U.S. patent number RE40,115 [Application Number 11/106,735] was granted by the patent office on 2008-02-26 for assembly including slim female usb connector and slim male usb connector with spring-engaging depressions, stabilizing dividers and wider end rails.
This patent grant is currently assigned to Super Talent Electronics, Inc.. Invention is credited to Ren-Kang Chiou, Tzu-Yih Chu, Edward W. Lee.
United States Patent |
RE40,115 |
Lee , et al. |
February 26, 2008 |
Assembly including slim female USB connector and slim male USB
connector with spring-engaging depressions, stabilizing dividers
and wider end rails
Abstract
A slim .Iadd.male .Iaddend.Universal-Serial-Bus (USB) connector
fits on only one side of the connector substrate in a standard
female USB connector. Wobble or vertical play is reduced by locking
depressions in the slim .Iadd.male .Iaddend.USB connector that
engage metal springs on a metal case that surrounds the female USB
connector, locking the two connectors together. Between metal
contacts on the slim USM connector are dividers that help fill in
gaps when the two connectors are connected together, further
reducing play. End rails on the slim USB connector fill in gaps on
the sides. The connector substrate of the slim .Iadd.male
.Iaddend.USB connector can be separate or can be integrated with a
circuit board that holds a flash memory chip and a USB controller
chip. The connector is wider than the standard width for a better
fit. A slim female USB connector for assembly .Iadd.use
.Iaddend.with the slim male USB connector is also disclosed.
Inventors: |
Lee; Edward W. (Concord,
CA), Chiou; Ren-Kang (Fremont, CA), Chu; Tzu-Yih (San
Jose, CA) |
Assignee: |
Super Talent Electronics, Inc.
(San Jose, CA)
|
Family
ID: |
34115677 |
Appl.
No.: |
11/106,735 |
Filed: |
April 13, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
Reissue of: |
10605146 |
Sep 11, 2003 |
06854984 |
Feb 15, 2005 |
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Current U.S.
Class: |
439/79;
439/607.41 |
Current CPC
Class: |
G06K
19/07732 (20130101); G06K 19/07733 (20130101); H01R
27/02 (20130101); H01R 24/62 (20130101) |
Current International
Class: |
H01R
12/00 (20060101) |
Field of
Search: |
;439/79,610,379,607,680,660,639,292,295 ;235/431,451,441 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
PQ1, "Intelligent Stick" F1ADP/1699 Web p. 9/03, 2 pp. cited by
examiner.
|
Primary Examiner: Gilman; Alexander
Attorney, Agent or Firm: Bever, Hoffman & Harms, LLP
Bever; Patrick T.
Claims
What is claimed is:
1. A slim .Iadd.male .Iaddend.Universal-Serial-Bus (USB) connector
.[.comprising.]. .Iadd.for transmitting USB signals to a female USB
connector, the female USB connector including a metal case defining
an opening for receiving the slim male USB connector, metal springs
formed by a portion of the metal case, and a female connector
substrate surrounded by the metal case, wherein the slim male USB
connector comprises: a connector substrate; a plurality of metal
contacts disposed on a contact surface of the connector substrate,
the metal contacts for carrying USB signals;.Iaddend. .[.locking
depressions formed below the connector substrate on a second
surface opposite to the contact surface; wherein the locking
depressions are for receiving metal springs from a female USB
connector when the slim USB connector is inserted into the female
USB connector;.]. and end rails, substantially parallel to the
metal contacts, along side edges of the connector substrate, the
side edges being smaller in area than the contact surface and
.[.the.]. .Iadd.a .Iaddend.second surface of the connector
substrate .Iadd.that is disposed opposite to the contact surface,
.Iaddend.and .Iadd.are .Iaddend.disposed between the contact
surface and the second surface; a plurality of dividers, each
divider disposed between an adjacent pair of the metal contacts,
the plurality of dividers rising above the contact surface of the
connector substrate; wherein the plurality of dividers are for
filling in a gap between the connector substrate and the female
connector substrate when the slim USB connector is inserted into
the female USB connector; wherein the end rails are for sliding in
gaps between sides of a female connector substrate of the female
USB connector and .[.a.]. .Iadd.the .Iaddend.metal case surrounding
the female connector substrate when the slim USB connector is
inserted into the female USB connector.
2. The slim .Iadd.male .Iaddend.USB connector of claim 1 wherein a
width of the slim .Iadd.male .Iaddend.USB connector is wider than a
substrate within a standard male USB connector, but a height of the
slim .Iadd.male .Iaddend.USB connector is less than a height of a
metal case surrounding a standard male USB connector.[., wherein
the female USB connector is a standard female USB connector or a
slim female USB connector having a reduced height compared with the
standard female USB connector.]. .
3. The slim .Iadd.male .Iaddend.USB connector of claim 2 wherein
the plurality of dividers are metal dividers formed on the contact
surface of the connector substrate, or are plastic dividers.
4. The slim .Iadd.male .Iaddend.USB connector of claim 2 further
comprising: a circuit substrate containing wiring traces; wherein
the connector substrate is attached to the circuit substrate or is
an extension portion of the circuit substrate.
5. The slim .Iadd.male .Iaddend.USB connector of claim 4 further
comprising: a flash memory chip mounted on the circuit
substrate.
6. The slim .Iadd.male .Iaddend.USB connector of claim 5 further
comprising: a controller chip mounted on the circuit substrate, for
reading data from and for writing data to the flash memory chip and
sending the data over the metal contacts as .Iadd.said .Iaddend.USB
signals to the female USB connector.
7. The slim .Iadd.male .Iaddend.USB connector of claim 6 further
comprising: a plastic case that at least partially surrounds the
circuit substrate and covers the flash memory chip and the
controller chip.
8. The slim .Iadd.male .Iaddend.USB connector of claim 7
.Iadd.further comprising locking depressions formed below the
connector substrate on the second surface opposite to the contact
surface for receiving metal springs from a female USB connector
when the slim USB connector is inserted into the female USB
connector,.Iaddend. wherein the locking depressions are formed from
a lower portion of the plastic case that at least partially covers
the second surface of the connector substrate; wherein the end
rails are formed from an upper portion of the plastic case that at
least partially covers the contact surface of the connector
substrate.
9. The slim .Iadd.male .Iaddend.USB connector of claim 8 .[.further
comprising: a plurality of dividers, each divider disposed between
an adjacent pair of the metal contacts, the plurality of dividers
rising above the contact surface of the connector substrate;
wherein the plurality of dividers are for filling in a gap between
the connector substrate and the female connector substrate when the
slim USB connector is inserted into the female USB connector,.].
wherein the dividers are formed from the upper portion of the
plastic case that at least partially covers the contact surface of
the connector substrate.
10. A Universal-Serial-Bus (USB) connector assembly comprising:
.Iadd.a female USB connector including: a metal case defining an
opening, a female connector substrate surrounded by the metal case,
and first metal contacts mounted on a surface of the female
connector substrate; and .Iaddend. a slim male USB connector
including: connector assembly body without a surrounding metal case
for insertion into .[.a.]. .Iadd.the .Iaddend.female USB connector;
end rails on side edges of the connector assembly body, the end
rails causing the connector assembly body to have an enlarged width
that is greater than a standard width of a standard connector
substrate on a standard USB male connector .[.when a metal case
surrounding the standard connector substrate is removed.]. ;
.Iadd.second .Iaddend.metal contacts disposed along one or more
upper surfaces between the side edges for making electrical contact
with .Iadd.the first metal contacts on .Iaddend.the female USB
connector; .Iadd.and.Iaddend. dividers, each between a pair of the
.Iadd.second .Iaddend.metal contacts, the dividers protruding
upward from the one or more upper surfaces.[.; and engaging
depressions, on a bottom surface opposite the one or more upper
surfaces, for engaging metal springs on the female USB connector,
whereby the engaging depressions and end rails provide a secure fit
into the female USB connector when the connector assembly body is
inserted without a surrounding metal case.]. .
11. The USB connector assembly of claim 10 further comprising: tabs
protruding from a back surface of the connector assembly body, the
tabs for making permanent electrical contact to a circuit board;
embedded metal extensions of the metal contacts, the embedded metal
extensions embedded within the connector assembly body and for
connecting the metal contacts to the tabs through the connector
assembly body.
12. The USB connector assembly of claim 11 .Iadd.further comprising
engaging depressions, on a bottom surface opposite the one or more
upper surfaces, whereby the engaging depressions and end rails
provide a secure fit into the female USB connector when the
connector assembly body is inserted, and.Iaddend. wherein the
engaging depressions engage metal springs on a first portion of the
female USB connector but do not engage metal springs on a second
portion of the female USB connector.[., whereby some metal springs
on the female USB connector are engaged but other metal springs are
not engaged.]. .
13. The USB connector assembly of claim 12 wherein a height of the
connector assembly body is less than a standard height of the
standard USB male connector having the metal case surrounding
.[.the.]. .Iadd.a .Iaddend.standard connector substrate, whereby
the .[.male.]. USB connector .[.assembly.]. has a reduced
height.
14. The USB connector assembly of claim 13 wherein the dividers are
plastic dividers or are metal dividers.
15. The USB connector assembly of claim 13 wherein the .Iadd.second
.Iaddend.metal contacts are flat metal contacts or are bent metal
contacts having a spring action, or are metal rail contactors.
16. The USB connector assembly of claim 13 wherein the .Iadd.slim
male USB connector further comprises .Iaddend.tabs .Iadd.that
.Iaddend.are soldered to a circuit board that has a flash memory
chip and a controller chip mounted thereon.
17. A reduced-height Universal-Serial-Bus (USB) connector
comprising: .Iadd.a female USB connector including:.Iaddend. a
metal case defining an opening and including metal springs formed
by a portion of the metal case, and a female connector substrate
surrounded by the metal case, and a slim male USB connector
including: connector body means, .[.without a surrounding wrap,.].
for insertion into .[.a.]. .Iadd.the .Iaddend.female USB connector,
metal contactor means, attached to the connector body means, for
making electrical contact with .[.a.]. .Iadd.the .Iaddend.female
USB connector, engaging means, formed on a lower surface of the
connector body means, the lower surface opposite the metal
contactor means, for receiving a portion of .Iadd.the
.Iaddend.metal springs on the female USB connector; end means, on
the connector body means, for extending side edges of the connector
body means to fill in gaps to sides of the female USB connector
produced by lack of the surrounding wrap surrounding the connector
body means; and divider means, attached to the connector body
means, for dividing gaps between the metal contractor means,
whereby stability when inserted into the female USB connector is
increased by the divider means, the end means, and the engaging
means.
18. The reduced-height USB connector .Iadd.assembly .Iaddend.of
claim .[.11.]. .Iadd.17 .Iaddend.wherein the connector body means
comprises .Iadd.one of .Iaddend.a molding.[. or comprises.].
.Iadd., and .Iaddend.a portion of a circuit board having integrated
circuits mounted on other portions thereon and one or more plastic
cases partially surrounding the circuit board.
19. The reduced-height USB connector .Iadd.assembly .Iaddend.of
claim 17.[. further comprising.]. .Iadd., wherein the female USB
connector comprises .Iaddend.a reduced-height female connector for
mating with the reduced-height .Iadd.male .Iaddend.USB connector,
.Iadd.the .Iaddend.reduced-height female connector having metal
contactor means on only one surface.
20. The reduced-height USB connector .Iadd.assembly .Iaddend.of
claim 19 wherein power and ground pins provide a higher power
supply current than defined by a USB specification.
.Iadd.21. A slim Universal-Serial-Bus (USB) connector assembly
comprising: a female USB connector including: a metal case
including a relatively long first wall and opposing, relatively
short second and third walls extending perpendicular to the first
wall, a first connector substrate mounted to the metal case such
that a rectangular opening is defined by the first, second and
third walls of the metal case and a contact surface of the first
connector substrate, and such that opposing side edges of the first
connector substrate respectively contact the second and third walls
of the metal case, and first metal contacts mounted on the first
surface of the first connector substrate; and a male USB connector
including: a second connector substrate, second metal contacts
disposed on a contact surface of the second connector substrate,
end rails, substantially parallel to the second metal contacts,
extending along side edges of the second connector substrate, and a
plurality of dividers, each divider disposed between an adjacent
pair of the second metal contacts, the plurality of dividers
protruding above the contact surface of the second connector
substrate, wherein the female USB connector and the male USB
connector are cooperatively arranged such that, when the male USB
connector is fully inserted into the rectangular opening with the
contact surface of the first connector substrate facing the contact
surface of the second connector substrate: the end rails of the
male USB connector abut the second and third walls of the metal
case, and each of the first metal contacts abut a corresponding
second metal contact..Iaddend.
.Iadd.22. The slim USB connector assembly according to claim 21,
wherein the plurality of dividers are one of (a) metal dividers
formed on the contact surface of the connector substrate, (b)
plastic dividers formed on the contact surface of the connector
substrate..Iaddend.
.Iadd.23. The slim USB connector assembly of claim 22, wherein the
slim male USB connector further comprises a circuit substrate
containing wiring traces, wherein the connector substrate is one of
(a) attached to the circuit substrate and (b) is an extension
portion of the circuit substrate..Iaddend.
.Iadd.24. The slim USB connector assembly of claim 23, wherein the
slim male USB connector further comprises a flash memory chip
mounted on the circuit substrate..Iaddend.
.Iadd.25. The slim USB connector assembly of claim 24, wherein the
slim male USB connector further comprises a controller chip mounted
on the circuit substrate, the controller including means for
reading data from and for writing data to the flash memory chip,
and for sending the data over the metal contacts as USB signals to
the female USB connector when the slim male USB connector is
mounted inside the slim female USB connector..Iaddend.
.Iadd.26. The slim USB connector assembly of claim 25, wherein the
slim male USB connector further comprises a plastic case that at
least partially surrounds the circuit substrate and covers the
flash memory chip and the controller chip..Iaddend.
.Iadd.27. The slim USB connector assembly of claim 26, wherein
locking depressions are formed from a lower portion of the plastic
case that at least partially covers a second surface of the
connector substrate disposed opposite to the contact surface, and
wherein the end rails are formed from an upper portion of the
plastic case that at least partially covers the contact surface of
the connector substrate..Iaddend.
.Iadd.28. The slim USB connector assembly of claim 27 wherein the
dividers are formed from the upper portion of the plastic case that
at least partially covers the contact surface of the connector
substrate..Iaddend.
.Iadd.29. The slim USB connector assembly of claim 21 wherein each
of the first and second metal contacts are one of (a) flat metal
contacts, (b) bent metal contacts having a spring action, and (c)
metal rail contactors..Iaddend.
.Iadd.30. A reduced-height female Universal-Serial-Bus (USB)
connector for connecting to a reduced-height USB male connector,
the reduced-height male USB connector including: a second connector
substrate, second metal contacts disposed on a contact surface of
the second connector substrate, end rails, substantially parallel
to the second metal contacts, extending along side edges of the
second connector substrate, and a plurality of dividers, each
divider disposed between an adjacent pair of the second metal
contacts, the plurality of dividers protruding above the contact
surface of the second connector substrate, wherein the
reduced-height female USB connector comprises: a metal case
including a relatively long first wall and opposing, relatively
short second and third walls extending perpendicular to the first
wall, a first connector substrate mounted to the metal case such
that a rectangular opening is defined by the first, second and
third walls of the metal case and a contact surface of the first
connector substrate, and such that opposing side edges of the first
connector substrate respectively contact the second and third walls
of the metal case, and first metal contacts mounted on the first
surface of the first connector substrate, wherein the
reduced-height female USB connector is arranged such that, when the
reduced-height male USB connector is fully inserted into the
rectangular opening with the contact surface of the first connector
substrate facing the contact surface of the second connector
substrate, the end rails of the reduced-height male USB connector
abut the second and third walls of the metal case, each of the
first metal contacts abut a corresponding second metal
contact..Iaddend.
.Iadd.31. The reduced-height female USB connector assembly of claim
30, wherein the metal case further comprises a fourth wall
connected to the third and fourth walls and arranged parallel to
the first wall such that the second connector substrate is located
between the first and fourth walls..Iaddend.
Description
BACKGROUND OF INVENTION
This invention relates to electronic connectors, and more
particularly to reduced-height Universal-Serial-Bus (USB)
connectors.
Rapid advances in technology in several areas have converged to
enable small, portable memory cards with vast capacities. Flash
memory technologies such as those using electrically-erasable
programmable read-only memory (EEPROM) have produced chips storing
128 M-Bytes or more. Small flash-memory cards have been designed
that have a connector that can plug into a specialized reader, such
as for compact-flash, secure-digital, memory stick, or other
standardized formats.
More recently, flash memory cards are being sold that contain a USB
connector. Such USB-flash memory cards do not require a specialized
reader but can be plugged into a USB connector on a personal
computer (PC). These USB-flash memory cards can be used in place of
floppy disks. A USB-flash card can have a capacity of more than ten
floppy disks in an area not much larger than a large postage
stamp.
FIG. 1A shows a prior-art flash-memory card with a USB connector.
Flash memory chip 12 may be a 128 Mega-byte non-volatile chip or
may have some other capacity. Controller chip 14 contains a
flash-memory controller that generates signals to access memory
locations within flash memory chip 12. Controller chip 14 also
contains a USB interface controller that serially transfers data to
and from flash memory chip 12 over a USB connection.
USB connector 20 may be mounted on board 10, which is a small
circuit board with chips 12, 14 mounted thereon. Multi-layer
printed-circuit board (PCB) technology can be used for board 10. A
plastic case (not shown) can surround board 10.
USB connector 20 contains a small connector substrate 16, which is
often white ceramic, black rigid plastic, or another sturdy
substrate. Connector substrate 16 has four or more metal contacts
18 formed thereon. Metal contacts 18 carry the USB signals
generated or received by controller chip 14. USB signals include
power, ground, and serial differential data D+, D-.
USB connector 20 contains a metal case that wraps around connector
substrate 16. The metal case touches connector substrate 16 on
three of the sides of connector substrate 16. The top side of
connector substrate 16, holding metal contacts 18, has a large gap
to the top of the metal case. On the top and bottom of this metal
wrap are formed holes 15. USB connector 20 is a male connector,
such as a type-A USB connector.
FIG. 1B shows a female USB connector. Female USB connector 22 can
be an integral part of a PC, or can be connected by cable 21.
Another connector substrate 26 contains four metal contacts 28 that
make electrical contact with the four metal contacts 18 of the male
USB connector 20 of FIG. 1A. Connector substrate 26 is wrapped by a
metal case, but small gaps are between the metal case and connector
substrate 26 on the lower three sides.
Locking is provided by metal springs 24 in the top and bottom of
the metal case. When male USB connector 20 of FIG. 1A is flipped
over and inserted into Female USB connector 22 of FIG. 1B, metal
springs 24 lock into holes 15 of male USB connector 20.
FIGS. 2A, 2B are cross-sections highlighting connections between
male and female USB connectors. Female USB connector 22 is on the
left while male USB connector 20 is being inserted from the right.
Male USB connector 20 is flipped over relative to the view of FIG.
1A. Metal contacts 18 are formed on the lower surface of connector
substrate 16 on male USB connector 20, while metal contacts 28 are
formed on the upper surface of connector substrate 26 on Female USB
connector 22. Thus the metal contacts face one another to allow for
electrical contact when male USB connector 20 is inserted into
Female USB connector 22 as shown in FIG. 2B.
Metal springs 24 formed on the metal case surrounding connector
substrate 26 on Female USB connector 22 fit into holes on the metal
case of male USB connector 20. This helps to lock the connectors
together.
FIG. 3 shows a prior-art USB flash memory card using a slim USB
connector. Male USB connector 20 of FIGS. 1, 2 is relatively large.
The metal case in particular is cumbersome and increases
manufacturing cost. Costs may be reduced by integrating male USB
connector 30 with board 32. Board 32 is a PCB that has flash memory
chip 12 and controller chip 14 mounted thereon. Board 32 is
extended to include male USB connector 30, which has metal contacts
38 formed on end 36 of board 32.
The width and thickness of board 32 at end 36 containing male USB
connector 30 is designed to approximately match that of connector
substrate 16 of FIG. 1A. Plastic case 34 can enclose board 32 but
have an opening for metal contacts 38. Plastic case 34 can cover
the bottom and sides of male USB connector 30 up to end 36 to
emulate potions of the metal case of the male USB connector of FIG.
1A.
FIGS. 4A, 4B show cross-sections of the prior-art slim USB
connector being inserted into a standard Female USB connector.
Board 32 that has male USB connector 30 formed on end 36 is flipped
over from the view shown in FIG. 3, and end 36 is inserted into
female USB connector 22 from the right side.
Metal contacts 38 are located on the lower surface of male USB
connector 30. Plastic case 34 has an opening on the lower surface
of male USB connector 30 to expose the metal contacts so they can
make electrical connection with metal contacts 28 on the upper
surface of connector substrate 26 of Female USB connector 22 when
inserted as shown in FIG. 4B.
Plastic case 34 helps to fill the gate between board 32 and the top
edge of the metal case of Female USB connector 22. However, no
holes are provided in plastic case 34, so metal springs 24 are
pushed up slightly when male USB connector 30 is inserted into
Female USB connector 22. Plastic case 34 is also formed along the
thin edges of board 32 and helps to fill in the gaps between
connector substrate 26 and the sides of the metal case of Female
USB connector 22 that are above and below the plane of FIG. 4B.
While slim USB connector 30 can be less expensive and smaller than
the standard USB connector, it fits less securely into a standard
Female USB connector. The lack of the metal case removes the
mechanical support provided as the male metal case that fit in the
gap below connector substrate 26 and the bottom side of the metal
case for the female connector. Also, plastic case 34 does not lock
into metal springs 24 on the top of Female USB connector 22. The
result is a noticeable wobble in the up and down direction when a
USB flash memory card containing male USB connector 30 is inserted
into Female USB connector 22. Vertical movement of 3-4 millimeter
at the end of a 4-centimeter flash card can occur with slight
finger pressure. This vertical play gives the user the feeling that
the flash memory card is cheap and unreliable, even when sufficient
electrical contact is made.
What is desired is a slim USB connector with reduced vertical
wobble. A slim USB connector that more securely fits into a
standard Female USB connector is desired. A slim USB connector with
a more secure fit is desire d that can be integrated with the
circuit board containing the flash memory chip is also
desirable.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1A shows a prior-art flash-memory card with a USB
connector.
FIG. 1B shows a female USB connector.
FIGS. 2A, 2B are cross-sections highlighting connections between
male and female USB connectors.
FIG. 3 shows a prior-art USB flash memory card using a slim USB
connector.
FIGS. 4A, 4B show cross-sections of the prior-art slim USB
connector being inserted into a standard Female USB connector.
FIGS. 5A-E show a slim USB connector with locking depressions,
dividers, and end rails.
FIGS. 6A-D show a male slim USB connector that is integrated with a
circuit-board substrate of a flash memory card.
FIGS. 7A-E show an alternative integrated male slim USB connector
integrated with metal dividers.
FIG. 8A shows an alternative embodiment of the male slim USB
connector using flat metal contactors.
FIG. 8B shows an alternative embodiment of the male slim USB
connector using metal rail contactors.
FIGS. 9A, 9B show an integrated male slim USB connector being
inserted into a standard female USB connector.
FIGS. 10A, 10B, 10C show a slim female USB connector and an
integrated male slim USB connector being inserted into the slim
female USB connector.
DETAILED DESCRIPTION
The present invention relates to an improvement in slim USB
connectors. The following description is presented to enable one of
ordinary skill in the art to make and use the invention as provided
in the context of a particular application and its requirements.
Various modifications to the preferred embodiment will be apparent
to those with skill in the art, and the general principles defined
herein may be applied to other embodiments. Therefore, the present
invention is not intended to be limited to the particular
embodiments shown and described, but is to be accorded the widest
scope consistent with the principles and novel features herein
disclosed.
FIGS. 5A-E show a slim USB connector with locking depressions,
dividers, and end rails. Male slim USB connector 40 does not
include a metal case surrounding a connector substrate, allowing
the height H (FIG. 5C) and cost of the connector to be reduced.
Instead, the width W (FIG. 5D, E) is wider than the standard male
USB connector. The width W is increased by twice the width of the
metal case that wraps the standard male USB connector. Thus the
increased width accounts for the missing metal case of the slim USB
connector.
Visible in the top view of FIG. 5A, metal contacts 42 are placed on
a top surface of male slim USB connector 40 between dividers 44 and
end rails 46. Metal contacts 42 can be flat, or can have a bend in
them to produce a spring action to provide better contact with the
metal contacts on a female USB connector. Dividers 44 and end rails
46 can have a low height to allow metal contacts 42 to reach the
metal contacts on the female USB connector.
Tabs 48 are electrically connected to metal contacts 42 through
metal lines or extensions 43 within male slim USB connector 40.
Tabs 48 can be surface mounted or soldered to a circuit board such
as one that contains flash memory and controller chips. Corners and
shapes can be changed on some embodiments to allow for easier
automated handling but may be deleted or of a different shape or
size in other embodiments. Other features such as posts, notches,
etc. may be present for a variety of purposes or reasons. For
example, two small holes 41 may be provided at the rear of male
slim USB connector 40 near tabs 48 to receive a metal clip for
securing male slim USB connector 40 to a board, such as a PCB.
Visible in the bottom view of FIG. 5B, locking depressions 54 are
formed on the lower side of male slim USB connector 40. Locking
depressions 54 are aligned with the metal springs on the female USB
connector. When male slim USB connector 40 is inserted into a
standard Female USB connector, metal springs are guided into
locking depressions 54 locking the two connectors together,
improving alignment and mechanical engagement and stability.
Depressions 54 perform the function of the holes in the metal case
of the prior-art male USB connector. Depressions 54 allow the metal
springs on the female USB connector to lock into a location in
locking depressions 54, securing the male and female USB connectors
together.
End rails 46 further help align male slim USB connector 40 when
inserted into a female USB connector, while dividers 44 help fill
the gap between connectors. Thus a more secure connection can be
made using male slim USB connector 40 since gaps are filled in more
precisely and locking depressions 54 can lock with metal springs on
a female USB connector. End rails 46 may be taller than dividers 44
or may be the same height as the dividers.
FIG. 5C is a side cross-sectional view of male slim USB connector
40. Metal extensions 43 electrically connect metal contacts 42 to
tabs 48. The height H of male slim USB connector 40 is less than
the height of a standard male USB connector.
FIG. 5D is a top view of male slim USB connector 40. Metal
extensions 43 electrically connect metal contacts 42 to tabs 48.
The width W of male slim USB connector 40 is greater than the width
of a standard male USB connector. The width is increased by twice
the thickness of the metal case wrap of a standard male USB
connector in one embodiment, but different widths may be used.
FIG. 5E is a bottom view of male slim USB connector 40. Locking
depressions 54 are visible from the bottom. Depressions 54 are on
the bottom surface opposite metal contacts 42.
FIGS. 6A-D show a male slim USB connector that is integrated with a
circuit-board substrate of a flash memory card. The USB
flash-memory card is assembled from upper case 62 of FIG. 6A, board
60 and its components of FIG. 6B, and lower case 64 of FIG. 6C,
which are sandwiched together to form the card of FIG. 6D.
In FIG. 6B, flash memory chip 75 and controller chip 78 are mounted
on board 60, which can be a multi-layer PCB or similar substrate
with wiring traces. Extension 61 of board 60 has a width that
approximately matches the width of the connector substrate in a
male USB connector. Metal contacts 70 are formed on extension 61 to
act as the USB metal contacts of the male slim USB connector. End
72 of board 60 is inserted into the female USB connector.
In FIG. 6A, upper case 62 can be made of plastic or other material.
Two end rails 66 and three dividers 68 are formed on the extension
end of upper case 62. Openings 69 in upper case 62 between dividers
68 and end rails 66 allow metal contacts 70 of FIG. 6B to be
exposed through upper case 62 when assembled. Dividers 68 and end
rails 66 can be made from the same material as the rest of upper
case 62, such as by all being part of one plastic molding. End
rails 66 may be taller than dividers 68 or may be the same height
as the dividers.
In FIG. 6C, lower case 64 includes extended region 80. Locking
depressions 82 are in extended region 80. A single molding can form
lower case 64 with locking depressions 82 in extended region
80.
Locking depressions 82 can be made in a variety of ways. For
example, locking depressions 82 can be made during molding of lower
case 64, or by milling, punching, or machining case 64 after
molding. Depressions 82 can be holes that completely pass through
case 64, or can be thinned regions that do not reach completely
through case 64.
FIG. 6D shows an assembled USB flash-memory card. Upper case 62 and
lower case 64 are plastic cases that fit together, enclosing board
60 of FIG. 6B. End rails 66 and dividers 68 in upper case 62 fit
over extension 61 of board 60. Metal contacts 70 on board 60 are
exposed through openings 69 in upper case 62 between dividers 68
and end rails 66. Locking depressions (not visible) are formed in
lower case 64.
FIGS. 7A-E show an alternative integrated male slim USB connector
integrated with optimal metal dividers. The USB flash-memory card
is assembled from upper case 62' of FIG. 7A, board 60 and its
components of FIG. 7B, and lower case 64' of FIG. 7C, which are
sandwiched together to form the card of FIG. 7D.
In FIG. 7B, flash memory chip 75 and controller chip 78 are mounted
on board 60, which can be a multi-layer PCB or similar substrate
with wiring traces. Extension 61 of board 60 has a width that is
slightly wider than the width of the connector substrate in a male
USB connector to account for the missing metal case wrap. Four
metal contacts 70 are formed on extension 61 to act as the USB
metal contacts of the male slim USB connector. End 72 of board 60
is inserted into the female USB connector.
Three metal dividers 76 are formed between pairs of metal contacts
70 on extension 61. These metal dividers help produce a better fit
by filling the gap between connectors when inserted and metal
contacts 70 depress the spring metal contacts on the female
connector.
In FIG. 7A, upper case 62' can be made of plastic or other
material. End rails and plastic dividers are not formed on upper
case 62'. Instead, upper case 62' ends before the connector
extension region. This allows metal contacts 70 of FIG. 7B to be
exposed when assembled. End rails may be added to upper case 62' to
further improve its fit into a female USB connector. The end rails
may be taller than the metal dividers or may be the same height as
the metal dividers.
In FIG. 7C, lower case 64' includes extended region 80'. Locking
depressions 82' are in extended region 80'. A single molding can
form lower case 64' with locking depressions 82' in extended region
80'.
Locking depressions 82' can be made in a variety of ways. For
example, locking depressions 82' can be made during molding of
lower case 64', or by milling, punching, or machining case 64'
after molding. Depressions 82' can be holes that completely pass
through case 64', or can be thinned regions that do not reach
completely through case 64'.
FIG. 7D shows an assembled USB flash-memory card. Upper case 62'
and lower case 64' are plastic cases that fit together, mostly
enclosing board 60 of FIG. 6B, although the edge of board 60 is
visible in this embodiment. Upper case 62' ends before extension 61
of board 60 to expose metal contacts 70 on board 60. Locking
depressions (not visible) are formed in lower case 64'.
FIG. 7E is an enlarged view of extension 61. Metal contacts 70 are
formed on the upper surface of board 60. Metal dividers 76 are also
formed on this upper surface, between pairs of metal contacts 70.
The two middle metal contacts 70 are shorter that the end metal
contacts 70, as is standard for male US3 connectors. Metal dividers
76 can be the full length of the end metal contacts 70. Metal
contacts 70 and metal dividers 76 can be bumped or superpositioned
metal fingers rather than just flat metal lines. Metal contacts 70
depress the spring metal contacts on the female connector.
FIG. 8A shows an alternative embodiment of the male slim USB
connector using flat metal contactors. Metal contacts 42' are flat
metal contactors placed on a top surface of male slim USB connector
40' between dividers 44 and end rails 46. Dividers 44 and end rails
46 can have a low height to allow metal contacts 42' to reach the
metal contacts on the female USB connector. End rails 46 may be
taller than dividers 44 or may be the same height as the
dividers.
FIG. 8B shows an alternate embodiment of the male slim USB
connector using metal rail contactors. Rather than use metal
contacts 42 of FIG. 5, metal rails 56, which are metal contactors
with a raised middle rail are used by male slim USB connector 40''
to make electrical contact with the female USB connector. Metal
rails 56 can have a desired height to make better contact with
spring metal contacts on the female USB connector. Narrow dividers
are shown as another alternative, but wider dividers 44 may be
substituted. End rails 46 may be taller than dividers 44 or may be
the same height as the dividers.
FIGS. 9A, 9B show an integrated male slim USB connector being
inserted into a standard female USB connector. A male slim USB
connector formed on extension 61 of board 60 is inserted from the
right. Since this connector is inverted for insertion, upper case
62 is on the bottom, and has dividers 68 and end rails (not
visible) formed near extension 61. Metal contacts (not shown) are
formed on the lower surface of board 60 between dividers 68 and
make electrical contact with metal contacts 28 when inserted.
Metal springs 24 in female USB connector 22 engage locking
depressions (not visible) in lower case 64. When fully inserted, as
shown in FIG. 9B, metal springs 24 can lock into the locking
depressions. Metal springs 24 on the bottom of female USB connector
22 are not engaged since the male slim USB connector does not
extend below connector substrate 26.
Dividers 68 fill in the gap between board 60 and connector
substrate 26. This provides a better, more secure fit, reducing
wobble. When combined with the locking action of metal springs 24
into the locking depressions, vertical play or wobble is
significantly reduced.
FIGS. 10A, 10B, 10C show an integrated male slim USB connector
being inserted into a slim female USB connector. FIG. 10A shows a
new slim female USB connector 92 that has a reduced height compared
to standard female USB connectors. Slim female USB connector 92 is
designed for connecting to the male slim USB connector of FIGS. 5,
6, 7, 8.
Connector substrate 96 is wider than the connector substrate in the
standard female USB connector, reaching the sides of the metal case
without a gap. Metal contacts 28 are formed on the top surface of
connector substrate 96 and electrically connect to wires in cable
21. Metal springs 24 are provided on the top of the metal case but
not on the bottom of the metal case. The metal case can cover the
bottom of connector substrate 96 or not extend over the bottom of
connector substrate 96.
FIG. 10B, a male slim USB connector formed on extension 61 of board
60 is inserted from the right. Since this connector is inverted for
insertion, upper case 62 is on the bottom, and has dividers 68 and
end rails (not visible) formed near extension 61. Metal contacts
(not shown) are formed on the lower surface of board 60 between
dividers 68.
Metal springs 24 in slim female USB connector 92 can lock into the
locking depressions in lower case 64 when fully inserted as shown
in FIG. 10C. No metal springs are present on the bottom of slim
female USB connector 92.
Dividers 68 fill in the gap between board 60 and connector
substrate 96, providing a better, more secure fit, with less
wobble. When combined with the locking action of metal springs 24
into the locking depressions, vertical play or wobble is
significantly reduced.
Alternative Embodiments
Several other embodiments are contemplated by the inventors. For
example, a variety of materials may be used for the connector
substrate, circuit boards, metal contacts, metal case, etc. Plastic
cases can have a variety of shapes and may partially or fully cover
different parts of the circuit board and connector, and can form
part of the connector itself.
The locking depressions can have a variety of shapes and sizes.
Oval, round, square, rectangular, trapezoidal, and other shapes may
be used. The locking depressions may be elongated into channels or
have channels that guide the metal springs into the depressions as
the connectors are inserted together. The depressions could be
formed as part of a separate lower case as shown, or may be part of
the connector substrate.
The slim connector may be considered "half-height", since it fits
on one side of the female's connector substrate but not on the
other side of the female's connector substrate. The actual
"half-height" connector may not be exactly half the height of a
standard connector, but is considered "half-height" because it
engages only half of the female connector. The slim connector may
be a reduction in height of only 30-40% rather than exactly
half.
The slim connector may be widened to accommodate extra metal
contacts to become an extended-USB connector for future USB
specification. Moreover, the width of the slim connector can be
widened, and the height and metal contacts of the slim connector
can be varied, making it into a general-purpose slim connector, for
USB, extended-USB, PCI Express, mini PCI Express applications,
etc.
Other embodiments may use a stand-alone male slim USB connector
such as shown in FIG. 5 rather than the integrated male slim USB
connector. Other embodiments include removing the dividers from the
stand-alone connector of FIG. 5. The end rails may be taller than
the dividers or may be the same height as the dividers.
Other applications besides flash drives include USB connectors on
desktop computers, notebook computers, PDA's, digital cameras,
cellular phones or handsets, TV set-top boxes, MP3, MPEG4, copiers,
printers, and other electronic devices. Such devices may use to
advantage the slim-ness of the new male and/or female USB
connectors, and may reduce size and space together with lower cost.
A USB flash drive with the new slim male connector can still be
directly inserted into a host PC with a legacy female USB
connector.
There are 4 pins in the current USB pin out of definition--VCC,
GND, D+, and D-. VCC is the 5V power pin. GND is the ground pin and
D+ and D- are the differential data I/O pins. For the USB 2.0
specification, data transfer rates are up to 480 M bits/sec, and
the power supply current is 500 mA. These might not meet future (or
even some current) needs of speed and power associated with some
USB devices, such as large flash memory cards.
Additional metal contacts can be added to the new connectors. These
additional metal contacts can serve as power, ground, and/or I/O
pins which are extensions to the USB specification, or as PCI
Express (or mini PCI Express) specifications. Greater power
capability can be obtained with (or without) additional power and
ground pins (or by a higher power supply current of the existing
power pin). Multiple power supplies can also be provided by the
additional power and ground pins. The improved power supply
capabilities allow more devices and/or more memory chips to be
powered. Extra I/O pins can be added for higher bandwidth and data
transfer speeds. The additional I/O pins can be used for
multiple-bit data I/O communications, such as 2, 4, 8, 12, 16, 32,
64, . . . bits. By adopting some or all of these new features,
performance of flash memory cards/devices can be significantly
improved. These additional pins could be located behind or adjacent
to the existing USB pins, or in various other arrangements. The
additional pins could be applied to male and female connectors,
both the current or the new slim connectors. New types of flash
memory cards/devices can be made with these new connectors, which
have the additional pins.
The abstract of the disclosure is provided to comply with the rules
requiring an abstract, which will allow a searcher to quickly
ascertain the subject matter of the technical disclosure of any
patent issued from this disclosure. It is submitted with the
understanding that it will not be used to interpret or limit the
scope or meaning of the claims. 37 C.F.R. .sctn. 1.72(b). Any
advantages and benefits described may not apply to all embodiments
of the invention. When the word "means" is recited in a claim
element, Applicant intends for the claim element to fall under 35
USC .sctn. 112, paragraph 6. Often a label of one or more words
precedes the word "means". The word or words preceding the word
"means" is a label intended to ease referencing of claims elements
and is not intended to convey a structural limitation. Such
means-plus-function claims are intended to cover not only the
structures described herein for performing the function and their
structural equivalents, but also equivalent structures. For
example, although a nail and a screw have different structures,
they are equivalent structures since they both perform the function
of fastening. Claims that do not use the word means are not
intended to fall under 35 USC .sctn.112, paragraph 6. Signals are
typically electronic signals, but may be optical signals such as
can be carried over a fiber optic line.
The foregoing description of the 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 disclosed. Many modifications and variations are
possible in light of the above teaching. It is intended that the
scope of the invention be limited not by this detailed description,
but rather by the claims appended hereto.
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