals, wherein the second opening is
smaller than the first opening; and an active optical component
configured to receive the optical data signals from the second
opening and to convert the optical data signals to electrical
signals, wherein the active optical component has a size
substantially the same size as the second opening.
2. The connector of claim 1, further comprising: a lens at the
first opening of the light collector.
3. The connector of claim 2, wherein the lens is made of
sapphire.
4. The connector of claim 2, wherein the lens and light collector
are formed as an integral piece, and wherein the lens and light
collector are made of a glass.
5. The connector of claim 2, further comprising: an optically clear
adhesive between the lens and the light collector.
6. The connector of claim 2, wherein the lens protrudes from an
external surface of the connector.
7. The connector of claim 1, further comprising: a receiving lens
device optically coupled with the first opening of the light
collector and configured to receive optical signals from the
corresponding connector.
8. The connector of claim 7, wherein the receiving lens device
includes aligning elements that receive an optical device of the
corresponding connector and aligns the optical device with a lens
of the lens device.
9. The connector of claim 1, wherein the active optical component
is a photodiode.
10. The connector of claim 1, wherein the light collector is a
parabolic concentrator.
11. An adapter comprising: a first connector interface for
receiving optical data signals; a light collector having a first
opening and a second opening opposite the first opening, the first
opening for receiving the optical data signals, wherein the second
opening is smaller than the first opening; a first light guide that
receives optical data signals at the second opening; and a second
connector interface for transmitting the optical data signals via
the first light guide to a corresponding connector interface.
12. The adapter of 11, wherein the first connector interface
includes the light collector.
13. The adapter of 11, further comprising a second light guide
having a diameter larger than the first light guide, the second
light guide optically coupled with the first opening of the light
collector.
14. The adapter of 13, wherein the first connector interface
includes a receiving lens that is optically coupled with the second
light guide.
15. The adapter of 11, wherein the light collector is a parabolic
concentrator.
16. A docking station comprising: a recess for receiving an
electronic device, the recess having a substantially planar bottom
surface and having alignment features; and a first optical
connector having a receiving lens underneath the bottom surface of
the recess, the receiving lens configured to receive optical
signals from a second optical connector on a bottom of the
electronic device, wherein the alignment features are configured to
hold the electronic device in a first position such that the first
optical connector and the second optical connector are adjacent to
each other in the first position.
17. The docking station of claim 16, wherein the first optical
connector includes an active optical component that converts the
received optical signals into electrical signals.
18. The docking station of claim 17, wherein the active optical
component is a photodiode.
19. The docking station of claim 16, wherein the bottom surface is
opaque to visible light.
20. The docking station of claim 16, wherein the alignment features
include four inner walls of the recess.
21. The docking station of claim 16, wherein the first optical
connector includes a light collector having a first opening and a
second opening opposite the first opening, the first opening for
receiving optical data signals, wherein the second opening is
smaller than the first opening.
22. The docking station of claim 21, wherein the light collector is
a parabolic concentrator.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a Continuation of PCT Application No.
PCT/US2011/038533, International Filing date May 31, 2011 which
claims priority to U.S. Provisional Patent Application Nos.
61/350,430, entitled "Hybrid Optical Connector," by Jason Sloey,
filed Jun. 1, 2010 and 61/379,335, entitled "Hybrid Optical
Connector," by Sloey et al., filed Sep. 1, 2010, the entire
contents of which are herein incorporated by reference for all
purposes.
[0002] This application is also related to the concurrently filed
and commonly owned Continuation patent application entitled "Hybrid
Optical Connector" by Sloey, et al. (Attorney Docket No.
90911-P8705US1-788546, the entire contents of which are herein
incorporated by reference for all purposes.
BACKGROUND
[0003] The present invention relates generally to connectors and
apparatus used to carry optical signals, and more specifically to
connectors that can carry both optical and electrical signals and
to optical connectors with advantageous properties.
[0004] Some devices, such as CD players, can output optical
signals. Cables with optical connectors (e.g. Toslink) and with
optical fiber carry these optical signals to another device (e.g. a
stereo receiver). Optical signals have certain advantages, such as
no electromagnetic interference. But optical signals also have
limitations as to the functionality and support that can be
provided. Current optical connectors also have limitations.
[0005] Therefore, it is desirable to have connectors that can carry
optical signals as well as other signals. It is also desirable to
have improved optical connectors that can have various advantageous
properties, such as easily connected, easily maintained, and
supporting high data rates.
SUMMARY
[0006] Accordingly, certain embodiments of the present invention
can provide optical connectors with a relatively large diameter for
the optical interface, while still providing high data rates (e.g.
over 1 Gbps). Optical connectors can include a collector for
receiving optical signals at a large opening and providing signals
to an optical receiver at a small opening, where the optical
receiver converts the optical signals to electrical signals.
Optical connectors with a large diameter for an optical interface
can also advantageously provide reduced alignment tolerances.
[0007] According to another embodiment, a connector connects with a
corresponding connector. The connector includes a light collector
and an active optical component. The light collector has a first
opening and a second opening opposite the first opening. The first
opening receives optical data signals, and the second opening is
smaller than the first opening. The active optical component is
configured to receive the optical data signals from the second
opening and to convert the optical data signals to electrical
signals. The active optical component has a size substantially the
same size as the second opening.
[0008] According to another embodiment, an adapter includes a first
connector interface, a light collector, a first light guide, and a
second connector interface. The first connector interface for
receiving optical data signals. The light collector has a first
opening and a second opening opposite the first opening. The first
opening is for receiving optical data signals, and the second
opening is smaller than the first opening. The first light guide
that receives optical data signals at the second opening. The
second connector interface is for transmitting the optical data
signals via the first light guide to a corresponding connector
interface.
[0009] According to another embodiment, a docking station includes
a recess and a first optical connector beneath a bottom surface of
the recess. The recess receives an electronic device and has a
substantially planar bottom surface, as well as alignment features.
The first optical connector has a receiving lens underneath the
bottom surface of the recess. The receiving lens is configured to
receive optical signals from a second optical connector on a bottom
of the electronic device. The alignment features are configured to
hold the electronic device in a first position such that the first
optical connector and the second optical connector are adjacent to
each other in the first position.
[0010] A better understanding of the nature and advantages of the
present invention may be gained with reference to the following
detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a block diagram illustrating a connector system
for communicating optical and electrical signals according to
embodiments of the present invention.
[0012] FIG. 2A shows a male plug connector at an end of a cable for
communicating optical and electrical signals according to
embodiments of the present invention.
[0013] FIG. 2B shows a female receptacle connector for
communicating optical and electrical signals according to
embodiments of the present invention.
[0014] FIG. 3 shows a lead frame for a female connector that has
electrical components for converting between electrical signals and
optical signals according to embodiments of the present
invention.
[0015] FIG. 4 shows pins of a lead frame assembly attached to a
substrate having at least one active optical component according to
embodiments of the present invention.
[0016] FIG. 5A shows a cross-sectional side view of substrate at
the connection point of an optical transmitter according to
embodiments of the present invention.
[0017] FIG. 5B shows a cross-sectional side view of substrate at
the connection point of an optical receiver according to
embodiments of the present invention.
[0018] FIG. 6A is a perspective view of a female connector capable
of communicating electrical and optical signals according to
embodiments of the present invention.
[0019] FIG. 6B is a front view of the female connector capable of
communicating electrical and optical signals according to
embodiments of the present invention.
[0020] FIG. 7 is a flowchart of a method for making a female
connector according to embodiments of the present invention.
[0021] FIG. 8 shows an adapter for converting optical data signals
from a large width fiber to a smaller width fiber according to an
embodiment of the present invention.
[0022] FIG. 9A illustrates a system with a docking station having
at least one active optical component and an electronic device
having at least one active optical component according to
embodiments of the present invention.
[0023] FIG. 9B is a cross-sectional side view of electronic device
and docking station according to embodiments of the present
invention.
[0024] FIG. 10 is a cross-sectional view of a male connector having
a spring mechanism for an optical element mated with a
corresponding female receptacle connector according to embodiments
of the present invention.
[0025] FIG. 11A is a cross-sectional view of an optical element
having a proud surface relative to an external surface of the
connector according to embodiments of the present invention.
[0026] FIG. 11B is a magnified view of the surface of the optical
element and the external surface according to embodiments of the
present invention.
[0027] FIG. 12A is a top view of a hybrid male plug connector with
a central connector according to embodiments of the present
invention.
[0028] FIG. 12B shows a side view of hybrid male plug connector
according to embodiments of the present invention.
[0029] FIG. 12C shows a front view of hybrid male plug connector
according to embodiments of the present invention.
[0030] FIG. 12D is an exploded view of hybrid male plug connector
according to embodiments of the present invention.
[0031] FIG. 13 is a perspective view of a hybrid male plug
connector with an active optical component according to embodiments
of the present invention.
[0032] FIG. 14 shows an exploded view of a passive male plug
connector according to embodiments of the present invention.
[0033] FIG. 15 shows an exploded view of an active male plug
connector according to embodiments of the present invention.
[0034] FIGS. 16 and 17A-17C are perspective, front, top, and side
views of a female hybrid connector 1500 according to embodiments of
the present invention.
[0035] FIG. 18 shows an exploded view of a female receptacle
connector according to embodiments of the present invention.
[0036] FIGS. 19A and 19B shows various views of a female receptacle
connector according to embodiments of the present invention.
[0037] FIG. 20A is a simplified perspective view of a connector
insert for hybrid male plug connector 50, while FIGS. 20B-20D are
simplified bottom, front and side plan views, respectively,
according to one embodiment of the present invention.
DETAILED DESCRIPTION
[0038] Certain embodiments can provide connector systems that carry
electrical signals and optical signals in a single connector. An
electro-optical connector can be made in a cost effective manner
and for easy incorporation into electronic devices and apparatus. A
male electro-optical connector can have an electrical insert
portion that fits into a receptacle of a female electro-optical
connector to provide a structural connection, thereby allowing the
optical interface to be near a front of the connectors for easy
maintenance.
[0039] Also, certain embodiments can provide optical connectors
with a relatively large diameter for the optical interface, while
still providing high data rates (e.g. over 1 Gbps). Optical
connectors can include a collector for receiving optical signals at
a large opening and providing signals to an optical receiver at a
small opening, where the optical receiver converts the optical
signals to electrical signals. Optical connectors with a large
diameter for an optical interface can also advantageously provide
reduced alignment tolerances.
I. Overview
[0040] FIG. 1 is a block diagram illustrating a connector system
100 for communicating optical and electrical signals according to
embodiments of the present invention. Having electrical signals can
allow legacy support for older interface standards. Electrical
signals can also provide power to electronic devices. Note that
FIG. 1 is not drawn to any particular scale.
[0041] Electronic device 110 includes an electro-optical connector
120, which may be any female connector as described herein.
Electronic device 110 may be any device that sends or receives data
(e.g. audio or video). For example, electronic device 110 may be a
media player that sends audio and video signals to another device
for displaying the video and playing the audio. Electro-optical
connector 120 may be a female or male connector, or have aspects of
both.
[0042] Electro-optical connector 120 includes electrical contacts
122 and an active optical component 124. Electrical contacts 122
can receive and send electrical signals directly from electrical
contacts of a corresponding connector as can occur in a purely
electrical connector. Active optical component 124 converts
electric signals from the electronic device into optical signals
and/or converts optical signals received from another device into
electrical signals that are usable by the electronic device. In
various embodiments, the active optical component can be an optical
transmitter, an optical receiver, or an optical transceiver that
includes both an optical transmitter and an optical receiver in a
single. Electro-optical connector 120 can have any number of active
optical components and may include lens devices for transferring
light to active optical component 124 (or active optical component
124 may include such lens devices). In one embodiment,
electro-optical connector 120 has two separate active optical
components, one for transmitting and one for receiving.
[0043] Electrically conductive pins 145 can travel from a circuit
140 to connector 120. A first set of pins 145 can carry electrical
signals to be converted by active optical component 124, or receive
electrical signals that result from optical signals being converted
to electrical signals. Thus, in once aspect, electronic device 110
(e.g. through circuit board 140) can receive electrical signals in
a same manner as for a purely electrical connector. Accordingly,
electronic device 110 could be built the same for electrical,
optical, or electro-optical connectors. A second set of pins 145
can carry electrical signals from circuit board 140 to electrical
contacts 122. In one embodiment, electrical contacts 122 are part
(e.g. a front end) of the second set of pins 145.
[0044] Electro-optical connector 120 can receive signals from a
first connector 160 of cable 150. First connector 160 may be any
male connector as described herein. Cable 150 has optical fibers
(e.g. glass or plastic fibers) for carrying optical signals to or
from electro-optical connector 120. A passive optical device 164 of
first connector 160 can receive or carry the optical signals to
active optical component 124, or to a lens device of connector 120
that is optically coupled with active optical component 124.
Optical device 164 is passive in that the optical signals are not
converted to/from electrical form, but stay in optical form while
being carried. In one embodiment, passive optical device 164 can be
an extension of an optical fiber or an additional device such as a
lens.
[0045] Cable 150 can also have electrical wires for carrying
electrical signals. Electrical contacts 162 connect with electrical
contacts 122 when first connector interface 160 is mated with
connector 120. In one embodiment, electrical contacts 162, and at
least part of a housing (an insulator core) in which contacts 162
are embedded, are used to provide alignment for the optical
interface. For example, electrical contacts 162 can fit inside
connector 120 to provide alignment of active optical component 124
and passive optical device 164. Such alignment can allow the
optical devices to be at a front of the connectors.
[0046] Having the optical devices at a front of a connector can
allow easy cleaning and maintenance of the optical interface. For
example, active optical component 124 may be coupled with passive
elements (e.g. a lens and/or a collector) that are also part of
connector 120. The passive elements can lie between passive optical
device 164 and active optical component 124. These passive elements
can be maintained easier when they lie at a front of connector
120.
[0047] In an embodiment with a single active optical component, the
component can be a transceiver. In this embodiment, different
optical frequencies (e.g. wavelength of 850 nm in one direction and
1350 nm in the other) can be used. Filters or other mechanisms can
be used to reduce optical cross talk, e.g., by blocking light from
the transmitting part to the receiving part.
[0048] In some embodiments, cable 150 has two fiber channels, one
for each direction of transmission. Each of these channels can be a
multi-core fiber, where multiple fibers transmit light in the same
direction. For example, the total diameter can be 200-500 microns,
with each fiber having a diameter of about 50-100 microns (e.g. 300
total diameter and 100 individual diameters). A multi-core fiber
can provide low light loss when bent (e.g. due to the small
individual fibers), and the total diameter can provide a large
total area for light transmission, which can help with alignment at
the connectors. In one embodiment, the total diameter of a
multi-core fiber is about the same value as the diameter of
receiving lens on connector 120.
[0049] In one embodiment, active optical component 124 may work
with electromagnetic radiation at a specific wavelength, but any
wavelength may be chosen. For example, a wavelength of 650 nm may
be used when plastic fibers are to be used in cables, and a
wavelength of 850 nm may be used when glass fibers are to be used,
as these wavelengths have low loss for these respective materials.
But 850 nm may also be used for plastic fibers when cables are not
expected to be long (e.g. 5 m or less).
[0050] FIG. 2A shows a male plug connector 260 at an end of a cable
for communicating optical and electrical signals according to
embodiments of the present invention. In one embodiment, male plug
connector can correspond to first connector interface 160.
[0051] Cable 250 includes male plug connector 260 for sending and
receiving optical signals and electrical signals. Housing 270
includes an insert portion 274 and base portion 272. Electrical
signals can be provided with electrical contacts at contact
locations in insert portion 274 of housing 270. The electrical
contacts can be embedded in the insert portion, e.g., embedded so
that the housing surrounds the contacts or embedded in an inner
surface, thereby forming the contacts on the inner surface. Base
portion 272 can include a passive optical component 274 for
carrying optical signals. In one embodiment, base portion 272 is
made integral with insert portion 274. In another embodiment, base
portion 272 is a separate piece from insert portion 274.
[0052] In various embodiments, passive optical device 274 can be an
extension of an optical fiber in cable 250 or an additional device
such as a lens. In one embodiment, male plug connector 260 can also
include an active optical component, and thereby can have only
electrical wires, and no optical fibers. In one embodiment, the
electrical contacts and electrical wires may be omitted when only
optical signals are to be carried. In instances where cable 250 is
only to transfer electrical signals, passive optical component may
be omitted, or just not connected with any optical fibers as the
cable would not have any. The other end of such a cable could be
any standard electrical connector, e.g., USB.
[0053] FIG. 2B shows a female receptacle connector 220 for
communicating optical and electrical signals according to
embodiments of the present invention. The connection of male plug
connector 260 to female connector 220 can provide communication of
both electrical and optical signals. The electrical signals can be
communicated via electrical contacts in insert portion 274 of male
plug connector, which can contact with electrical contacts 222 when
the connectors are mated. Electrical contacts 22 (e.g. acting as a
front end of a pin) can transmit the electrical signals to pins at
a back end of the female connector 220, and then to a circuit board
to which the pins can be electrically connected (e.g. soldered).
The optical signals can be communicated via passive optical
components 264 to optical links 240. In various embodiments, the
passive optical components 264 can include a lens optically coupled
with a fiber or the front end of a fiber, where the front end can
be polished.
[0054] Insert portion 244 of housing 240 can fit (at least
partially) inside opening 205 of female connector 220. The
insertion of insert portion 244 can provide a structural connection
between male plug connector 260 and female connector 220. This
structural connection can provide alignment of optical links 240
with passive optical components 264.
[0055] An optical link of optical links 240 can include an active
optical component and passive optical components. In one
embodiment, one optical link can include one active optical
component (e.g. in the optical link on the left) for transmitting
optical signals and the other optical link can include another
active optical component (e.g. in the optical link on the right)
for receiving optical signals. Passive optical components (e.g. a
lens) can carry the light from a front of female connector 220 to
the active optical component.
[0056] In embodiments where the optical links 240 have a lens that
is at the front of the connector (e.g., within 1 cm of the front
edge or less than 1/4 the depth of opening 205), optical links 240
can be easily maintained. For example, any debris on the lens can
be brushed away. Also, the external surface of the lens can be
cleaned and/or polished to provide good transmission of optical
signals. In one aspect, the use of insert portion 274 to provide
structural connection and broad alignment allows a surface of
optical links to be near the front edge of connector 220.
[0057] In another embodiment, optical links 240 can be on one side
and the electrical pins could be on the other side. In yet another
embodiment, electrical contacts 222 can be separated and at the
edges, with optical links 240 in the middle.
II. Female Hybrid Connector with Centered Optical Elements
[0058] FIG. 3 shows a lead frame 300 for a female connector that
has electrical components for converting between electrical signals
and optical signals according to embodiments of the present
invention. As shown, lead frame 300 is at an intermediate point of
manufacturing. As shown, lead frame has optical elements in the
center. Examples of an optical element include a fiber, lens,
collector, or active optical component. Other embodiments herein
(e.g. female receptacle connector 220 can have the optical elements
at the edges). Embodiments with optical elements at the edges can
have intermediate stages that are similar to lead frame 300.
[0059] Carrier 310 holds the pins 315 and 317. Carrier 310 and pins
35 and 317 can be made of an electrically conductive material (e.g.
copper). Both sets of pins can carry electrical signals, but pins
315 are configured to carry electrical signals to/from electrical
contacts of a corresponding connector. Pins 317 are configured to
carry electrical signals to/from active optical components on
substrate 320. Substrate 330 includes active optical components and
lenses 340 and 345. Lenses 340 and 345 receive and transmit light
to optical devices (e.g. lenses) of the corresponding
connector.
[0060] Although 16 total pins are shown, there can be any number of
total pins, which can be split up in any manner between pins 315
and pins 317. Pins 315 and 317 can correspond to pins 145 of FIG.
1. As used herein, the term "pin" is used to refer to a conductive
material that can carry electrical signals. Part of the pins can
come in contact with pins of another connector, and these pins
(e.g. pins 315) may also be called contacts.
[0061] Pins 317 eventually can be connected with a circuit board
(e.g. circuit board 140 of FIG. 1) and communicate electrical
signals to the circuit board, where the electrical signals
correspond to optical signals (i.e. converted from or to be
converted into the optical signals). The same circuit board can
also be connected with pins 315 and can receive electrical signals
on pins 315, wherein the electrical signals are received from
electrical contacts of the corresponding connector.
[0062] In one embodiment, the back ends of pins 315 and 317 can lie
in a single row. After carrier 310 is cut away, a circuit board can
be positioned in a similar manner to carrier 310. Thus, the circuit
board can lie behind the connector, thereby allowing the electronic
device to be thinner. Also, having the pins in a single row can
allow a connection of the pins to an edge of the circuit board,
thereby allowing the circuit board to be smaller.
[0063] FIG. 4 shows pins 417 of a lead frame assembly 400 attached
to a substrate 430 having at least one active optical component
according to embodiments of the present invention. Lead frame
assembly 400 includes active optical components and pins 417 that
carry the electrical signals to/from the active optical components.
In one embodiment, lead frame assembly 400 corresponds to the
substrate 330 and attached components of FIG. 3.
[0064] A substrate 430 is attached to pins 417. For example, pins
417 can be electrically bonded (e.g. soldered) to a pad on the back
of substrate 430. Pins 417b can send signals to substrate 430. In
one embodiment, the signals on pins 417b can include power, ground,
and two data signals (e.g. data signals). Traces in substrate 430
can send the electrical signals to a laser integrated circuit (IC)
and other electrical components 455. In one embodiment, laser IC
and EE components 455 can be put onto one IC as opposed to multiple
ICs.
[0065] Laser IC and EE components 455 can convert the electrical
signals to signals that drive an optical transmitter (e.g. a
laser). The drive signals can include power, ground, and one data
signal. The power signal can be refined, if necessary, to provide a
proper power and voltage to the optical transmitter. In one
embodiment, the optical transmitter can be behind the transmission
lens 445. The optical transmitter can then provide optical signals
to transmission lens 445, and transmission lens 445 can then
provide the converted optical signals to a corresponding lens.
[0066] A receiving lens 440 can receive optical signals from the
corresponding connector. A collector (e.g. parabolic concentrator
460) can collect the light and provide the light to an optical
receiver (e.g. a photodiode), which converts the optical signals
into electrical signals. A photodiode IC and EE components 458 can
receive the electrical signals and modify them to confirm to
specifications of the electronic device in which pins 417a are
connected. Photodiode IC and EE components 455 can be put onto one
IC or onto multiple ICs.
[0067] In some embodiments, IC and EE components 458 can include a
transimpedance amplifier (which converts photocurrent to electrical
current) and limiting amplifier. The limiting amplifier can take
electrical current and convert it into a voltage signal. The
voltage signal can then be provided to a circuit board on pins 417a
to provide the proper data that was originally conveyed in the
received optical signals.
[0068] In one embodiment, middle pins 417c can also provide ground
to substrate 430. The ground can be used for devices on the
substrate and/or for shielding of certain devices. For example,
ground plate 460 can provide shielding of the active optical
components on the back of substrate 430. Ground plate 460 can be
created at the same time that pins 417 are stamped.
[0069] For DisplayPort or other formats that have multiple signals
(channels), the electrical signals on pins 417a or 417b could be
combined and put into a single line before being sent to the
substrate assembly (substrate 420 and attached devices). In another
embodiment, electronics on the substrate could perform the
combining (e.g. in components 455).
[0070] In one embodiment, the substrate assembly is created before
being attached to pins 417. For example, components 455 and 458 can
be attached to substrate 430 before it is attached to pins 417. For
example, components 455 and 458 can be bonded (e.g. to pads) on the
front of substrate 430, which can have traces that carry signals
between the components.
[0071] In another embodiment, the substrate is ceramic for
providing high insulation between electronic components to keep
capacitive coupling low. Ceramic material can be molded, and then
components attached. Ceramic molding can reduce capacitive coupling
between the differential signals going into laser IC and EE
components 455, or the differential signal coming out of photodiode
IC and EE components 458. Some embodiments can provide up to 10
gigabit/second throughput. There is no electromagnetic interference
for optical signals, but after conversion to electrical signals,
electromagnetic interference and crosstalk can exist. As the
ceramic has a high dielectric constant, the electrical components
can be placed closer together and the traces in the ceramic can be
placed closer together.
[0072] FIG. 5A shows a cross-sectional side view of substrate 530
at the connection point of an optical transmitter 570 according to
embodiments of the present invention. In one embodiment, substrate
530 can correspond to substrate 430 of FIG. 4. Substrate 530 can be
machined to have certain shapes for the attachment of devices to
it.
[0073] In one embodiment, a laser 570 or other optical transmitter
is mounted to the back of substrate 530. A pocket has been cut into
the back of substrate 530. Laser 570 is placed inside the pocket,
which allows ground plate 560 (which can correspond to ground plate
460) to cover laser 570. Ground can be received at ground plate 560
from pins 517c. In one aspect, ground plate 560 can cover laser 570
while remaining flat, thereby providing easy manufacturing. In one
embodiment, substrate 530 is ceramic, which can be machined to
higher tolerances than plastic (e.g. FR4).
[0074] A hole 575 formed through substrate 530 can allow light from
laser 570 to shine through to transmission lens 545. For example,
laser 570 can shine light through hole 575 to transmission lens 545
when electrical signals are received from other electronics on
substrate 530. In one embodiment, laser 570 is a vertical cavity
surface emitting laser (VACSEL).
[0075] Transmission lens 545 can include a barrel shaped tube with
a lens (e.g. a curved lens), which can provide light out in a
generally parallel direction. The front of substrate 530 can be
machined to receive the back end of transmission lens 545. For
example, the very back end of lens 545 can be made to fit into hole
575. In one embodiment, an air gap can exist between laser 570 and
transmission lens 454. In another embodiment, the back of
transmission lens 545 can be in contact with laser 570.
[0076] FIG. 5B shows a cross-sectional side view of substrate 530
at the connection point of an optical receiver 580 according to
embodiments of the present invention. A receiving lens 545 can
receive optical signals from an optical device of a corresponding
connector.
[0077] As shown receiving lens 545 is attached to or part of
collector 547 (e.g. a parabolic concentrator), which collects light
and provides the light to a photodiode 580 or other optical
receiver. Substrate 530 can be machine to have pockets on the front
and the back in a similar manner as the pockets for laser 570 and
transmission lens 545. The photodiode 580 creates electrical
signals from the optical signals. The electrical signals can be
modified with other electronics and provided to a circuit board via
pins 517a.
[0078] Collector 547 has a large opening at receiving lens 545 and
a small opening at substrate 530. Collector 547 can be molded,
e.g., from plastic. Light is delivered to an active area of
photodiode 580 through the small opening, which can allow
photodiode 580 to be small, thus reducing its capacitance. Thus,
light is collected at a larger diameter and delivered at a smaller
diameter. This collection of light can allow more light to be
provided to photodiode 580 than if receiving lens 545 was the same
size as photodiode 580.
[0079] In one aspect, since receiving lens 545 is relatively large,
the alignment between receiving lens 545 and an optical device
(e.g. a fiber, lens, or fiber/lens combination) of the
corresponding connector is not as crucial. For example, when light
leaves the optical device of the corresponding connector, the light
diffuses out and might miss the lens. As collector 547 can be made
wide (e.g. wider than the optical device), misalignment can still
not cause a significant amount of light to be lost. In this manner,
some misalignment can be accommodated while still providing a
functioning connector.
[0080] The capacitance of photodiode 580 can increase as the active
area of photodiode 580 gets bigger. A photodiode with an active
area the same size as receiving lens 545 would have a large
capacitance. A high capacitance causes problems at high data rates.
Thus, for high data rates, such a large photodiode would be
problematic. In one embodiment, photodiode 580 has a capacitance of
0.6 pf or less.
[0081] Accordingly, collector 547 can allow the use of a smaller
photodiode, so that higher data rates can be achieved, while still
allowing relatively large alignment tolerances. In one embodiment,
the alignment tolerance can be 150 microns. For example, a 150
micron change in alignments off-axis will not result in diminished
operation for the transmission of the optical signals.
[0082] Along with providing larger tolerances for alignment,
collector 547 can accommodate cables with larger fibers. For
example, a fiber in the connecting cable can have a relatively
large diameter (e.g., about 200 to 500 microns), as opposed to
smaller standards (e.g. 50-80 microns). This larger diameter can be
less susceptible to scratches and debris (such as dust, hair, or
lint). Collector 547 can be designed specifically for a particular
sized fiber. The shape of collector 547 can be dependent on the
size (e.g. width and shape) of the large opening, the size of the
small opening (which may correspond to the size of photodiode 580),
and the wavelength of the light being used.
[0083] To provide fine alignment of the optical interface,
receiving lens 545 and/or transmission lens 545 can include an
aligning element 548. Aligning element 548 can be angled so that
front edges of the fiber (or lens over the fiber) of the
corresponding connector are moved toward the center of receiving
lens 545. Other alignment features, such as the shape of the plug
(see FIG. 2), can help to provide initial alignment to get the
front of the fiber (e.g. passive optical component 264) close to
receiving lens 545. Thus, aligning element 548 can provide lateral
alignment of the optical interface.
[0084] To ensure that the corresponding fiber or other optical
element makes contact with aligning elements 548, the corresponding
connector (e.g. male plug connector 260) can have a spring (e.g. a
coil spring) that pushes the optical element forward to make
contact with aligning element 548. The lens device may have angled
aligning elements that engage aligning element 548. A combination
of the spring and the aligning element 658 can control the gap
between the fiber and receiving lens 545 to be within a
tolerance.
[0085] In one embodiment, receiving lens 545 can have a rounded
shape to provide some focusing of the light from the fiber toward
the lens so that the light does not escape. In another embodiment,
receiving lens 545 and collector 547 may be a single piece (e.g. an
integral piece of glass). In yet another embodiment, receiving lens
545 may be a separate piece from collector 547. For example,
receiving lens 545 could be made of sapphire, glass, clear
ceramics, or harder material to prevent scratching, where as
collector 547 could be made of plastic. In another aspect, a
coating could be applied to receiving lens 545. Receiving lens 545
can be close to the end of the connector to allow for easy
replacement.
[0086] FIG. 6A is a perspective view of a female connector 600
capable of communicating electrical and optical signals according
to embodiments of the present invention. FIG. 6B is a front view of
the female connector 600 capable of communicating electrical and
optical signals according to embodiments of the present invention.
Female connector 600 may be a finished connector that can be put
into an electronic device, docking station, or other device.
[0087] In one embodiment, female connector 600 has an insulator
core 610. Insulator core 610 may be created by applying an overmold
to a lead frame assembly (e.g. as shown in FIG. 3 without carrier
310). For example, a plastic housing could be molded over pins 617,
a substrate with active optical components, and pins that connect
with the substrate. Insulator core 610 can cover the electronics
(e.g. electrical components 455 and 458) on the front of the
substrate, and cover part of lenses 640 while still leaving the
front of lenses 640 exposed.
[0088] Pins 617 and pins that service the active optical components
of the substrate may be exposed in the back female connector 600,
prior to incorporation into a device. A shell 650 can be placed
around insulator core 610, or at least a front part of insulator
core 610. Shell 650 can be made of metal in order to shield pins
617 from electromagnetic interference. In one embodiment, a front
edge of female connector 600 can be the front edge of insulator
core 610, which may coincide with a front edge of shell 650.
[0089] In one embodiment, lenses 640 could be added in after
insulator core 610 is over molded. For example, insulator core 640
could be drilled to form holes where lenses 640 are to be placed.
In one aspect, the substrate would already have the holes in the
proper place, and thus just the overmold may need to be drilled. In
another embodiment, insulator core 610 could be formed with a space
for the lenses to be fit. As lenses 640 can have their front
surface at a front of the connector, lenses 640 can be cleaned
easily to ensure continued operation.
[0090] Female connector 600 can have alignment features of an
opening 605 for an insert portion of a male plug connector (e.g.
insert portion 274). Fine alignment of the optical interface can be
provided by aligning elements of lenses 640 (e.g. aligning element
548). Thus, alignment features of female connector 600 can be
sufficient to provide proper alignment of the optical interface. In
some embodiments, the height and width of shell 650 is consistent
with connectors that are purely electrical.
III. Manufacturing of Female Hybrid Connector
[0091] FIG. 7 is a flowchart of a method 700 for making a female
connector according to embodiments of the present invention. Method
700 can be used to create various intermediate assemblies and
connectors as shown in FIGS. 3-6.
[0092] In block 710, a lead frame having pins is formed. Lead frame
can be made from a single piece of conductive material. For
example, a strip of conductive material can be stamped into a shape
that has a carrier piece (e.g. carrier 310) and a plurality of pins
(e.g. pins 315 and 317). The plurality of pins can include a first
electrical set (e.g., 315) and a second optical set (e.g. 317) of
pins. The different sets may be designated for different types of
electrical signals (e.g. one set may be for electrical signals that
are communicated via an optical interface). The pins may be of
varying length and shape.
[0093] The plurality of pins can extend from the carrier piece in
the same plane as the carrier piece. In one aspect, there may be
gaps between certain pins. For example, the gaps may be the same as
the gaps between pins 417a or 417b and pins 417c. In one
embodiment, one or more of the optical pins may have a plate at the
end of them, e.g. ground plate 460. The ground plate can be created
at the same time that pins 417 are stamped.
[0094] In block 720, the pins are bent. In one aspect, the pins are
bent to allow connection to a circuit board once they are cut from
the carrier piece, and to allow additional steps to be performed.
The different sets of pins can be bent into different shapes. For
example, the electric pins can be longer and be bent down at the
front tips, whereas the optical pins can be bent up for later
attachment to a substrate (e.g. substrate 430). Also, the different
pins within a set can bent differently. For example, pins for
carrying ground can be bent differently than the pins for carrying
data signals.
[0095] In block 730, a substrate (e.g. substrate 430) is attached
to the optical set of pins. The substrate can have at least one
active optical component for receiving and/or transmitting optical
signals to a corresponding connector. At least a portion of the
optical set of pins are communicably coupled with the at least one
active optical component and are configured to carry electrical
signals corresponding to the optical signals.
[0096] In one embodiment, the substrate has been previously
machined to have pockets on the front and back for accommodating
active optical components and for accommodating a transmission lens
and a receiving lens apparatus, which can include a light
collector. Holes may be formed between corresponding pairs of
pockets on the front and back end for light to pass through.
[0097] In block 740, an insulator core (e.g. insulator core 610) is
molded onto the pins. In one aspect, the insulator core can be
molded over only a portion of each pin (e.g. a front portion). The
insulator core can also be molded over the substrate. In one
embodiment, the insulator core covers the electrical pins up to and
potentially past their front tips. The electrical set of pins can
extend past the optical set of pins toward a front of the connector
for mating with electrical contacts of the corresponding
connector.
[0098] In block 750, lenses may be inserted into the insulator
core. In one embodiment, the insulator core can be drilled to form
holes for the lenses. The holes may be drilled where pockets have
already been formed into the substrate. In another embodiment, the
insulator core can be molded with the holes already in place. In
yet another embodiment, the lenses may be attached to the substrate
before the insulator core is molded.
[0099] In block 760, a back end of the pins are cut. The back end
of the pins can then later be electrically connected (e.g.
soldered) to a circuit board.
[0100] In block 770, a shell is placed around the insulator core.
The shell (e.g. shell 650) can be placed around all of the
insulator core or only part of it (e.g. a front portion). The shell
may provide shielding from electromagnetic interference, and it
also may act as alignment feature for a male plug that is inserted
into an opening in the female connector.
IV. Adapter Using Collector
[0101] FIG. 8 shows an adapter 800 for converting optical data
signals from a large width fiber to a smaller width fiber according
to an embodiment of the present invention. As mentioned above,
connectors consistent with embodiments of the present invention can
receive optical signals from optical cables that have relatively
large optical fibers. However, it may be desirable to provide a
connection to an interface that uses a fiber with a relatively
small width. In one aspect, collector 810 (e.g. collector 547) can
provide such conversion in adapter 800. As used herein, an optical
data signal carries bits of data in pulses of light.
[0102] Optical cable 850 can have a first connector (not explicitly
shown) that connects with an electronic device 810 having an
optical or electro-optical connector 820, e.g. a connector
interface described in FIGS. 1-6. For example, the first connector
can be the male plug connector 260 of FIG. 2. Optical cable 850 can
carry optical signals using an optical fiber 855 (which may include
a multi-core fiber) that has a relatively large diameter. In one
embodiment, optical cable 850 can correspond to cable 150 of FIG.
1.
[0103] In one embodiment, if the electronic device (e.g. device
110) needs to connect to another electronic device 880 that has an
interface that uses a smaller fiber, adapter 850 can provide the
conversion of the optical signals from a large diameter fiber to a
small diameter fiber. Adapter 800 can have one end that receives
optical data signals with a first fiber 858 having the large width.
Collector 810 (e.g. a parabolic concentrator) can collect the light
at the large width and provide the light to a small width fiber
820. In another embodiment, collector 810 may received the light
directly from fiber 855, and thus adapter 800 would not have fiber
858.
[0104] Adapter 800 can then provide optical signals using small
fiber 820 to a connector 830 of a receiving device 880. As
connector 830 requires a smaller fiber at its interface, adapter
800 is used. Typically, connector 830 will have a smaller tolerance
for alignment than other connectors mentioned herein.
[0105] In another embodiment, cable 850 can include adapter 800
that reduces the width of the connector down to the smaller fiber.
In this embodiment, cable 850 would include collector 810 coupled
with fiber 855, thereby making cable 850 into an adapter. Cable 850
can also include smaller-width fiber 820, which can then be
connected with connector 830. If such an optical cable 850 is only
to convey optical signals to connectors of the type of connector
830 (or other optical only connectors), then optical cable 850 may
not have electrical contacts or electrical wires.
[0106] In yet another embodiment, adapter 800 (or cable 850
constructed as an adapter) can have two collectors in opposite
directions. Once collector could be used for transmission to
another electronic device 880 and the other collector could be used
for transmission from another electronic device 880.
V. Docking Station with Optical Element
[0107] FIG. 9A illustrates a system with a docking station 960
having at least one active optical component and an electronic
device 952 having at least one active optical component according
to embodiments of the present invention. FIG. 9B is a
cross-sectional side view of electronic device 952 and docking
station 960 according to embodiments of the present invention. In
one embodiment, electronic device 952 and docking station 960 have
connectors that include a collector, which allows a high tolerance
for misalignment. Thus, only a coarse alignment features are used,
which can provide optical communication with no structural
connection. In one aspect, such a connection does not use
electrical contacts.
[0108] Docking station 950 can allow an electronic device 952 or
other electronic device to communicate with other media devices
(not shown). As shown, docking station 950 includes a housing 954
that encloses internally various electrical and structural
components and that defines the shape or form of docking station
950. The shape of housing 954 may be widely varied. For example, it
may be rectangular, circular, triangular, cubical, and the like. In
the illustrated embodiment, housing 954 has a rectangular shape.
Housing 954 may be formed by one or more housing components. For
example, as shown, housing 954 may be made up of a top member 956
and a base member 958. The manner in which members 956 and 958 are
connected may be widely varied (e.g., screws, bolts, snaps, latch,
etc.).
[0109] Within a top surface 960 of housing 954, there is provided a
media bay opening 962 for physically receiving a bottom portion 964
of the electronic device 952. As shown, the media bay opening 962
has shape that coincides with the shape of electronic device 952,
i.e., bottom portion 964 of electronic device 952 may be inserted
within media bay opening 962. The depth of opening 962 can
generally configured to keep the user interface of the electronic
device 952 exposed to the user. Opening 962 may be vertical or
sloped. As shown in FIG. 9B, opening 962 is sloped so that
electronic device 952 rests in a tilted position within the docking
station 950. As should be appreciated, a tilted electronic device
952 is easier to use (e.g., more ergonomic). The slope may be
widely varied. For example, it may tilt electronic device 952 about
5 to about 25 degrees and more particularly about 15 degrees.
[0110] Beneath a bottom surface of opening 962, there is provided a
first optical connector 966 for engaging a corresponding optical
connector disposed on the bottom surface of electronic device 952.
By way of example, first optical connector 966 may include lenses
and a collector 968 as described in FIGS. 4, 5A, and 5B. However,
in one embodiment, there are no electrical contacts.
[0111] One or more active optical component s 969 can optically
coupled with a small opening of the collector, e.g., a photodiode
can receive light at the small opening of collector 968. The
electrical signals from the photodiode can be modified or sent
directly to a circuit board 970. As should be appreciated, the
sides of the opening 962 can serve as alignment elements for
placing the connectors in the correct position. As the alignment is
not too sensitive, other general alignment features besides the
sides of the bay opening can also serve as the alignment
features.
[0112] The corresponding optical connector of electronic device 952
can have a transmitting lens that has a similar dimension as the
large opening of collector 968 of first optical connector 966.
Thus, as both connectors have similar and relatively large
dimension, the alignment between the connectors is not as critical.
The connectors do not have to be perfectly aligned in order to
still communicate optical signals. Thus, a structural connection,
as provided with an insert portion described for FIG. 2 is not
needed. Note that as the active optical components in both
connectors can be kept small, high data rates can be achieved.
[0113] Accordingly, the bottom surface of opening 962 can be flat.
Also, the bottom surface of opening 962 can be made of material
that is opaque to visible light, but which transmits light in the
wavelength (which is not in the visible spectrum) that is used to
communicate the optical signals between electronic device 952 and
docking station 950. Thus, docking station 950 can communicate data
without a need for a physical connection to electronic device 952.
In fact, docking station 950 may appear as if there is no connector
at all.
[0114] In one embodiment, docking station 960 can also include
inductive charging mechanism. For example, a vertical wall can
extend from surface 960 to engage a back of electronic device 952.
The vertical wall can have inductive coils that can charge
electronic device 952, which also has inductive coils.
V. Male Plug with Spring for Optical Elements
[0115] As mentioned above, embodiments of connectors with optical
elements can have a spring that pushes an optical element toward an
optical element of the corresponding connector. This movement can
provide alignment of the corresponding optical elements and can
provide a smaller distance between the optical elements, which can
reduce signal loss and interference. One or more of the mating
optical elements (e.g. lens or fiber) of the male plug connector
and/or the female receptacle connector can have a spring mechanism,
as opposed to having a fixed fiber and ferrule as may occur in
other embodiments.
[0116] FIG. 10 is a cross-sectional view of a male connector 1000
having a spring mechanism for an optical element mated with a
corresponding female receptacle 1050 connector according to
embodiments of the present invention. Male plug connector 1000 can
include an enclosure 1020, a connector housing 1030, and a fiber
1005 with a sleeve 1007, which may provide protection and may be
reflective. Near the interface with female connector 1050, fiber
1005 can have a ferrule 1010 surrounding it. In one embodiment,
ferrule 1010 is made of metallic material.
[0117] In various embodiments, ferrule 1010 can provide strength to
fiber 1005 and can provide alignment. In one embodiment, ferrule
1010 has an aligning element 1012 (e.g. a chamfer) that helps to
provide alignment. In another embodiment, a spring 1017 pushes
ferrule 1010, along with fiber 1005, forward toward the female
connector 1050. The forward force can cause ferrule 1010 to engage
aligning elements 1062 (e.g. aligning elements 548 from FIG. 5) of
female connector 1050. The aligning elements 1062 (e.g. a chamfer)
can cause fiber 1005 to move up or down to being fiber 1005 more in
alignment with lens 1060 (or other optical element).
[0118] The ferrule and fiber combination of male connector 1000 can
have a freedom of movement at least in an up and down direction (as
shown). For example a space can exist between ferrule 1010 and
housing 1030. This freedom of movement along with a force from the
engagement of the aligning elements can provide the relative
movement of fiber 1005 and lens 1060 to bring them into
alignment.
[0119] As one can see, fiber 1010 can be aligned with a center of
lens 1060. Fiber 1010 can also be aligned with collector 1065 and
active optical component 1075. With better alignment, more light
from fiber 1005 can reach the active optical component 1075,
thereby providing a stronger signal. In one embodiment, the
aligning elements 1012/1062 can ensures fiber X/Y alignment to
.+-.0.07 mm, where X/Y is vertical and in/out of the paper, as
shown.
[0120] In some embodiments, a surface of lens 1060 is only slightly
below an enclosure surface 1070. Having distance 1080 between these
two surface be small (e.g. 15 mm) can help to prevent debris from
being trapped and can allow for cleaning of lens 1060. Distance
1080 being small can also help provide a small gap between the
optical elements of the two connectors.
[0121] In other embodiments, aligning elements 1012/1062 can
maintain a gap between lens (e.g. a transmission or a receiving
lens) and fiber 1005 to prevent or reduce abrasion. The width of
the distance between the upper and lower aligning elements 1062 can
be smaller than a width of ferrule 1010 to provide gap 1080. Spring
1017 can keep ferrule 1010 seated against aligning elements 1062,
which can keep end gap to a maximum of 0.15 mm. In one embodiment
to reduce abrasions, lens 1060 may be made of a hard material, such
as hardened glass (e.g. aluminosilicate glass), sapphire, clear
ceramics, spinel (e.g., Magnesium Aluminum Oxide), and aluminum
oxynitride (e.g. ALON.TM.), which can be transparent in the
wavelength of the transmitted light. With a durable lens, it may be
acceptable, and even desirable, to have the two optical elements to
actually touch, thereby providing better transmission of light from
one connector to another. The lens can cause a reduction in total
light transmitted under perfect conditions, but the lens can
provide durability (e.g. less scratches) so that the total light
that can be transmitted does not severely diminish over time, e.g.
due to scratches.
VI. Proud Lens on Female Connector
[0122] In some embodiments, it may be desirable to have optical
elements of the female connector protrude to engage optical
elements of the female connector. Such a protruding construction
can provide for cheaper manufacturing, and allow the optical
elements on the male connector to be flush or recessed with an
enclosure surface. Having a front edge of an optical element of the
male plug connector being flush or recessed can provide for a more
durable male plug connector. As the make plug connector may be used
for many devices, often shove in a drawer or other space with other
objects, and other such hard use, it may be desirable for the
optical element of the male plug connector to not protrude as in
FIG. 10. Such a protruding construction for the female connector
can also provide contact between two surfaces of optical elements
of the connectors, which can provide better transmission of
light.
[0123] FIG. 11A is a cross-sectional view of an optical element
having a proud surface relative to an external (outer) surface of
the connector according to embodiments of the present invention.
Connector 1110 is shown having an external surface 1105. In the
embodiment shown, connector 1110 includes a lens 1115, optically
clear adhesive 1120, collector 1125, optical fiber 1130, and an
active optical component 1140. In various other embodiments,
optical fiber may be omitted such that collector 1125 transmits
light directly to active optical component 1140; collector 1125 and
lens 1115 may be an integral piece (thus obviating a need for an
adhesive); and lens 1115 may be made of a hard material such as
sapphire.
[0124] In one embodiment, the optical clear adhesive can be a
liquid. In one embodiment, the adhesive is a pressure sensitive
adhesive. In another embodiment, the front surface of collector
1125 can be non-flat (e.g. concave) and the liquid adhesive can
flow to fill in the uneven surface of the connector. The
corresponding male plug connector can also have a sapphire lens,
which can be attached to the fiber with an optically clear
adhesive. In another embodiment, air gaps do not occur between the
collector 1125 and lens 1115.
[0125] FIG. 11B is a magnified view of the surface of the optical
element and the external surface according to embodiments of the
present invention. Lens 1115 has a surface that protrudes from (is
proud of) outer surface 1105. In one embodiment, an edge of a
surface of lens 1115 is angled, e.g. to provide an aligning element
such as a chamfer. The aligning element can be used in a similar
manner as described for FIG. 10, but with the male plug connector
having a recess for receiving the proud surface of lens 1115. In
one embodiment, connector 1110 can also have a spring mechanism to
move lens 1115 closer to the surface of the corresponding optical
element of the male connector.
[0126] In one embodiment, lens 1115 and a corresponding optical
element (e.g. another lens) of the male plug connector both
protrude from respective outer surfaces. In another embodiment,
both or just one of the surfaces are flush, as opposed to
protruding. The protrusion from a surface can provide easier access
to the lens in order to remove dirt. In yet another embodiment,
lens 1115 (and other lenses mentioned herein) can be rounded, which
can cause debris on the lens may naturally fall to the edges. The
lens and collector could be a single integral part, which could be
made of sapphire or other suitably hard and optically clear
material. As an example, lens 1115 can be about 1.5 mm to 2 mm in
diameter, with a thickness of about 0.5 mm.
VII. Male Hybrid Connector with Small Insert
[0127] In some embodiments having connectors with an electrical and
optical interface, it can be desirable to have the insert for the
electrical interface be small while still providing a sufficient
number of contacts. Having the insert be small can reduce the size
of the female connector, thereby allowing the electronic device to
be smaller or to free up space for additional circuitry in the
electronic device.
[0128] As an example, the male plug connector 260 can be reduced in
size. The male plug connector 260 of FIG. 2A has an insert 274 that
fits around the tongue in which electrical contacts 22 reside. In
one embodiment, insert portion 274 can be made smaller by removing
the top surface of the insert so that the contacts are exposed on
one side. The sidewalls can still provide alignment features so
that the insert portion is not inserted incorrectly. With a top
surface removed, electrical contacts 222 can be placed on a bottom
surface of opening 205 instead of being on a tongue that sticks
into the middle of opening 205. Thus, receptacle connector 220 can
be made smaller.
[0129] However, even with such changes, it may be desirable to have
an even smaller insert. The sidewalls of insert portion 274 can
also be removed, thereby having the contacts be on an outmost
surface of the insert. Such an embodiment could lead to users
plugging in the insert with an incorrect orientation, which could
be ameliorated with other alignment devices, such as notches and
keys. Even with the contacts an outer surface, the insert may still
have a large width to accommodate all of the contacts in a row
(horizontal as shown). To provide enough contacts while still
limiting size, some embodiments can have inserts with contacts on
more than one surface and/or have contacts that are dependent on
depth of insertion.
[0130] Regarding one embodiment, contacts can be on a top and
bottom surface of the insert. For example, four contacts can be on
top and four different contacts can be on the bottom. Thus, eight
contacts can be obtained with the same amount of width. In one
aspect, the corresponding receptacle would also have mating
contacts on a top and bottom interior surface of opening 205,
thereby possible causing receptacle connector 220 to have greater
height. But, the overall size including width and height can be
made smaller. In this manner, more contacts can be fit into a
smaller space. However, such an embodiment may still not provide
the desired number of contacts within the desired space.
[0131] Accordingly, one embodiment has different contacts at
different depths. For example, an insert could have a first contact
near a front (distal) tip of the insert, and a second contact at
the same horizontal location but behind the first contact. The
corresponding receptacle connector would have corresponding
contacts at different depths within the opening. In this manner,
many contacts can be fit onto a small insert. The provisional
applications referenced above contain various inserts, which may be
used with embodiments of the present invention.
[0132] FIG. 12A is a top view of a hybrid male plug connector 1200
with a central connector according to embodiments of the present
invention. Connector 1200 has an insert 1210 with two contacts 1215
on a top surface and one or more contacts 1217 on the sides of
insert 1210. Contact 1217 may be a ring that extends from one side
over the front of insert 1210 to the other side. In one embodiment,
contact 1217 is a ground contact and contacts 1215 can include a
power contacts or be contacts for data signals. In one embodiment,
insert 1210 is symmetric with regards to the top and bottom. For
example, the bottom surface can have two contacts in a same
position as contacts 1215. Other embodiments can have more than two
contacts (e.g., 4 or 6) on the top surface and/or the bottom
surface. Yet other embodiments can have a contact on a front face
of insert 1210.
[0133] In the embodiment shown, optical links 1219 are shown on
either side of insert 1210. In one implementation, one optical link
is a transmission link and the other is a receiving link. Interior
cable 1215 can be an electrical cable for transmitting electrical
signals to/from the electrical contacts of insert 1210. In one
embodiment, interior cable 1208 is an optical fiber for
communicating optical signals to and/or from an optical link
1219.
[0134] FIG. 12B shows a side view of hybrid male plug connector
1200 according to embodiments of the present invention. A recess
1220 (e.g. a notch) is on a side edge. Recess 1220 can be used to
secure connector 1200 into the corresponding receptacle connector
using a retention mechanism in the corresponding female connector,
e.g., with a cantilevers spring or a detent. The top surface with
contacts 1215 can be considered a major surface as it is larger
than the edge surfaces. Thus, insert 1210 has five contacts in a
relatively small space.
[0135] FIG. 12C shows a front view of hybrid male plug connector
1200 according to embodiments of the present invention. In one
embodiment, optical elements 1230 of optical links 1219 can provide
transmission and/or reception of optical signals. Optical elements
1230 can correspond to lenses, active optical elements, collectors,
and fibers as described herein.
[0136] FIG. 12D is a perspective view of a hybrid male plug
connector 1200 according to embodiments of the present invention.
In the embodiment shown, optical signals can be passively sent
through an optical fiber 1208, which is optically coupled with a
lens 1232. Fiber 1208 can be covered with a ferrule 1234. The
optical signals can then be sent from lens 1232 to a corresponding
optical element of a female connector. In one embodiment, lens 1232
can be a sapphire lens. In another embodiment, ferrule 1234 can be
a fixed fiber ferrule, as can be other ferrules mentioned
herein.
[0137] FIG. 13 shows an exploded view of a passive male plug
connector 1300 according to embodiments of the present invention.
The male plug 1300 is passive in that internal fiber 1308 transmit
optical signal to optical link 1319 for sending to the
corresponding female connector. Ferrule 1334 can cover fiber 1308
at the end. Optical elements 1330 can be of various shapes,
materials, forms, and functions as described herein. Contacts 1315
can lie on top of a pad 1316. Internal cables 1305 can carry power,
ground, and/or data signals for contacts 1315, and other
contacts.
[0138] FIG. 14 is a perspective view of a hybrid male plug
connector 1400 with an active optical component according to
embodiments of the present invention. In one embodiment, plug
connector 1400 has a same connector insert 1410 as plug connector
1200. But, the optical aspects of plug connector 1400 can differ
from passive plug connector 1200. For example, plug connector 1400
can convert electrical signals to optical signals, and vice versa,
such that only electrical signals are carried through cable 1470.
For example, a lens 1432 can receive an optical signal, which can
be collected by a parabolic concentrator 1455 (or other collector)
and sent to an active optical component 1460 for conversion to an
electrical signal.
[0139] FIG. 15 shows an exploded view of an active male plug
connector 1500 according to embodiments of the present invention.
In the embodiment shown, a circuit board 1590 is coupled with
optical modules 1560 and 1565. Electrical signals from wires (not
shown) inside a cable 1570 can be attached to circuit board 1590
and transmitted to optical module 1565 for conversion into optical
signals. Optical module 1560 can receive optical signals and
convert the optical signals to electrical signals transmitted to
the wires via circuit board 1590.
VIII. Female Hybrid Connector for Receiving a Small Insert
[0140] FIG. 16 is a perspective view of a female hybrid connector
1600 according to embodiments of the present invention. Female
connector 1600 has a lens 1623, collector 1655, and active optical
component 1660 as described herein. An opening 1605 can receive an
insert, e.g., insert 1210 of male connector 1200. Contacts 1622 on
the top and bottom surfaces of opening 1605 can provide an electric
connection with contacts 1215 of male connector 1200. Contacts 1627
on the sides of opening 1605 can make an electrical connection with
contact 1217 on the edges of insert 1210. In one embodiment,
contacts 1627 engage recesses 1220 in contacts 1217, thereby
providing a retention mechanism and an electrical connection. The
contacts 1627 can be part of a cantilever spring or a detent. In
another embodiment, recesses 1220 engage a retention mechanism that
is separate from contacts 1627.
[0141] FIG. 17A is a front view of a female hybrid connector 1700
according to embodiments of the present invention. An opening 1705
can receive an insert of a corresponding male connector, e.g.
connector 1200 or 1400. Opening 1705 has a tip inner surface 1780,
a bottom inner surface 1782, and two side inner surfaces 1784. In
one embodiment, four contacts 1722 on the top and bottom inner
surfaces can receive electrical signal from an insert. In one
embodiment, there is one power contact, one identification contact,
and two data contacts, which can provide a differential signal. Two
contacts 1727 can receive two signals or the same signal from side
contacts on an insert. In one embodiment, contacts 1727 both
receive ground.
[0142] In various embodiments, contacts 1722 can receive power,
data, or an identification signal, or any combination thereof. The
identification signal can be used to determine the type of device
that the male plug connector is part of, and thus which type of
data signals are to be sent (e.g. audio, video, etc.). The type of
signals to be sent can also be determined based on a program that
is being run on a processor of the electronic device to which the
female connector is part of. Female connector 1700 also has two
lenses 1732 for receiving optical signals from the corresponding
male connector.
[0143] FIG. 17B is a top view of a female hybrid connector 1700
according to embodiments of the present invention. FIG. 17B shows
different sets of pins 1722a, 1772a, and 1770. In one embodiment,
pins 1722a are a tail end of contacts 1722, and thus contacts 1722
can be considered front ends of pins 1722a. In another embodiment,
pins 1727a are a tail end of contacts 1727, and thus contacts 1727
can be considered front ends of pins 1727a. Any of the pins may be
electrically connected (e.g. soldered) to a circuit board. In one
embodiment, pins 1722a can provide power and/or data to the circuit
board, and pins 1727a can provide ground. In another embodiment,
pins 1770 can provide power, ground, and other signals to an active
optical component, such as 1660. Pins 1770 can also carry the data
signal that was converted from optical to electrical, or vice
versa.
[0144] FIG. 17C is a side view of a female hybrid connector 1700
according to embodiments of the present invention. As shown, pins
1772 are at an end of the connector 1700 and flatten out for
connection to a circuit board. Pins 1722a are shown coming from two
locations within the connector, at a top and a bottom of the
opening 1705.
[0145] As an example, suppose data signals are sent over the two
contacts 1722 on top inner surface 1780, or over one contact on top
inner surface 1780 and one contact on bottom inner surface 1722. In
one implementation, the signal can be a differential signal. In
another implementation, a signal can be sent over just one contact.
In one embodiment, various signals can be sent through these data
contacts at different times. This multiplexing/demultiplexing can
be achieved with a circuit in the connector or on a circuit of an
electronic device. The circuit can send certain signals at one
point in time and then send other signals at a different point in
time. Thus, instead of having certain contacts dedicated to a
particular type of signal (e.g. audio or video), one contacts or
pair of contacts can transmit any type of signal.
[0146] In one embodiment, both the male plug connector and the
female plug connector can multiplex many signals onto one data path
(connection between one or a pair of data contacts). In another
embodiment, both the male plug connector and the female plug
connector can demultiplex many signals from the one data path to
many paths. For example, on the female connector, two contacts 1722
can receive the multiplexed data signals, and a circuit in the
connector can separate the incoming signal (e.g. 1 signal
demultiplexed to N signals) and provide the demultiplexed signals
on pins at the back of the connector. But, this may cause the
connector to still be large. Thus, the demultiplexing may occur on
the circuit board that pins 1722a are connected. The optical
signals may also be multiplexed in a similar fashion, for example,
either with a circuit on a substrate that the active optical
component is part of or by a circuit on the circuit board.
[0147] The male plug connector can also perform the demultiplexing
on signals from the female connector. In one embodiment, the
multiplexed N signals can be provided each over N or 2N wires in a
cable to which the male plug connector is part of. For example,
multiple channels of a display port signal can be sent along a
single data path, either electrical or optical. The
multiplexing/demultiplexing can be synchronized between the
circuits of the connectors. As examples, this synchronization can
occur according to a protocol (which dictates a specific timing,
including a specific order, of the signals) or according to control
signals which specify which data signals are following a control
signal.
[0148] In one embodiment, a subassembly of pins 1770 and 1772 for
one active optical component can be manufactured as a single piece.
The two pieces for the active optical components can then be
assembled together with an overmold. The electrical contacts could
then be added into (e.g. pressed into) the overmolded insulator
core. In another embodiment, each of the pins 1722, 1770, and 1772
can initially be one lead frame (e.g. attached to a carrier) to
control spacing. The housing 1790 (insulator core) can be
overmolded over all pins at the same time.
[0149] FIG. 18 shows an exploded view of a female receptacle
connector according to embodiments of the present invention.
Contact/pins 1822 are shown on the top and bottom inner surface of
opening 1805 of housing 1890. Contacts/pins 1827 are shown on side
inn surfaces of opening 1805. In one embodiment, contacts 1827 can
be part of a retention mechanism, and can provide ground or other
signal to pins 1827a at a tail end of the contact/pin. In another
embodiment, pins 1870 are electrically coupled with the active
optical component 1860 and any collector/lens combination 1855.
[0150] FIGS. 19A and 19B shows various views of a female receptacle
connector according to embodiments of the present invention. As
shown, the pins 1927 lie in a different plane than at least some of
the pins 1922 and the pins 1970. In one embodiment, pins in
different planes can be attached to different sides of a same
circuit board.
[0151] Other examples of a connector insert for a hybrid male plug
connector can be found in FIGS. 20A-20D. FIG. 20A is a simplified
perspective view of a connector insert for hybrid male plug
connector 50, while FIGS. 20B-20D are simplified bottom, front and
side plan views, respectively, according to one embodiment of the
present invention. As mentioned above, any number of contacts can
be one a top surface and a bottom surface, and these embodiments
show six on top and six on the bottom.
[0152] As shown, connector 50 includes a tab 52 that extends from
an outer shell 54 that can be made from a dielectric material such
as a thermoplastic polymer and formed in an injection molding
process. Tab 52 has a front major surface 56a upon which six
contacts 58.sub.(1) and 58.sub.(6) are positioned and a back major
surface 56b upon which an additional six contacts 58.sub.(7) and
58.sub.(12) are located. In one embodiment, spacing is consistent
between each of the contacts on the front and back sides and
between the contacts and the edges of the connector providing 180
degree symmetry so that plug connector 50 can be inserted into a
corresponding receptacle connector in either of two orientations as
discussed below.
[0153] In one aspect, a significant portion of tab 52 can be part
of a ground ring 55 that extends from a distal tip of the connector
towards the outer shell and partially surrounds contacts
58.sub.(1)-58.sub.(12) along an outer periphery of tab 52. Ground
ring 55 can be made from any appropriate metal or other conductive
material and in one embodiment is stainless steel plated with
copper and nickel. Two indentations or pockets 60a and 60b can be
formed in ground ring 55 and located on opposing sides 56c and 56d
of the tab near its distal end. In operation, tab 52 can be
inserted into a receptacle connector until pockets 60a and 60b
operatively engage with a retention mechanism, such as a
cantilevered spring or detent. The retention mechanism fits within
pockets 108 and provides a retention force that secures connector
50 to the matching receptacle connector. In order for the
connectors to be separated, a force greater than the retention
force can be supplied in a direction that pulls the mated
connectors away from each other. In other embodiments, other
retention mechanisms can be used such as mechanical or magnetic
latches or orthogonal insertion mechanisms.
[0154] As shown in FIGS. 20A-20D, contacts 58.sub.(1)-58.sub.(12)
are external contacts that are positioned along an outer surface of
tab 52 and connector 50 does not include an exposed cavity in which
particles and debris may collect. To improve robustness and
reliability, connector 50 can be fully sealed and includes no
moving parts. Furthermore, connector 50 has a considerably reduced
insertion depth and insertion width as compared to commonly
available TRS and TRRS connectors described above. In one
particular embodiment, tab 52 of connector 50 has a width, X, of
4.0 mm; a thickness, Y, of 1.5 mm; and a insertion depth, Z, of 5.0
mm. It is understood that the dimensions of connector 50 as well as
the number of contacts may vary in different embodiments.
[0155] When connector 50 is properly engaged with a receptacle
connector, each of contacts 58.sub.(1)-58.sub.(12) is in electrical
contact with a corresponding contact in the receptacle connector.
In one embodiment, tab 52 has a 180 degree symmetrical, double
orientation design which enables the connector to be inserted into
a connector jack in both a first orientation where surface 56a is
facing up or a second orientation where surface 56b is facing up.
Thus, connector 50 can be said to be orientation agnostic. In one
embodiment, the contact order on the bottom side of the connector,
from left to right, can be as follows: the first two contacts are
designated for a pair of differential data signals, the third
contact is designated for a power contact, the fourth contact is
designated for an audio contact and the fifth and sixth contacts
are designated for another pair of differential data signals.
Similarly, the contact order on the bottom side of the connector,
from left to right, can be as follows: the first two contacts are
designated for a pair of differential data signals, the third
contact is designated for an audio contact, the fourth contact is
designated for a power contact and the fifth and sixth contacts are
designated for another pair of differential data signals.
[0156] The specific details of particular embodiments may be
combined in any suitable manner or varied from those shown and
described herein without departing from the spirit and scope of
embodiments of the invention.
[0157] The above description of exemplary embodiments of the
invention has been presented for the purposes of illustration and
description. It is not intended to be exhaustive or to limit the
invention to the precise form described, and many modifications and
variations are possible in light of the teaching above. The
embodiments were chosen and described in order to best explain the
principles of the invention and its practical applications to
thereby enable others skilled in the art to best utilize the
invention in various embodiments and with various modifications as
are suited to the particular use contemplated.
* * * * *