PATENT DOCUMENT

Publication Number: US-11674245-B2
Application Number: US-202117355095-A
Country: US
Kind Code: B2

Title: Braided electronic device cable, braiding machine and method for braiding an electronic device cable

Abstract:
This application relates to cable assemblies with an outer (exterior) layer formed from braiding materials together. To achieve a desired pattern, a machine tool forming the outer layer undergoes several modifications. For a machine tool with two tracks (e.g., inner and outer track) with multiple carriers of material to be braided, each carrier position may include multiple bobbins, with each bobbin carrying a spool/coil of the material. During a braiding operation performed by the machine tool, each track rotates in opposite directions. Moreover, some bobbins include an arm that guides the material in a particular manner. For example, during rotation of the track, the arm provides a swinging motion, causing the material carried by the arm to move in a periodic (e.g., sinusoidal) motion. An additional track may be used to guide the arms.

Claims:
What is claimed is: 
     
       1. A cable assembly, comprising:
 a first connector; 
 a second connector; 
 a cord extending between the first connector and the second connector, the cord configured to provide power and data transmission from the first connector to the second connector, the cord comprising:
 an outer layer, the outer layer comprising: 
 a first set of strands, wherein each strand of the first set of strands comprises a circular cross section, 
 a second set of strands adjacent to the first set of strands, and 
 a third set of strands weaved with the first set of strands and the second set of strands; 
 
 an insulated wire electrically connected to the first connector and the second connector; 
 an uninsulated wire electrically connected to the first connector and the second connector, wherein the insulated wire and the uninsulated wire are configured to provide the power and data transmission from the first connector to the second connector; and 
 a fill material between the insulated wire and the uninsulated wire, wherein the fill material contacts the insulated wire and the uninsulated wire. 
 
     
     
       2. The cable assembly of  claim 1 , wherein the first set of strands and the second set of strands includes yarn. 
     
     
       3. The cable assembly of  claim 1 , wherein each of the first set of strands, the second set of strands, and the third set of strands includes two strands. 
     
     
       4. The cable assembly of  claim 1 , wherein each of the first set of strands, the second set of strands, and the third set of strands includes exactly two strands. 
     
     
       5. The cable assembly of  claim 1 , wherein the first set of strands is parallel with respect to the second set of strands. 
     
     
       6. The cable assembly of  claim 1 , wherein the outer layer defines an exterior of the cord. 
     
     
       7. The cable assembly of  claim 1 , wherein:
 the first connector is configured to plug into an electronic device, and 
 the second connector is configured to plug into a power adapter. 
 
     
     
       8. A cable assembly, comprising:
 a first connector; 
 a second connector; and 
 a cord extending between the first connector and the second connector, the cord comprising an outer layer, the outer layer comprising:
 a first pair of strands, 
 a second pair of strands adjacent to the first pair of strands, and 
 a third of pair strands, wherein the third pair of strands passes over the first pair of strands and passes under the second pair of strands; 
 a plurality of insulated wires electrically connected to the first connector and the second connector; 
 a plurality of uninsulated wires electrically connected to the first connector and the second connector, wherein the plurality of insulated wires and the plurality of uninsulated wires are configured to provide power and data transmission from the first connector to the second connector; and 
 a fill material between the plurality of insulated wires and the plurality of uninsulated wires, wherein the fill material contacts i) each insulated wire of the plurality of insulated wires and ii) each uninsulated wire of the plurality of uninsulated wires. 
 
 
     
     
       9. The cable assembly of  claim 8 , wherein the first pair of strands is parallel with respect to the second pair of strands. 
     
     
       10. The cable assembly of  claim 8 , wherein at least one of the first pair of strands, the second pair of strands, and the third pair of strands comprises yarn. 
     
     
       11. The cable assembly of  claim 8 , wherein:
 the first pair of strands comprises two strands, and 
 the second pair of strands comprises two strands. 
 
     
     
       12. The cable assembly of  claim 11 , wherein the third pair of strands comprises two strands. 
     
     
       13. A cable assembly, comprising:
 a connector; 
 a cord connected to the connector, the cord comprising an outer layer, the outer layer comprising:
 a first set of strands, 
 a second set of strands parallel to the first set of strands, and 
 a third of set strands, wherein the third set of strands passes over the first set of strands and passes under the second set of strands; 
 
 a plurality of insulated wires electrically connected to the connector; 
 a plurality of uninsulated wires electrically connected to the connector; and 
 a fill material between, and in contact with, the plurality of insulated wires and the plurality of uninsulated wires. 
 
     
     
       14. The cable assembly of  claim 13 , wherein the first set of strands is adjacent to the second set of strands. 
     
     
       15. The cable assembly of  claim 13 , wherein at least one of the first set of strands, the second set of strands, and the third set of strands comprises yarn. 
     
     
       16. The cable assembly of  claim 13 , wherein:
 the first set of strands comprises two strands, and 
 the second set of strands comprises two strands. 
 
     
     
       17. The cable assembly of  claim 16 , wherein the third set of strands comprises two strands.

Description:
FIELD 
     The described embodiments relate generally to cable assemblies, or cord assemblies, for portable electronic devices. More particularly, the present embodiments relate to yarn braiding techniques used to create an exterior for cable assemblies. 
     BACKGROUND 
     A cable may include a sheath, or sleeve, used to bundle together multiple wires of the cable. Typically, the sheath is covered by an outer layer using materials such as polymers (e.g., polyvinyl chloride or the like) that forms the exterior of the cable. The sheath may include several metal wires, such as copper wires, that form a protective cover for the wires that carry electrical signals. Additionally, the sheath can protect users from energized wires. 
     Machine automation is commonly used for sheath production. There are several factors for using sheath-like design as an interior feature as opposed to an exterior, aesthetic exterior for a consumer product. For instance, braided sheaths produced by typical machine braiding tools often include inconsistencies in wire angle, percent coverage, and density. While this can be tolerated when the sheathed is covered, it becomes easily detectable issue when the sheath represents an exterior. When machine modifications are adopted to increase consistency of manufacture, the throughput (i.e., rate of production) often decreases making less feasible to produce a sheath-like design as an exterior feature. As a result, manufacturers are typically limited in design choice. 
     SUMMARY 
     In one aspect of the present disclosure, a machine tool for manufacturing a cable assembly is described. The machine tool may include a first set of bobbins configured for rotational movement in a first direction. The first set of bobbins may include a first bobbin and a second bobbin. The machine tool may further include a second set of bobbins configured for rotational movement in a second direction different from the first direction. The second set of bobbins may include a third bobbin that carries a material. The machine tool may include a track defining a periodic pattern. The machine tool may include an arm coupled with the track. The arm can be configured to actuate the material over the first bobbin and under the second bobbin based on the periodic pattern. 
     In another aspect of the present disclosure, a method for manufacturing a cable assembly is described. The method may include, by a machine tool, driving a first track in a first direction. The first track may carry a first set of strands. The method may further include, by the machine tool, driving a second track in a second direction opposite the first direction. The second track may carry a second set of strands. The method may further include, by the machine tool, actuating, by a plurality of arms, the second set of strands while the plurality of arms moves in the second direction. In some embodiments, the plurality of arms guides the second set of strands in accordance with a periodic pattern. 
     In another aspect of the present disclosure, a cable assembly is described. The cable assembly may include a first connector. The cable assembly may further include a second connector. The cable assembly may further include a cord extending between the first connector and the second connector. The cord may include an outer layer. The outer layer may include a first set of strands. The outer layer may further include a second set of strands adjacent to the first set of strands. The outer layer may further include a third set of strands weaved with the first set of strands and the second set of strands. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
     This Summary is provided merely for purposes of summarizing some example embodiments so as to provide a basic understanding of some aspects of the subject matter described herein. Accordingly, it will be appreciated that the above-described features are merely examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements. 
         FIG.  1    illustrates an isometric view of an embodiment of a cable assembly; 
         FIG.  2    illustrates a cross sectional view of the cable assembly taken across line  2 - 2 , showing various internal features of the cable assembly. 
         FIG.  3    illustrates a plan view of the outer layer of the cable assembly; 
         FIG.  4    illustrates a partial cross sectional view of the outer layer, showing a pattern of the strands of material of the outer layer; 
         FIG.  5    illustrates a plan view of a machine tool designed to manufacture outer layers for cable assemblies, in accordance with some described embodiments; 
         FIG.  6    illustrates an enlarged view of the machine tool shown in  FIG.  5   , showing exemplary movement at various positions of a bobbin during operation; 
         FIG.  7    illustrates an enlarged view of an alternate embodiment of a machine tool, showing multiple bobbins at a single carrier position, in accordance with some described embodiments; 
         FIG.  8    illustrates an enlarged view of an alternate embodiment of a machine tool, showing a different movement of arms, in accordance with some described embodiments; 
         FIG.  9    illustrates an isometric view of a fixture designed for use with machine tools, in accordance with some described embodiments; 
         FIG.  10    illustrates a partial cross sectional view of a fixture used to manufacture a cable assembly, in accordance with some described embodiments; 
         FIGS.  11 A- 11 C  illustrate alternate embodiments of fixtures; 
         FIG.  12    illustrates a cross sectional view of a strand used to form an outer layer of a cable, in accordance with some described embodiments; 
         FIG.  13    illustrates a plan view of an outer layer of a cable, showing additional relationships of the strands of the outer layer, in accordance with some described embodiments; 
         FIG.  14    illustrates a flowchart showing a method for manufacturing a cable assembly, in accordance with some described embodiments; and 
         FIG.  15    illustrates a block diagram of a machine tool used to form an outer layer for a cable assembly, in accordance with some described embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     This application is directed to cable assemblies with a braided outer layer, or braided exterior, as well as a machine tool used to form the braided outer layer. Cable assemblies described herein are used to facilitate power transmission from a power adapter used to connected to, for example, a 110-120 Volt (“V”) source to an electronic device (e.g., smartphone, desktop computing device, smartwatch, laptop computing device, tablet computing device, or the like). Alternatively, or in combination, cable assemblies described herein are used to facilitate power transmission and/or communication (e.g., data) from one electronic device to another electronic device. 
     In an exemplary embodiment, a cable assembly includes an outer layer made from multiple strands of yarn braided together. In particular, the outer layer may include a braided pattern in accordance with the formula
 
a×b−c
 
where a is the group number of strands (e.g., yarns) passing over a group number of b strands and under a group number of b strands, and c is the number of strands in each of the aforementioned groups. For example, a 1×1−2 braided pattern includes 1 group of strands passing over 1 group of strands and under 1 group of strands, with each group having 2 strands. In this manner, a machine tool can form a 1×1−2 braided pattern by using 2 (or c) bobbins at each carrier position. In this detailed description, a and b may vary from 1 to 5, while c may vary from 1 to 10.
 
     In order to create the outer layer of a cable assembly, the machine tool may include a rotary braiding machine with several modifications. For example, a 2-track machine tool, each with multiple carriers used to hold a bobbin (or multiple bobbins at a single carrier position), may include a track with several arms used to guide or direct the strand of material as it rolls off of a respective bobbin. The arm can be passively driven, i.e., connected to an additional track that cause the arm to move along a path defined by the additional track. In some exemplary embodiments, the additional track includes a periodic pattern such as a sinusoidal pattern. Based on the position of the track on the machine tool, the actuation of the strands of material (guided by their respective arm) moves the strand toward and away from the other track of bobbins, thus providing a braiding/weaving operation. In some exemplary embodiments, the 2-track machine tool includes an inner and outer track, each with several carriers. Each bobbin on the outer track includes an arm that guides the strands of material off of the bobbin in a direction toward (and in some cases, radially inside) bobbins on the inner track, and also away from (and radially outside) the bobbins on the inner track, thus defining a periodic pattern. As an alternative to a track with a design with a periodic pattern, a motor can be equipped to each arm to drive the arm in a desired manner, which may include a periodic motion. 
     Traditional rotary braiding machines for cable assemblies form sheaths used to hold together wires of the cable assembly. These braided sheaths are subsequently covered by an outer layer such that the sheath is unseen. However, the braiding operation described herein is used to create the outer, or exterior, layer, and accordingly, factors such as strand angle, percent coverage, and strand density—all related to the appearance of the outer layer, and subsequently the cable assembly—are relatively more important. In this regard, an additional modifications to machine tools can be used. For example, machine tools described herein may include a fixture centrally mounted to the machine tools. The fixture is used as an initial receiving surface for the outer layer undergoing a braiding operation. The fixture further includes a hollow cylindrical body that defines a through hole through which the internal features (e.g., cable core that includes wires and other internal features) of cable assemblies pass. Additionally, the fixture may include a tapered body in which a diameter at one end is greater than that of the other end. This fixture is designed to reduce tension on the braided outer layer during a manufacturing operation and keep the braided outer layer momentarily separated from the cable core. As a result, the braided outer layer undergoes less stress and tension, leading to a more consistent and aesthetic finish. 
     These and other embodiments are discussed below with reference to  FIGS.  1 - 15   . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIG.  1    illustrates an isometric view of an embodiment of a cable assembly  100 . Cable assembly  100  (representative of other cable assemblies shown and described herein) is designed for use with various electronic devices including, but not limited to, smartphones, laptop computing devices, desktop computing devices, tablet computing devices, wireless headphones, and digital styluses. As shown, cable assembly  100  includes a connector  102   a  and a connector  102   b . Each of connectors  102   a  and  102   b  may include an electrical connector designed in accordance with an industry standard including, but not limited to, Universal Serial Bus (“USB”), USB-C, Lightning, Thunderbolt, or micro-USB. 
     Also, cable assembly  100  includes a cable  104 , or cord, extending between and connected with connectors  102   a  and  102   b . Cable  104  is designed to cover and carry one or more wires used for power transmission and/or data transmission from connector  102   a  to connector  102   b , or vice versa, and accordingly, cable assembly  100  can provide power transmission and/or data transmission, respectively, to various electronic devices. As shown in the enlarged view, cable  104  includes an outer layer  106 , also referred to as an exterior or exterior layer. In some embodiments, outer layer  106  includes several strands of material braided or interweaved together. The strands of material may include yarn, as a non-limiting example. Outer layer  106 , including the manufacturing and design, will be shown and described below. 
       FIG.  2    illustrates a cross sectional view of cable assembly  100  taken across line  2 - 2 , showing various internal features of cable  104 . As shown, outer layer  106  provides an exterior structure and surface of cable  104 . Additionally, cable  104  includes a wire  108   a , a wire  108   b , and a wire  108   c , each of which are covered/wrapped by an insulator  110   a , insulator  110   b , and insulator  110   c , respectively. Wires  108   a ,  108   b , and  108   c  provide an electrically conductive pathway and accordingly include a conductive metal, such as copper. Wires  108   a ,  108   b , and  108   c  are electrically connected to connectors  102   a  and  102   b  (shown in  FIG.  1   ). Insulators  110   a ,  110   b , and  110   c  include electrically an insulating material, such as a polymer. Additionally, in order to increase power transmission and/or data transmission, cable  104  may include an uninsulated wire  112   a , an uninsulated wire  112   b , and an uninsulated wire  112   c , each of which is electrically connected to connectors  102   a  and  102   b . Also, cable  104  may further include a fill material  114 , such as nylon. Fill material  114  may generally include any material(s) with flexible properties while providing some rigidity. 
     Additionally, cable  104  may include a sheath  115  used to provide some compression forces to the components of cable  104 . Additionally, cable  104  may include a metal separator  117  designed to provide some grounding for static charges. The features and components within and include sheath  115  may define a cable core for cable  104  of cable assembly  100 . 
       FIG.  3    illustrates a plan view of outer layer  106  of cable assembly  100 . As shown, outer layer  106  is detached from cable assembly  100  and laid flat. Outer layer  106  includes multiple strands of material (shown, not labeled) braided or interweaved together. Accordingly, several strands of material pass over some strands of material and pass under other strands of material. 
       FIG.  4    illustrates a partial cross sectional view of outer layer  106 , showing a pattern of the strands of material of outer layer  106 . As shown, outer layer  106  includes a strand  116   a  and a strand  116   b  extending along the same direction. In other words, strands  116   a  and  116   b  are parallel to each other. Outer layer  106  includes additional strands that extend along a different direction as compared to strands  116   a  and  116   b , and accordingly, can cross/intersect strands  116   a  and  116   b . For example, outer layer  106  includes a strand  118   a  and a strand  118   b  extending along the same direction, as well as a strand  120   a  and a strand  120   b  extending along the same direction. As shown, strands  116   a  and  116   b  pass over strands  118   a  and  118   b , and subsequently pass under strands  120   a  and  120   b.    
     The strands may be divided into groups. For example, strands  116   a  and  116   b  define a group  122   a  of strands, strands  118   a  and  118   b  define a group  122   b  of strands, and strands  120   a  and  120   b  define a group  122   c  of strands. In this manner, it can be said that group  122   a  passes over group  122   b , and subsequently passes under group  122   c . In some embodiments (as shown in  FIG.  4   ), groups  122   b  and  122   c  are adjacent to each other. With reference to strands, the term “adjacent” or phrase “adjacent groups” as used in this detailed description and in the claims can refer to two groups (including their respective strands) extending in the same direction (i.e., parallel) and not separated by another group. Also, as shown, group  122   a  is interweaved with adjacent groups, with groups  122   b  and  122   c  being representative examples. 
       FIG.  5    illustrates a plan view of a machine tool  230  designed to manufacture outer layers for cable assemblies, in accordance with some described embodiments. Machine tool  230  includes multiple carrier positions designed to hold one or more bobbins, or spools, loaded with material used to create an outer layer. For example, machine tool  230  includes a bobbin  232   a  and a bobbin  234  at a respective carrier position, each of which representing additional bobbins of machine tool  230 . As shown, bobbins  232   a  and  234  each provide a strand  236   a  and a strand  236   b , respectively. Strands  236   a  and  236   b  may include one or more fibers of material. In this regard, strands  236   a  and  236   b  may include yarn, as a non-limiting example. However, various fabrics and synthetic materials are also possible for strands  236   a  and  236   b . While each of bobbins  232   a  and  234  include a strand of material, bobbins  232   a  and  234  are located on different tracks. For example, bobbin  232   a , as well as other similarly-looking bobbins, are carried on a track  238   a  while bobbin  234 , as well as other similarly-looking bobbins, are carried on a track  238   b . Tracks  238   a  and  238   b  may be referred to an inner track and an outer track, respectively, based upon their respective locations. 
     In order for perform a braiding operation, machine tool  230  drives tracks  238   a  and  238   b  in opposite directions. For example, track  238   a  is designed to be driven in a direction denoted by an arrow  240   a , while track  238   b  is designed to be driven in a direction denoted by an arrow  240   b . Although not shown, tracks  238   a  and  238   b  may be driven by one or more motors of machine tool  230 . The directions denoted by arrows  240   a  and  240   b  may denote a counterclockwise direction and a counter-clockwise direction, respectively. Generally, machine tool  230  may function by driving each of tracks  238   a  and  238   b  in their respective opposite directions as shown. The respective strands on the bobbins on track  238   a  are braided with strands on the bobbins on track  238   b.    
     Additionally, in order to further create a desired finish an outer layer of a cable assembly, machine tool  230  may include additional modifications to at least some of the bobbins. For example, machine tool  230  include a track  238   c  as well as an arm  242  that is coupled with track  238   c . Track  238   c  can define a periodic pattern, repeating at defined intervals. For example, in some embodiments, track  238   c  defines a sinusoidal pattern that repeats itself each period. As a result, when track  238   b  moves in direction of arrow  240   b  (i.e., a circular motion), arm  242 , being coupled with track  238   c , moves not only with bobbin  234  in the direction of arrow  240   b , but also swings or oscillates in a manner defined by the shape and curvature of track  238   c , i.e., the periodic pattern. Additionally, strand  236   b  (located on bobbin  234 ) is directed/guided by arm  242 , and accordingly, strand  236   b  also moves in accordance with the periodic pattern of track  238   c . As shown, additional arms (not labeled) are coupled to a bobbin on track  238   b  and capable of directing a respective strand loaded on a bobbin on track  238   b.    
     Further, in addition to the periodic pattern, the layout and dimensions of track  238   c , allow arm  242  and strand  236   b  to pass between adjacent bobbins. For example, based on track  238   c , arm  242  and strand  236   b  can pass between bobbin  232   a  and a bobbin  232   b , where bobbin  232   b  is adjacent to bobbin  232   a  and on track  238   a . With reference to bobbins, the term “adjacent” or the phrase “adjacent bobbins” as used in this detailed description and in the claims can refer to two bobbins on the same track and not separated by another bobbin on the same track. 
       FIG.  6    illustrates an enlarged view of machine tool  230  shown in  FIG.  5   , showing exemplary movement at various positions of bobbin  234  during operation. For purpose of illustration and simplicity, some features of machine tool  230  are removed. The dotted lines show several different positions of bobbin  234 , arm  242 , and strand  236   b  during operation of machine tool  230 . For example, while bobbin  234  travels along track  238   b , arm  242  moves along the periodic pattern defined by track  238   c , and accordingly, although both bobbin  234  and arm  242  move along the direction of arrow  240   b , arm  242  nonetheless moves relative to bobbin  234 . Additionally, strand  236   b  is directed by arm  242 , and accordingly moves along the periodic pattern defined by track  238   c.    
       FIG.  7    illustrates an enlarged view of an alternate embodiment of a machine tool  330 , showing multiple bobbins at a single carrier position, in accordance with some described embodiments. Machine tool  330  may include any features shown and described herein for a machine tool. Additionally, however, machine tool  330  may include two bobbins at a single carrier position. For example, machine tool  330  includes a bobbin  332   a  and a bobbin  332   b  at a carrier position on a track  338   a , and carrying a strand  336   a  and a strand  336   b , respectively. Also, machine tool  330  includes a bobbin  334   a  and a bobbin  334   b  at a carrier position on a track  338   b , and carrying a strand  336   c  and a strand  336   d , respectively. Additionally, bobbins  334   a  and  334   b  include an arm  342   a  and an arm  342   b , respectively, with arms  342   a  and  342   b  used to guide strands  336   c  and  336   d , respectively. Bobbins  334   a  and  334   b  are coupled to track  338   b  by a support  344   a , while arms  342   a  and  342   b  coupled to track  338   c  by a support  344   b . Supports  344   a  and  344   b  are positioned in grooves of tracks  338   b  and  338   c , respectively. 
     Tracks  338   a ,  338   b , and  338   c  may include similar features and designs for tracks  238   a ,  238   b , and  238   c , respectively (shown in  FIG.  5   ). Accordingly, tracks  338   a  and  338   b  can be driven in directions  340   a  and  340   b , respectively (i.e., opposite directions), and track  338   c  may define a periodic pattern, including a sinusoidal pattern. In this manner, during operation, arms  342   a  and  342   b  can move with bobbins  334   a  and  334   b , respectively, and simultaneously move/swing/oscillate, thereby guiding strands  336   c  and  336   d , respectively, along the periodic pattern. The movement action of the arms  342   a  and  342   b  can cause strands  336   c  and  336   d , respectively, to move radially inside and outside bobbins  332   a  and  332   b  located on track  338   a . In this manner, track  338   a  may include an opening  346  that allows strands  336   c  and  336   d  to pass through track  338   a.    
     Based on the dual bobbin configuration, machine tool  330  can form an outer layer (previously described) with a 1×1−2 braided pattern. In other words, a single group of two strands (e.g., strands  336   a  and  336   b ) can pass over another single group of two strands (e.g., strands  336   c  and  336   d ) and under another group of two strands (i.e., another dual bobbin at a carrier position on track  338   b ). In this regard, although not shown, arms  342   a  and  342   b  can swing strands  336   c  and  336   d , respectively, over another dual bobbin configuration located on track  338   a  that is adjacent to bobbins  332   a  and  332   b . With multiple groups of dual bobbins at various carrier positions (not shown in  FIG.  7   ) of machine tool  330 , the outer layer can be formed in accordance with the 1×1−2 pattern. Further, although not shown, the “2” in 1×1−2 can be altered (increased or decreased) based upon the number of bobbins at a single carrier position. 
       FIG.  8    illustrates an enlarged view of an alternate embodiment of a machine tool  430 , showing a different movement of arms, in accordance with some described embodiments. Machine tool  430  may include any features shown and described herein for a machine tool. For example, machine tool  430  includes a bobbin  432   a  and a bobbin  432   b  on a track  438   a , and carrying a strand  436   a  and a strand  436   b , respectively. Also, machine tool  430  includes a bobbin  434   a  and a bobbin  434   b  at a carrier position on a track  438   b , and carrying a strand  436   c  and a strand  436   d , respectively. Additionally, bobbins  434   a  and  434   b  include an arm  442   a  and an arm  442   b , respectively. 
     Tracks  438   a  and  438   b  may include similar features and designs for tracks  238   a  and  238   b , respectively (shown in  FIG.  5   ). Accordingly, tracks  438   a  and  438   b  can be driven in opposite directions. In order to drive arms  442   a  and  442   b , machine tool  430  may further include motors (e.g., servo motors) that drive arms  442   a  and  442   b  to swing/oscillate arms  442   a  and  442   b  in a direction of the two-sided arrow  448 . In this manner, during operation, track  438   b  moves in the direction of the arrow  440 , causing bobbins  434   a  and  434   b  as well as arms  442   a  and  442   b  to move with track  438   b , while arms  442   a  and  442   b  additionally swing/oscillate, thereby driving strands  436   c  and  436   d , respectively, along the periodic pattern denoted by the arrow  450 . The movement action of the arms  442   a  and  442   b  can cause strands  436   c  and  436   d , respectively, to move above bobbin  432   b  and below  432   a . Additionally, track  438   a  may include an opening  446   a  and an opening  446   b , each of which allowing strands  436   c  and  436   d  to pass through track  438   a.    
       FIG.  9    illustrates an isometric view of a fixture  460  designed for use with machine tools, in accordance with some described embodiments. Fixture  460  can be mounted to any machine tool described herein. As shown, fixture  460  defines a cylindrical (or generally cylindrical) body having one end with a diameter  462   a , a tapered region  464 , and another end with a diameter  462   b . Based upon tapered region  464 , diameter  462   a  is greater than diameter  462   b . Fixture  460  further includes a through hole  466  that opens to an opening  468   a  at one end (i.e., a receiving end) and an opening  468   b  at the other end (i.e., transmission end). In order to secure fixture  460  to a machine tool, a base  470  may be mounted to the machine tool. In this regard, fixture  460  includes a flange  469  designed to fit into a groove  472  of base  470 . 
     Fixture  460  is designed to decrease tension on an outer layer (not shown in  FIG.  9   ) during an assembly operation of the outer layer. For example, fixture  460  can be centrally mounted on a machine tool described herein, and during operation, the strands used to form the outer layer pass over the outer surface of fixture  460  while the cable core passes initially through a through hole  474  of base  470  and then through the through hole  466  by initially passing through opening  468   a  and then subsequently through opening  468   b.    
       FIG.  10    illustrates a partial cross sectional view of a fixture  560  used to manufacture a cable assembly, in accordance with some described embodiments. Fixture  560  may include any features shown and described for fixture  460  (shown in  FIG.  9   ). During operation, both a cable core  574  of a cable assembly and strands  576  from various bobbins of a machine tool are directed to fixture  560 . Strands  576  are braided to form an outer layer  506 , which passes over the outer surface of fixture  560 , while cable core  574  passes through a through hole (not labeled, but similar to through hole  466  in  FIG.  9   ) of fixture  560 . An arrow  580  is used to denote a direction of travel of cable core  574  and outer layer  506  during operation. 
     As shown, fixture  560  provides physical separation between outer layer  506  and cable core  574  during the formation of outer layer  506 . As a result, cable core  574  imposes minimal, if any, stress on outer layer  506 . This decoupling between outer layer  506  and cable core  574  provides a reduced stress environment for outer layer  506 , and increases braiding consistency and aesthetics of outer layer  506 . Further, a tapered region (not labeled, but similar to tapered region  464  in  FIG.  9   ), along with the reduced end (similar to end with diameter  462   b  shown in  FIG.  9   ) of fixture  560  provides a smooth transition of outer layer  506  to slip off of fixture  560  and onto cable core  574 . In this manner, fixture  560  allows outer layer  506  transition onto cable core  574  without cable core  574  stretching outer layer  506  in a manner that alters the appearance of outer layer  506  in an undesired manner. 
       FIGS.  11 A- 11 C  illustrate cross sectional views of alternate embodiments of fixtures. Either of the fixtures shown and described in  FIGS.  11 A- 11 C  can substitute for fixture  560  (shown in  FIGS.  9  and  10   ). Additionally, fixtures  460  and  560  (shown in  FIGS.  9  and  10   , respectively) may be modified to include at least some features for the fixtures shown and described in  FIGS.  11 A- 11 C .  FIG.  11 A  illustrates a cross sectional views of a fixture  660 , in accordance with some described embodiments. Fixture  660  may define a cylindrical (or generally cylindrical) body having a tapered region  664  that transitions from a relatively larger diameter of fixture  660  to a relatively smaller diameter of fixture  660 . Fixture  660  further includes a through hole  666  that extends through the body of fixture  660 . Additionally, fixture  660  includes an end  669  that is rounded, or generally rounded, as opposed to an end with a flat surface. In some embodiments, end  669  is rounded with a half-cylinder shape. 
       FIG.  11 B  illustrates a cross sectional views of a fixture  760 , in accordance with some described embodiments. Fixture  760  may define a cylindrical (or generally cylindrical) body having a tapered region  764  that transitions from a relatively larger diameter of fixture  760  to an end  769  of fixture  760 , with end  769  defining a relatively smaller diameter. Fixture  760  further includes a through hole  766  that extends through the body of fixture  760 . Also, end  769  can be rounded, flat, or pointed. 
       FIG.  11 C  illustrates a cross sectional views of a fixture  860 , in accordance with some described embodiments. Fixture  860  may define a cylindrical (or generally cylindrical) body having a tapered region  864  that transitions a relatively larger diameter of fixture  860  to a relatively smaller diameter of fixture  860 . Fixture  860  can resemble a body of a needle. For example, the relatively smaller diameter portion of fixture  860  is substantially longer than the relatively larger diameter portion of fixture  860 . Accordingly, the strands (not shown in  FIG.  11 C ) will pass over the relatively smaller diameter portion of fixture  860  during the braiding operation for a substantial duration of the braiding operation. Fixture  860  further includes a through hole  866  that extends through the body of fixture  860 . Also, fixture  860  includes an end  869  that can be rounded, flat, or pointed. 
       FIGS.  12  and  13    show and describe features of strands of material used to form an outer layer, as well as relationship between braided strands that form an outer layer. The machine tools shown and described herein can be programmed or otherwise modified to produce outer layers with features and relationships shown and described in  FIGS.  12  and  13   . 
       FIG.  12    illustrates a cross sectional view of a strand  932  used to form an outer layer of a cable assembly, in accordance with some described embodiments. As shown, strand  932  includes a diameter  978 . Diameter  978  is approximately in the range of 0.1 to 1 millimeters. Also, strand  932  is shown as generally having a circular cross section. However, other cross sectional shapes, including oblong shapes due strand being stretched and under tension, are possible. 
       FIG.  13    illustrates a plan view of an outer layer  1006  of a cable assembly, showing additional relationships of the strands of the outer layer  1006 , in accordance with some described embodiments. As shown, outer layer  1006  includes a strand  1032  positioned an angle α relative to an imaginary vertical line  1082 . Angle α may be approximately in the rage of 15 to 60 degrees. Also, the strands (including strand  1032 ) of outer layer  1006  provide a substantial cover or jacket for a cable assembly. However, some gaps, or openings, between adjacent strands may be present. For example, a gap  1084  between (and defined by) several surrounding strands is shown. Gap  1084  represents an uncovered area of a cable assembly by outer layer  1006 , i.e., where no strands of outer layer  1006  are present. Based upon the manufacturing process, outer layer  1006  is designed to provide coverage approximately in the range of 75% to 95%. Additionally, a region  1086  of outer layer  1006  is shown. Within region  1086  (representative of remaining areas of outer layer  1006 ), the picks per inch (“ppi”) is approximately in the range of 10 to 60 ppi. 
       FIG.  14    illustrates a flowchart  1100  showing a method for manufacturing a cable assembly, in accordance with some described embodiments. The method shown and described in flowchart  1100  can be implement by machine tools described herein. In particular, flowchart  1100  shows and describes a manner in which machine tools can braid/weave an outer layer for cable assemblies. 
     In step  1102 , a first track is driven in a first direction. The first track can carry a first set of strands. For example, the first track may include several carrier positions designed to hold one or more bobbins. Each bobbin may include a strand of material used to form an outer layer of the cable assembly. As a non-limiting example, the strand of material may include yarn. 
     In step  1104 , a second track is driven in a second direction opposite the first direction. The first and second directions may include opposing rotational directions. Similar to the first track, the second track can also carry a second set of strands with material similar to that of the first set of strands. While the material may be similar, other appearances (e.g., color) can differ. Alternatively, the material, including the make-up, can differ on different tracks and/or on different bobbins. 
     In step  1106 , several arms actuate the second set of strands while the arms moves in the second direction. For example, in some embodiments, the arms (one for each bobbin on the second track) can guide the second set of strands in accordance with a periodic pattern, which may include a (repeating) sinusoidal pattern. The machine tool may include a third track that defines the periodic pattern. In this manner, while the second set of strands and the arms move in the second direction, the arms further guide the material (i.e., strand) along the periodic pattern. When the first track is inside the second track (or alternatively put, the second track is outside the first track), the arm can guide the strands toward (including inside of) the bobbins on the first track, as well as guide the strands away from (including outside of) the bobbins on the first track. Alternative to the third track, each arm can be driven by a motor (e.g., servo motor) in accordance with the periodic pattern. 
       FIG.  15    illustrates a block diagram  1200  of a machine tool used to form an outer layer for a cable assembly, in accordance with some described embodiments. The features in the machine tool may be present in other machine tools described herein. The machine tool may include one or more processors  1210  for executing functions of the machine tool. One or more processors  1210  can refer to at least one of a central processing unit (CPU) and at least one microcontroller for performing dedicated functions. Also, one or more processors  1210  can refer to application specific integrated circuits. 
     According to some embodiments, the machine tool can include a display unit  1220 . Display unit  1220  is capable of presenting a user interface that includes icons (representing software applications), textual images, and/or motion images. In some examples, each icon can be associated with a respective function that can be executed by one or more processors  1210 . In some cases, display unit  1220  includes a display layer (not illustrated), which can include a liquid-crystal display (LCD), light-emitting diode display (LED), or the like. According to some embodiments, display unit  1220  includes a touch input detection component and/or a force detection component that can be configured to detect changes in an electrical parameter (e.g., electrical capacitance value) when the user&#39;s appendage (acting as a capacitor) comes into proximity with display unit  1220  (or in contact with a transparent layer that covers the display unit  1220 ). Display unit  1220  is connected to the one or more processors  1210  via one or more connection cables  1222 . 
     According to some embodiments, the machine tool can include one or more sensors  1230  capable of providing an input to one or more processors  1210  of the machine tool. One or more sensors  1230  may include proximity sensors (e.g., inductive proximity sensors, capacitive sensors, photoelectric sensors, or the like) used to determine the position of one or more bobbins and/or one or more arms of the machine tool. One or more sensors  1230  is/are connected to one or more processors  1210  via one or more connection cables  1232 . 
     According to some embodiments, machine tool can include one or more motors  1240 . In some cases, one or more motors  1240  includes alternating current (“AC”) motors, direct current (“DC”) motors, and/or servo motors. The one or more motors  1240  can drive the tracks that carry the bobbins. Additionally, some of the one or motors  1240  can drive the arms in accordance with a periodic pattern. When one or more one or more motors  1240  are used, one or more motors  1240  is/are connected to one or more processors  1210  via one or more connection cables  1242 . 
     According to some embodiments, machine tool can include a controller  1250  that is capable of providing commands to one or more motors  1240 . As an example, controller  1250  may include a programmable logic controller. Controller  1250  can be connected to one or more processors  1210  via one or more connection cables  1252 . 
     According to some embodiments, machine tool can include memory  1260 , which can include a single disk or multiple disks (e.g., hard drives), and includes a storage management module that manages one or more partitions within memory  1260 . In some cases, memory  1260  can include flash memory, semiconductor (solid state) memory or the like. Memory  1260  can also include a Random Access Memory (“RAM”) and a Read-Only Memory (“ROM”). The ROM can store programs, utilities or processes to be executed in a non-volatile manner. The RAM can provide volatile data storage, and stores instructions related to the operation of machine tool. In some embodiments, memory  1260  refers to a non-transitory computer readable medium. One or more processors  1210  can also be used to execute software applications. In some embodiments, a data bus  1262  can facilitate data transfer between memory  1260  and one or more processors  1210 . 
     According to some embodiments, machine tool can include wireless communications components  1270 . A network/bus interface  1272  can couple wireless communications components  1270  to one or more processors  1210 . Wireless communications components  1270  can communicate with other electronic devices via any number of wireless communication protocols, including at least one of a global network (e.g., the Internet), a wide area network, a local area network, a wireless personal area network (WPAN), or the like. In some examples, wireless communications components  1270  can communicate using NFC protocol, BLUETOOTH® protocol, or WIFI® protocol. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a non-transitory computer readable medium. The non-transitory computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the non-transitory computer readable medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The non-transitory computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings. 
     It is well understood that the use of personally identifiable information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or governmental requirements for maintaining the privacy of users. In particular, personally identifiable information data should be managed and handled so as to minimize risks of unintentional or unauthorized access or use, and the nature of authorized use should be clearly indicated to users.

Metadata:
Filing Date: 20210622
Publication Date: 20230613
Grant Date: 20230613
Priority Date: 20210622
Inventors: WEBER, ROBERT V.
KIM, MIN CHUL
SHA, JAY E.
Assignee: APPLE INC
CPC Classifications: [{"code": "D07B2201/209", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C3/32", "inventive": true, "first": false, "tree": "[]"}, {"code": "D07B7/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C3/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "D04C1/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "D07B2201/2089", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01B11/1808", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01B13/008", "inventive": true, "first": false, "tree": "[]"}, {"code": "D04C3/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01B7/17", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2403/0241", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01B7/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "D04C1/12", "inventive": true, "first": false, "tree": "[]"}, {"code": "D10B2403/0333", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C1/12", "inventive": true, "first": true, "tree": "[]"}, {"code": "D07B2201/2075", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C3/22", "inventive": false, "first": false, "tree": "[]"}, {"code": "D07B2201/209", "inventive": false, "first": false, "tree": "[]"}, {"code": "D07B2201/2075", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C3/22", "inventive": false, "first": false, "tree": "[]"}, {"code": "D07B7/021", "inventive": false, "first": false, "tree": "[]"}, {"code": "D07B2201/2089", "inventive": false, "first": false, "tree": "[]"}, {"code": "D04C1/12", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 84490656