Assembly including slim female USB connector and slim male USB connector with spring-engaging depressions, stabilizing dividers and wider end rails

Abstract

A slim male 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 male 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 male 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 use with the slim male USB connector is also disclosed.

1. A slim male Universal-Serial-Bus (USB) connector comprising  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; 
 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  a second surface of the connector substrate that is disposed opposite to the contact surface, and are 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  the metal case surrounding the female connector substrate when the slim USB connector is inserted into the female USB connector.  
 
     
     
       2. The slim male USB connector of  claim 1  wherein a width of the slim male USB connector is wider than a substrate within a standard male USB connector, but a height of the slim male 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 male 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 male 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 male USB connector of  claim 4  further comprising:
 a flash memory chip mounted on the circuit substrate.  
 
     
     
       6. The slim male 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 said USB signals to the female USB connector.  
 
     
     
       7. The slim male 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 male USB connector of  claim 7  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,   
 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 male 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: 
       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      
       
         a slim male USB connector including:  
         connector assembly body without a surrounding metal case for insertion into a  the 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 ;  
         second metal contacts disposed along one or more upper surfaces between the side edges for making electrical contact with the first metal contacts on the female USB connector; and 
         dividers, each between a pair of the second 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  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   
 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  a 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 second 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 slim male USB connector further comprises tabs that 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: 
       a female USB connector including:   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  the female USB connector,  
         metal contactor means, attached to the connector body means, for making electrical contact with a  the 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 the 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 assembly of claim  11    17  wherein the connector body means comprises one of a molding or comprises , and 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 assembly of  claim 17  further comprising , wherein the female USB connector comprises a reduced-height female connector for mating with the reduced-height male USB connector, the reduced-height female connector having metal contactor means on only one surface. 
     
     
       20. The reduced-height USB connector assembly of  claim 19  wherein power and ground pins provide a higher power supply current than defined by a USB specification. 
     
     
       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.     
     
     
       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. 
     
     
       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. 
     
     
       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. 
     
     
       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. 
     
     
       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. 
     
     
       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.     
     
     
       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. 
     
     
       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. 
     
     
       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.     
     
     
       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.