PATENT DOCUMENT

Publication Number: US-11152752-B2
Application Number: US-201916428696-A
Country: US
Kind Code: B2

Title: Audio jack having integrated grounding

Abstract:
Audio jacks and device enclosures that provide proper grounding, are readily reworkable, provide improved ventilation, and have an aesthetically pleasing appearance. An example can include a device enclosure including an enclosure wall and a sleeve for an audio jack. The sleeve can connect to ground through various paths. The audio jack housing can be inserted in the sleeve and kept in place using a fastener. This arrangement can allow the audio jack to be readily reworkable. The sleeve can be narrow at the enclosure wall for improved ventilation and an aesthetically pleasing appearance.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a device enclosure for the electronic device, the device enclosure comprising: 
 an enclosure wall having an opening; 
 a sleeve integrally formed with the enclosure wall, the sleeve having a front aperture aligned with the opening in the enclosure wall, the sleeve extending into the electronic device from the enclosure wall and terminating in a rear opening; and 
 an audio jack assembly located in the sleeve and comprising:
 a housing; 
 a plurality of contacts supported by the housing, each of the plurality of contacts comprising a contacting portion and a contact tail; 
 an organizer around the contact tails of the plurality of contacts; 
 a board attached to the contact tails of the plurality of contacts, wherein the board includes an opening; 
 a stiffener between the organizer and the board; and 
 a fastener attached to the sleeve at the rear opening and physically and electrically contacting the stiffener through the opening in the board. 
 
 
     
     
       2. The electronic device of  claim 1  wherein the housing comprises a passage to accept a corresponding audio plug. 
     
     
       3. The electronic device of  claim 2  wherein the board is a flexible circuit board. 
     
     
       4. The electronic device of  claim 3  wherein the fastener, stiffener, and sleeve are conductive, such that a first ground path is through the sleeve, the fastener, and the stiffener to electrically contact a ground in the flexible circuit board. 
     
     
       5. The electronic device of  claim 4  further comprising a ground contact, where the ground contact comprises a contacting portion physically and electrically contacting the sleeve, and a tail portion attached to the flexible circuit board. 
     
     
       6. The electronic device of  claim 5  wherein a second ground path is through the sleeve, the ground contact, and a ground path in the flexible circuit board. 
     
     
       7. An audio jack comprising:
 a housing to fit in a sleeve of a device enclosure, the housing comprising a passage defining a circular front opening, the passage and circular front opening shaped to accept a corresponding audio plug, the housing further comprising a plurality of contact openings; 
 a plurality of contacts supported by the housing, each of the contacts comprising a contacting portion at a first end to mate with a corresponding contact on the audio plug when the audio plug is inserted into the audio jack, and a contact tail at a second end, wherein each contacting portion is positioned in a corresponding contact opening in the passage in the housing; 
 a board; 
 an organizer between the board and the housing; 
 and 
 a stiffener between the organizer and the board, 
 wherein each contact tail extends through the organizer and the stiffener and is attached to the board. 
 
     
     
       8. The audio jack of  claim 7  wherein the housing comprises a passage to accept the corresponding audio plug. 
     
     
       9. The audio jack of  claim 8  wherein the board comprises an opening to allow a fastener to contact the stiffener. 
     
     
       10. The audio jack of  claim 9  wherein the board is a flexible circuit board. 
     
     
       11. The audio jack of  claim 10  further comprising the sleeve and a fastener, the fastener attached to the sleeve and contacting the stiffener, wherein the fastener, stiffener, and sleeve are conductive, such that a first ground path is through the sleeve, the fastener, and the stiffener to electrically contact a ground in the flexible circuit board. 
     
     
       12. The audio jack of  claim 11  further comprising a ground contact, where the ground contact comprises a contacting portion physically and electrically contacting the sleeve, and a tail portion attached to the flexible circuit board. 
     
     
       13. The audio jack of  claim 9  wherein the fastener contacts the stiffener through the opening in the board. 
     
     
       14. An electronic device comprising:
 a device enclosure for the electronic device, the device enclosure comprising: 
 an enclosure wall having an opening; and 
 a sleeve integrally formed with the enclosure wall, the sleeve having a front aperture aligned with the opening in the enclosure wall, the sleeve extending into the electronic device from the enclosure wall and terminating in a rear opening, the sleeved having a cutout extending from the rear opening towards the enclosure wall; and 
 an audio jack assembly located in the sleeve and comprising: 
 a housing; 
 a plurality of contacts supported by the housing, each of the contacts comprising a contacting portion and a contact tail; 
 a fastener attached to the sleeve at the rear opening to secure the housing in the sleeve between the fastener and the enclosure wall; and 
 a board, wherein inside the sleeve, the board is attached to each contact tail of the plurality of contacts, and the board exits the sleeve through the cutout and between the fastener and housing. 
 
     
     
       15. The electronic device of  claim 14  wherein the housing comprises a passage to accept a corresponding audio plug. 
     
     
       16. The electronic device of  claim 15  wherein the board is a flexible circuit board. 
     
     
       17. The electronic device of  claim 16  further comprising an organizer having a corresponding opening for each of the contact tails. 
     
     
       18. The electronic device of  claim 17  wherein the housing comprises a first post and a second post to pass through corresponding openings in the organizer. 
     
     
       19. The electronic device of  claim 18  wherein the first post and the second post have different shapes. 
     
     
       20. The electronic device of  claim 14  wherein the electronic device is a desktop computer.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional patent application No. 62/736,391, filed Sep. 25, 2018, which is incorporated by reference. 
    
    
     BACKGROUND 
     Portable electronic devices, desktop computers, and other devices can provide audio signals to drive speakers, headphones, and other sound re-creation devices. To facilitate this, these devices can include audio jacks, into which an audio plug connected to a speaker or headphone can be inserted. 
     An audio jack can be located at a surface of a device enclosure of an electronic device. The device enclosure can be conductive and grounded. The audio jack can include ground contacts that can also be grounded. But improper or insufficient grounding of the device enclosure or audio jack can generate noise that can degrade the audio performance. For improved audio performance, it can be desirable that the device enclosure and audio jack be properly grounded. 
     Audio jacks can include several contacts and other components that can be subject to yield loss. This can occasionally require that an audio jack be reworked after assembly. Being able to rework an audio jack can allow an otherwise nonfunctional electronic device or component to be made functional. Accordingly, it can be desirable to be able to readily rework these audio jacks. 
     These electronic devices can include circuits, such as central processing units, graphics processing circuits, and other circuits. These circuits can consume large amounts of power and dissipate a great deal of heat. This heat can compromise device performance. For example, this heat can shorten circuit lifetime and can slow the circuits of the electronic devices. It can therefore be desirable that the device enclosure allow this heat to escape. That is, it can be desirable to provide device enclosures having improved ventilation. 
     The appearance of these device enclosures and audio jacks can be perceived to reflect upon the quality and value of the electronic devices. An aesthetically pleasing appearance can provide a user with a sense of quality and value. Accordingly, it can be desirable that these device enclosures and audio jacks have an aesthetically pleasing appearance. 
     Thus, what is needed are audio jacks and device enclosures that provide proper grounding, are readily reworkable, provide improved ventilation, and have an aesthetically pleasing appearance. 
     SUMMARY 
     Accordingly, embodiments of the present invention can provide audio jacks and device enclosures that provide proper grounding, are readily reworkable, provide improved ventilation, and have an aesthetically pleasing appearance. 
     An illustrative embodiment of the present invention can provide audio jacks and device enclosures that are properly grounded. A device enclosure for an electronic device can provide an enclosure wall having an opening through which an audio plug can be inserted into a corresponding audio jack. The enclosure wall can further include a sleeve for the audio jack that can extend from the enclosure wall into the electronic device. The audio jack can be located in the sleeve. The sleeve can electrically connect to an endcap of the audio jack, which can further connect though a fastener to a stiffener, which can be connected to a ground on a flexible circuit board or other appropriate substrate. This first ground path can ground the device enclosure through the audio jack. Also, a ground contact in the audio jack can include a contacting portion that can physically and electrically connect to the sleeve. This contact can be connected to the ground on the flexible circuit board or other appropriate substrate. This second ground path can also ground the device enclosure through the audio jack. A third ground path through a ground contact in the audio jack that mates with a corresponding ground contact on an audio plug can also be included. The third ground path can be kept isolated, for example using a filter, from the first and second ground paths for noise reasons. 
     An illustrative embodiment of the present invention can provide audio jacks that can be readily reworked. For example, a housing assembly can be inserted through a rear opening and into a corresponding sleeve. An endcap and fastener can be inserted into the rear opening of the sleeve, and the fastener can be turned in a first direction (for example, clockwise) to lock the housing assembly in place. In these and other embodiments of the present invention, the fastener and endcap can be a single piece. The audio jack housing can be keyed to prevent it from rotating when the fastener is turned. Rework can be readily performed by turning the fastener in a second direction opposite the first direction (for example, counter-clockwise), removing the endcap and fastener, and removing the housing assembly. 
     The housing assembly can be formed in various ways. For example, the housing can be formed around the contacts, or the contacts can be inserted in the housing. An organizer can be attached to the back of the housing to keep tails of the contacts aligned. A stiffener can be attached to, or formed as part of, a flexible circuit board. The flexible circuit board and stiffener can be placed against a back of the organizer such that the stiffener can be against the organizer and between the organizer and the flexible circuit board. The flexible circuit board can be soldered to the tails of the contacts. The flexible circuit board can have an opening such that the fastener can physically contact the stiffener and not crush or damage the flexible circuit board. 
     In these and other embodiments of the present invention, the enclosure wall and sleeve can be integrally formed. In these and other embodiments of the present invention, the enclosure wall and sleeve can be formed separately. The sleeve can then be attached to the enclosure wall, for example by soldering, laser or spot welding, or other technique. 
     An illustrative embodiment of the present invention can provide device enclosures having improved ventilation. For example, an enclosure wall can be formed as a mesh or other non-solid surface. In these and other embodiments of the present invention, the enclosure wall can be formed to have the appearance of being a mesh. The enclosure wall can include a pattern of perforations or holes to allow the passage of air to improve ventilation. For example, a pattern of holes can be formed in the enclosure wall to give the enclosure wall a mesh-like appearance. 
     In these and other embodiments of the present invention, the sleeve can be arranged to help to improve air flow though the mesh of the enclosure wall. For example, the enclosure wall can have an opening for an audio jack. A sleeve can have a front opening or front aperture aligned with the enclosure wall opening. In these and other embodiments of the present invention, the front aperture can have a minimum width to accept a corresponding audio plug. 
     The sleeve can have a thickness that is limited to at least approximately the thickness of the mesh of the enclosure wall, where the thickness of the mesh is the lateral thickness of the mesh of the enclosure wall between adjacent holes or perforations. This limited profile for an audio jack can improve ventilation through the enclosure wall. 
     The sleeve can act as a shield for the audio jack. This can allow contacts or other portions of the audio jack to be pulled away from the enclosure wall thereby allowing a narrower sleeve front aperture. This narrow front end to the sleeve can help to further improve ventilation and prevent air flow through the enclosure wall from being blocked by the sleeve and audio jack. 
     A sleeve can taper to a rear aperture away from the enclosure wall and inside the electronic device. The rear aperture can be wider or larger than the front aperture and it can be wide enough to accept a front end of an audio jack and a corresponding audio plug. The sleeve can widen in steps from the front aperture to the rear aperture. The sleeve can instead widen in a line or curve from the front aperture to the rear aperture. In these and other embodiments of the present invention, the sleeve can have other widening contours. In these and other embodiments of the present invention, the sleeve can maintain its width, it can have narrowing portions, or it can have other contours. 
     An illustrative embodiment of the present invention can provide audio jacks and device enclosures having an aesthetically pleasing appearance. For example, even though an enclosure wall can have a number of holes or perforations for a mesh appearance, the audio jacks might only be visible to a limited extent. For example, a tapered sleeve can provide a minimal front aperture for an improved appearance. The tapered sleeve can limit the visibility of the audio jacks and their structures as viewed from outside the electronic device. Some or all of the enclosure wall and sleeve can be darkened to absorb light and reduce reflections. Some of all of these structures can be darkened using a conductive black PVD (physical vapor deposition) process, cosmetic tape, paint, pad printing, plating, laser darkening, or other process or material. In these and other embodiments of the present invention, a flexible circuit board supporting the audio jack can be colored to match either or both the enclosure wall and sleeve. For example, these structures can each be colored black, though they can have other colors as well. This can give an audio jack at an opening in the enclosure wall the appearance that it is floating in the mesh of the enclosure wall. 
     These enclosure walls and sleeves can be formed in various ways in these and other embodiments of the present invention. For example, they can be formed by machining, such as by using computer numerical controlled machines, stamping, deep drawing, forging, metal-injection molding, micro-machining, 3-D printing, or other manufacturing process. These enclosure walls and sleeves can be formed of various materials. For example, they can be formed of aluminum, steel, stainless steel, copper, bronze, or other material. In these and other embodiments of the present invention, a material having good electrical and thermal conductivity can be chosen. 
     In various embodiments of the present invention, contacts, stiffeners, endcaps, fasteners, and other portions of audio jacks and device enclosures can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. These portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. Other portions, such as audio jack housings and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. These portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. 
     Embodiments of the present invention can provide audio jacks and device enclosures that can be located in, or can connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, smartphones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. 
     Various embodiments of the present invention can incorporate one or more of these and the other features described herein. A better understanding of the nature and advantages of the present invention can be gained by reference to the following detailed description and the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system according to an embodiment of the present invention; 
         FIG. 2  illustrates a portion of a device enclosure according to an embodiment of the present invention; 
         FIG. 3  illustrates a cross-section of an audio jack and device closure according to an embodiment of the present invention; 
         FIG. 4  illustrates another cross-section of an audio jack and device closure according to an embodiment of the present invention; 
         FIG. 5  through  FIG. 10  illustrate a method of manufacturing an audio jack according to an embodiment of the present invention; 
         FIG. 11  illustrates a portion of a device enclosure according to an embodiment of the present invention; 
         FIG. 12-14  illustrate a method of manufacturing an audio jack according to an embodiment of the present invention; 
         FIG. 15  is a rear view of an audio jack and device enclosure according to an embodiment of the present invention; 
         FIG. 16  illustrates another cross-section of an audio jack and device closure according to an embodiment of the present invention; 
         FIG. 17  illustrates a portion of an audio jack according to an embodiment of the present invention; and 
         FIG. 18  illustrates an organizer for an audio jack according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
       FIG. 1  illustrates an electronic system according to an embodiment of the present invention. This figure, as with the other included figures, is shown for illustrative purposes and does not limit either the possible embodiments of the present invention or the claims. 
     In this example, an electronic system can include desktop computer  110  that is in communication with monitor  120  and headphones  150 . Desktop computer  110  can include a Peripheral Component Interconnect Express (PCIe) card or computer expansion card, or other electronic device having enclosure wall  112 . Desktop computer  110  can be housed in a device enclosure including case  116  and computer expansion card enclosure wall  112 . In these and other embodiments of the present invention, enclosure wall  112  can be a portion of a device enclosure placed in an opening in case  116  of desktop computer  110 . For example, enclosure wall  112  can be located in an opening in a front, top, or a rear of case  116  of desktop computer  110 , or it can be located in these or other locations on other electronic devices. Desktop computer  110  can use the computer expansion card to provide graphics information to monitor  120  over cable  130 , and to provide audio information over cable  140  to headphones  150 . In these and other embodiments of the present invention, this computer expansion card can provide graphics, sound, networking, and other functions for desktop computer  110 . In these and other embodiments of the present invention, desktop computer  110  can employ two or more such computer expansion cards, for example, where a first computer expansion card provides graphics and other information to monitor  120 , while a second computer expansion card provides audio signals over cable  140  to headphones  150 . 
     Cable  130  can be one of a number of various types of cables. For example, it can be a Universal Serial Bus (USB) cable such as a USB Type-A cable, USB Type-C cable, HDMI, Thunderbolt, DisplayPort, Lightning, or other type of cable. Cable  130  can include compatible connector inserts  132  that plug into connector receptacle  114  on desktop computer  110  and a connector receptacle (not shown) on monitor  120 . Cable  140  can be an audio cable having an audio plug  142  at one end that is inserted into opening  118  for audio jack  320  (shown in  FIG. 3 ) in enclosure wall  112 . 
     In these and other embodiments of the present invention, either or both desktop computer  110  and monitor  120  can instead be portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, smart phones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, or other devices. Headphones  150  can be speakers, sound bars, or other audio equipment. 
       FIG. 2  illustrates a portion of a device enclosure according to an embodiment of the present invention. In this example, enclosure wall  112  can be a portion of a computer expansion card and can be located in an opening in case  116  (shown in  FIG. 1 ), or it can be a portion of a device enclosure such as case  116  of desktop computer  110 . In these and other embodiments of the present invention, enclosure wall  112  can be located in an opening in a front, top, or rear or case  116  of desktop computer  110 , and it can be there or elsewhere in another device enclosure for another type of electronic device. 
     These and other embodiments of the present invention can provide device enclosures, such as enclosure walls  112 , having improved ventilation. For example, enclosure wall  112  can be formed as a mesh or other non-solid surface. In these and other embodiments of the present invention, enclosure wall  112  can be formed to have the appearance of being a mesh. Enclosure wall  112  can include a pattern of holes or perforations  250  to allow the passage of air to improve ventilation. For example, a pattern of holes or perforations  250  can be formed in enclosure wall  112  to give enclosure wall  112  a mesh-like appearance. In these and other embodiments of the present invention, enclosure wall  112  can instead be formed already having holes or perforations  250 . 
     These holes or perforations  250  can allow improved ventilation for components inside case  116 . In this example, enclosure wall  112  can further include opening  118  for an audio jack  320  (shown in  FIG. 3 .) Opening  118  can have a minimal size or front aperture  260  while still being able to accept a corresponding audio plug  142  (shown in  FIG. 1 .) Opening  118  can provide access to contacts  220 , which can be supported by housing  210 . Opening  118  can be surrounded by an enclosure opening ring  221  having an annular ring width  223  that is limited to at least approximately the thickness  225  of the mesh, where the thickness of the mesh is the lateral thickness  225  of the mesh of enclosure wall  112  between adjacent holes or perforations  250 . The reduced size or enclosure opening ring  221  can help to preserve the mesh appearance at the surface of enclosure wall  112 . This reduced size can also help to improve ventilation of desktop computer  110  and its components by reducing the size of structures that can otherwise block holes or perforations  250  in enclosure wall  112 . Further details of enclosure walls  112 , including their structure, methods of manufacturing, and the materials that can be used, can be found in U.S. Provisional Patent Application No. 62/736,299, titled “HOUSING CONSTRUCTION,” filed Sep. 25, 2018, and co-pending U.S. patent application Ser. No. 16/412,240, titled “HOUSING CONSTRUCTION,” filed May 14, 2019, which are incorporated by reference. 
     In these and other embodiments of the present invention, ventilation can be further improved by employing sleeve  310  as a shield for audio jack  320 . This sleeve  310  can be integrally formed with enclosure wall  112 . In these and other embodiments of the present invention, sleeve  310  can be formed separately from enclosure wall  112  and then attached to enclosure wall  112  by soldering, spot or laser welding, or other method. Sleeve  310  can further help to reduce the size of structures that can otherwise block holes or perforations  250  in enclosure wall  112 . Sleeve  310  can also allow structures to be positioned away from enclosure wall  112  further into the electronic device such that ventilation is improved. Cross-sections of audio jack  320  are shown in the following figures. 
       FIG. 3  illustrates a cross-section of an audio jack and device closure according to an embodiment of the present invention. This cross-section is taken along cutline “3-3” of  FIG. 2 . In this example, audio jack  320  can be located in sleeve  310 , which can be formed as part of enclosure wall  112 . Enclosure wall  112  can include holes or perforations  250  for ventilation. Sleeve  310  can extend from enclosure wall  112  into an electronic device. Sleeve  310  can widen or taper towards an interior of the device where it can have rear aperture  375 . Rear aperture  375  can be wider or larger than front aperture  260  (shown in  FIG. 2 .) Front aperture  260  can be wide enough to accept a front end of audio jack  320  and corresponding audio plug  142  (shown in  FIG. 1 .) Sleeve  310  can widen in steps from front aperture  260  to rear aperture  375 . Sleeve  310  can instead widen in a line or curve from front aperture  260  to rear aperture  375 . In these and other embodiments of the present invention, sleeve  310  can have other widening contours. In these and other embodiments of the present invention, sleeve  310  can maintain its width, it can have narrowing portions, or it can have other contours. 
     Housing  210  can be located in sleeve  310 . Housing  210  can include passage  302  that can accept a corresponding audio plug  142  (shown in  FIG. 1 .) Housing  210  can support a number of contacts  220 . Contacts  220  can include contacting portions  222  that can physically and electrically connect to contacts on the corresponding audio plug  142 . Contacts  220  can further include contact tails  224 . Contacts  220  can be relatively long since they terminate at a rear of housing  210 . Accordingly, organizer  390  can be used to align contact tails  224  of contacts  220 . Contact tails  224  can be soldered or otherwise attached to flexible circuit board  230 . Flexible circuit board  230  can be routed to other electronic audio circuits (not shown) in the electronic device. 
     Housing  210  and organizer  390  can be held in place by endcap  360  and fastener  350 . In these and other embodiments of the present invention, endcap  360  and fastener  350  can be formed as a single piece. Fastener  350  can include hole  352  for a tool (not shown), where the tool can be used to turn fastener  350  and endcap  360 . Endcap  360  and fastener  350  can be inserted in a rear opening of sleeve  310  and turned to lock endcap  360  in place. A stiffener  240  can be attached to, or formed as part of, flexible circuit board  230 . Flexible circuit board  230  and stiffener  240  can be positioned such that stiffener  240  is between flexible circuit board  230  and organizer  390 . Flexible circuit board  230  can include opening  610  (shown in  FIG. 6 ) such that fastener  350  presses against stiffener  240  directly and does not crush a portion of flexible circuit board  230 . 
     In this example, sleeve  310 , endcap  360 , fastener  350 , and stiffener  240  can be conductive. This can form a first ground path through sleeve  310 , endcap  360 , fastener  350 , and stiffener  240  to a ground in flexible circuit board  230 . 
     A second ground path can be formed through contact  380 . Specifically, contact  380  can include contacting portion  382  that can physically and electrically contact sleeve  310 . Contact  380  can further include contact tail  384 , which can electrically connect to a ground in flexible circuit board  230 . Contact  380  can be supported by extended portion  392 , shown in  FIG. 18 . 
     A third ground path through a ground contact, which can be one of the contacts  220  in audio jack  320 , that mates with a ground contact on an audio plug can also be included. The third ground path can be kept isolated, for example using a filter, from the first and second ground paths for noise reasons. 
     During assembly, contacts  220  can be stamped or otherwise formed. These contacts  220  can be inserted in housing  210 , or housing  210  can be formed around contacts  220 . Contact  380  can be placed in extended portion  392  of organizer  390 . Organizer  390  can be placed against an end of housing  210 . Stiffener  240  can be placed against a rear of organizer  390 . Stiffener  240  can be attached to, or formed as part of, flexible circuit board  230 , which can be attached to contact tails  224 , for example by soldering, reflow soldering, waves soldering, or other soldering or attachment process. Fastener  350  can be attached to endcap  360 . Fastener  350  can be fit in a rear opening of sleeve  310  and turned, thereby locking endcap  360  in place in sleeve  310 . 
       FIG. 4  illustrates another cross-section of an audio jack and device enclosure according to an embodiment of the present invention. This cross-section is taken along cut section “4-4” in  FIG. 2 . Again, audio jack  320  can be located in sleeve  310 , which can be formed as part of enclosure wall  112 . Sleeve  310  can extend from enclosure wall  112  into an electronic device. 
     Housing  210  can be located in sleeve  310 . Housing  210  can include passage  302  that can accept corresponding audio plug  142  (shown in  FIG. 1 .) Housing  210  can support a number of contacts  220 . Contacts  220  can include contacting portions  222  that can physically and electrically connect to contacts on the corresponding audio plug. Contacts  220  can further include contact tails  224 . Posts  212  of housing  210  can pass through organizer  390  to align organizer  390  to housing  210 . Organizer  390  can be used to align contact tails  224  of contacts  220 . Contact tails  224  can be soldered or otherwise attached to flexible circuit board  230 . Flexible circuit board  230  can be routed to other electronic audio circuits (not shown) in the electronic device. 
     Housing  210  and organizer  390  can be held in place by endcap  360  and fastener  350 . Fastener  350  can include hole  352  for a tool (not shown), where the tool can be used to turn fastener  350  and endcap  360 . Endcap  360  and fastener  350  can be inserted in a rear opening of sleeve  310  and turned to lock endcap  360  in place. A stiffener  240  can be placed between flexible circuit board  230  and organizer  390 . Flexible circuit board  230  can include opening  610  (shown in  FIG. 6 ) such that fastener  350  presses against stiffener  240  directly and does not crush a portion of flexible circuit board  230 . Endcap  360  can include locking tab  364 , which can engage locking feature or tab  312  on sleeve  310 . 
       FIG. 5  through  FIG. 10  illustrates a method of manufacturing an audio jack according to an embodiment of the present invention. In  FIG. 5 , housing  210  and organizer  390  have been inserted into sleeve  310  of enclosure wall  112 . Enclosure wall  112  can have holes or perforations  250  for ventilation. Housing  210  can support a number of contacts  220 . Contacts  220  can include contacting portions  222  for contacting a corresponding contact on an audio plug. Organizer  390  can be placed against a rear of housing  210  to support contact tails  224 . Posts  212  of housing  210  can be used to align organizer  390  to housing  210 . Contact  380  can be supported by extended portion  392  of organizer  390  and can include contacting portion  382  that physically and electrically connects to in inside surface of sleeve  310 . 
     Housing  210  can include keying feature  219  that can mate with keying feature  319  on sleeve  310 . These keying features  219  and  319  can prevent housing  210  from rotating inside of sleeve  310  during further assembly steps, for example, when fastener  350  is turned to lock endcap  360  in place in sleeve  310 , as shown below in  FIGS. 8-10 . 
       FIG. 6  illustrates a rear view of an audio jack after stiffener  240  and flexible circuit board  230  have been attached to housing  210  (shown in  FIG. 5 ) and the assembly has been located in sleeve  310 . Stiffener  240  and flexible circuit board  230  can be attached either before or after housing  210  is inserted into sleeve  310 . In this example, flexible circuit board  230  can include solder areas  602 ,  604 ,  606 , and  608 . These solder areas  602 ,  604 ,  606 , and  608  can be used to connect contact tails  224  and  384  to traces in flexible circuit board  230 . That is, contact tails  224  and  384  can pass through openings in stiffener  240  and flexible circuit board  230  and can be soldered at solder areas  602 ,  604 ,  606 , and  608  to form connections to traces or paths in flexible circuit board  230 . Flexible circuit board  230  can further include opening  610 . Fastener  350  (shown in  FIG. 3 ) can physically and electrically contact stiffener  240  through opening  610 . Sleeve  310  can include locking features or tabs  312 . Posts  212  can be used below to align organizer  390  to housing  210  (shown in  FIG. 17 .) Posts  212  can include two different posts, identified here as posts  212 A and  212 B. In  FIG. 7 , fastener  350  can be mated with endcap  360 . Fastener  350  can include hole  352  that can accept a tool (not shown), where the tool can be used to rotate fastener  350 . Fastener  350  can physically and electrically connect to stiffener  240  (shown in  FIG. 6 ) at surface  354 . In these and other embodiments of the present invention, endcap  360  and fastener  350  can be formed as a single piece. In  FIG. 8 , endcap  360  and fastener  350  can be inserted into a rear opening of sleeve  310 . Endcap  360  can be aligned such that tabs  364  do not engage tabs  312  on a back of sleeve  310 . Fastener  350  and endcap  360  can be rotated using a tool (not shown) in hole  352 . When this is done, tabs  364  on endcap  360  can be aligned with tabs  312  on sleeve  310 , as shown in  FIG. 9 . This can secure endcap  360  in sleeve  310 . In  FIG. 10 , tabs  364  of endcap  360  are held in place by tabs  312  of sleeve  310 . 
       FIG. 11  illustrates a portion of a device enclosure according to an embodiment of the present invention. In this example, the mesh formed by perforations  250  (shown in  FIG. 2 ) has been omitted and enclosure wall  112  can have a more solid surface. Audio jack  320  (shown in  FIG. 3 ) including housing  210  supporting contacts  220  can be located in opening  118  of enclosure wall  112 . 
       FIG. 12-14  illustrate a method of manufacturing an audio jack according to an embodiment of the present invention. In  FIG. 12 , an audio jack  320  can be inserted in sleeve  310  of enclosure wall  112 . Housing  210  can support contacts  220 , which can terminate at contact tails  224 . Contact tails  224  can be supported by organizer  390  and can be soldered to flexible circuit board  230 . Stiffener  240  can be between organizer  390  and flexible circuit board  230 . Stiffener  240  can be formed separately or stiffener  240  can be formed on a surface of flexible circuit board  230 . 
     Flexible circuit board  230  can be routed out of sleeve  310  through cutout  311 . Fastener  1350  can be threaded or otherwise inserted into sleeve  310 . For example, fastener  1350  can include a threaded surface  1353  that can mate with threaded surface  313  inside of sleeve  310 . Fastener  1350  can be turned using a tool (not shown) placed in hole  1352 . A front portion of connector receptacle  114  (shown in  FIG. 13 ) can be inserted into sleeve  314  of enclosure wall  112 . 
       FIG. 13  illustrates another rear view of an audio jack after flexible circuit board  230  has been attached to housing  210  (shown in  FIG. 5 ) and the assembly has been located in sleeve  310 . Enclosure wall  112  can be attached to board  710  by fastener  714  (shown in  FIG. 15 ), which can pass through opening  712  in board  710  and into a hole (not shown) in extended portion  113  of enclosure wall  112 . Flexible circuit board  230  can terminated in contacts  231 . Contacts  231  can be formed on a surface of flexible circuit board  230  and can be supported in connector  720 , which can be located on board  710 . Contact tails  224  can be soldered to flexible circuit board  230 . A cutout  311  can be formed in sleeve  310  to allow for the passage of flexible circuit board  230  out of sleeve  310 . Connector receptacle  114  can be mounted on board  710 . In  FIG. 14 , fastener  1350  can be inserted in sleeve  310  and rotated into position using a tool (not shown) in hole  1352 . Flexible circuit board  230  can escape sleeve  310  at cutout  311  (shown in  FIG. 12 ) and can terminate at connector  720  on board  710 . Sleeve  310  can terminate in enclosure wall  112 , which can be mounted, along with connector receptacle  114 , on board  710 . 
       FIG. 15  is a rear view of an audio jack and device enclosure according to an embodiment of the present invention. Fastener  1350  can be in place in a rear opening of sleeve  310 . Flexible circuit board  230  can be routed through cutout  311  in sleeve  310  of enclosure wall  112 . Enclosure wall  112  can be attached to board  710  (shown in  FIG. 13 ) by fastener  714 . Fastener  714  can pass through opening  712  (shown in  FIG. 13 ) in board  710  (shown in  FIG. 13 ) and be threaded or otherwise fixed in a hole (not shown) in extended portion  113  of enclosure wall  112 . 
       FIG. 16  illustrates another cross-section of an audio jack and device closure according to an embodiment of the present invention. Housing  210  and organizer  390  can be located in sleeve  310  of enclosure wall  112 . Housing  210  can support a number of contacts  220 . Contacts  220  can include contacting portions  222  for contacting a corresponding contact on a corresponding audio plug  142  (shown in  FIG. 1 .) Organizer  390  can be placed against a rear of housing  210  to support contact tails  224 . Contact  380  can be supported by extended portion  392  of organizer  390  and can include contacting portion  382  that physically and electrically connects to in inside surface of sleeve  310 . 
     Housing  210  can include keying feature  219  that can mate with keying feature  319  on sleeve  310 . These keying features  219  and  319  can prevent housing  210  from rotating inside of sleeve  310  during further assembly steps, for example, when fastener  1350  is screwed or threaded into sleeve  310 . Threads on threaded surface  1353  on fastener  1350  can mate with threads on threaded surface  313  of sleeve  310 . Again, fastener  1350  can be turned using a tool (not shown) in hole  1352 . Fastener  1350  can secure flexible circuit board  230 , stiffener  240 , and organizer  390  in place at a rear of housing  210 . Fastener  1350  can physically and electrically connect to stiffener  240  (shown in  FIG. 6 ) through opening  610  (shown in  FIG. 6 ) in flexible circuit board  230  at surface  1354 . 
     Enclosure wall  112  can include an extended portion  113  that can have a hole (not shown) to accept an end of fastener  714 . Fastener  714  can pass through opening  712  (shown in  FIG. 13 ) in board  710  and be threaded or otherwise fixed in the hole in extended portion  113 . Flexible circuit board  230  can terminate at contacts  231 , which can be supported by connector  720 . 
       FIG. 17  illustrates a portion of an audio jack according to an embodiment of the present invention. In this example, contacts  220  are supported by housing  210 . Contacts  220  can include contact tails  224  which can be available at openings  1120  in organizer  390 . Posts  212 A and  212 B can pass through openings  1124  and  1126  in organizer  390 . Posts  212  A and  212  B can have different shapes corresponding to shapes of openings  1124  and  1126  to aid in device assembly. 
       FIG. 18  illustrates an organizer for an audio jack according to an embodiment of the present invention. Organizer  390  can include openings  1120  for contact tails  224  (shown in  FIG. 17 .) Organizer  390  can include openings  1124  and  1126  for posts  212 A and  212 B of housing  210  (shown in  FIG. 17 .) Organizer  390  can further include a slot  1212  on extended portion  392 . This slot  1212  and extended portion  392  can support contact  380  (shown in  FIG. 5 .) 
     An illustrative embodiment of the present invention can provide audio jacks  320  and device enclosures, including enclosure wall  112 , having an aesthetically pleasing appearance. For example, even though an enclosure wall  112  can have a number of holes or perforations  250  for a mesh appearance, audio jack  320  can only be visible to a limited extent. For example, tapered sleeve  310  can provide a minimal front aperture  260  for an improved appearance. Tapered sleeve  310  can limit the visibility of the audio jack and their structures as viewed from outside the electronic device. Some or all of the sleeve  310  and flexible circuit board  230  can be darkened to absorb light and reduce reflections and match an enclosure wall  112 . Some of all of these structures can be darkened using a conductive black PVD (physical vapor deposition) process, cosmetic tape, paint, pad printing, plating, laser darkening, or other process or material. These structures can each be colored black, though they can have other colors as well. This can give the audio jacks  320  at openings in enclosure wall  112  the appearance that they are floating in the mesh of the enclosure wall  112 . 
     These enclosure walls  112  and sleeves  310  can be formed in various ways in these and other embodiments of the present invention. For example, they can be formed by machining, such as by using computer numerical controlled machines, stamping, deep drawing, forging, metal-injection molding, micro-machining, 3-D printing, or other manufacturing process. These enclosure walls  112  and sleeve  310  can be formed of various materials. For example, they can be formed of aluminum, steel, stainless steel, copper, bronze, or other material. In these and other embodiments of the present invention, a material having good electrical and thermal conductivity can be chosen. 
     In various embodiments of the present invention, contacts  220 , stiffeners  240 , endcaps  360 , fasteners  350 , and other portions of audio jacks  320  and device enclosures can be formed by stamping, metal-injection molding, machining, micro-machining, 3-D printing, or other manufacturing process. These portions can be formed of stainless steel, steel, copper, copper titanium, phosphor bronze, or other material or combination of materials. They can be plated or coated with nickel, gold, or other material. Other portions, such as audio jack housings and other structures can be formed using injection or other molding, 3-D printing, machining, or other manufacturing process. These portions can be formed of silicon or silicone, rubber, hard rubber, plastic, nylon, liquid-crystal polymers (LCPs), ceramics, or other nonconductive material or combination of materials. 
     Embodiments of the present invention can provide audio jacks  320  and device enclosures, including enclosure wall  112 , that can be located in, or can connect to, various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, smartphones, storage devices, portable media players, navigation systems, monitors, power supplies, video delivery systems, adapters, remote control devices, chargers, and other devices. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20190531
Publication Date: 20211019
Grant Date: 20211019
Priority Date: 20180925
Inventors: AMINI, MAHMOUD R.
ZHOU, RUI
NILKANTH, AMEYA V.
Harper, James E.
LANAS, MARIEL L.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/436", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/4367", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/436", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/4367", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/405", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/592", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 69884562