PATENT DOCUMENT

Publication Number: US-9778705-B2
Application Number: US-201615256470-A
Country: US
Kind Code: B2

Title: Electronic device with moveable contacts at an exterior surface

Abstract:
An accessory device comprising: an enclosure; one or more electrical components positioned within or attached to the enclosure; an attachment feature connected to the enclosure and configured to magnetically couple the accessory device with the electronic device, the attachment feature comprising: an exterior surface; a corresponding plurality of openings formed through the exterior surface; a plurality of movable contacts corresponding in number to the plurality of openings, each movable contact extending out of one of the plurality of openings; one or more biasing members operatively coupled to the plurality of movable contacts to bias the contacts such that a contacting portion of each contact protrudes beyond the exterior surface of the attachment feature through its respective opening; and an alignment feature comprising at least one magnet positioned adjacent to the plurality of openings.

Claims:
What is claimed is: 
     
       1. An accessory device suitable for use with an electronic device, the accessory device comprising:
 an enclosure; 
 one or more electrical components positioned within or attached to the enclosure; 
 an attachment feature connected to the enclosure and configured to magnetically couple the accessory device with the electronic device, the attachment feature comprising:
 an exterior surface; 
 a corresponding plurality of openings formed through the exterior surface; 
 a plurality of movable contacts corresponding in number to the plurality of openings, each movable contact extending out of one of the plurality of openings; 
 one or more biasing members operatively coupled to the plurality of movable contacts to bias the contacts such that a contacting portion of each contact protrudes beyond the exterior surface of the attachment feature through its respective opening; and 
 an alignment feature comprising at least one magnet positioned adjacent to the plurality of openings. 
 
 
     
     
       2. The accessory device set forth in  claim 1  wherein the attachment feature is connected to the enclosure by a flexible member. 
     
     
       3. The accessory device set forth in  claim 2  wherein the attachment feature has an elongated shape with a back portion extending along a length of the attachment feature and concavely curved front portion opposite the back portion, and wherein the plurality of movable contacts are exposed at a center location within the front portion. 
     
     
       4. The accessory device set forth in  claim 2  wherein the flexible member enables the attachment feature to be rotated with respect to the enclosure around an axis that is parallel to a length of the attachment feature. 
     
     
       5. The accessory device set forth in  claim 1  wherein the accessory device includes a raised portion around the plurality of openings. 
     
     
       6. The accessory device set forth in  claim 1  wherein each of the plurality of contacts comprises a flexible lever arm having first and second ends; and wherein the contact portion is attached to the first end and a barb is formed on the second end. 
     
     
       7. The accessory device set forth in  claim 6  wherein each contact includes a wider body portion and a narrowed end. 
     
     
       8. The accessory device set forth in  claim 1  wherein the plurality of openings are formed in a surface that is substantially flush with surrounding exterior surfaces and each contact in the plurality of contacts protrudes above the exterior surface by no more than 1 mm. 
     
     
       9. The accessory device set forth in  claim 1  wherein the alignment feature comprises first and second arrays of magnets positioned on opposite sides of the plurality of openings. 
     
     
       10. An accessory device suitable for use with an electronic device, the accessory device comprising:
 a cover; 
 one or more electrical components embedded within or attached to the cover; 
 an attachment feature connected to the cover by a flexible member and configured to couple the accessory device with the electronic device, wherein the attachment feature comprises: 
 a first housing; 
 an opening within the housing; 
 a contact structure positioned within the opening at an exterior surface of the attachment feature, the contact structure including: (i) a second housing; (ii) a plurality of openings formed in the second housing; (iii) a plurality of movable contacts corresponding in number to the plurality of openings, each of the plurality of movable contacts having a contacting portion; and (iv) one or more biasing members positioned within the second housing and operatively coupled to the plurality of movable contacts to bias the contacts such that the contacting portion of each contact protrudes outside of the second housing through its respective opening; and 
 an alignment feature positioned within the first housing and comprising first and second magnets positioned on opposing sides of the opening, the first magnet positioned adjacent to a first end of the opening and the second magnet positioned adjacent to a second end of the opening; 
 wherein at least one of the plurality of movable contacts is operatively coupled to the one or more electrical components enabling data to be exchanged between the accessory device and the electronic device. 
 
     
     
       11. The accessory device set forth in  claim 10  wherein the second housing comprises an electrically nonconductive cover attached to a lower housing portion, and wherein the plurality of opening are formed within the cover. 
     
     
       12. The accessory device set forth in  claim 11  wherein the cover includes a raised portion sized and shaped to fit within the opening of the first housing. 
     
     
       13. The accessory device set forth in  claim 10  wherein each of the plurality of contacts comprises a flexible lever arm having first and second ends; and wherein the contact portion is attached to the first end and a barb is formed on the second end and inserted into the housing. 
     
     
       14. The accessory device set forth in  claim 13  wherein each contact includes a wider body portion and a narrowed end. 
     
     
       15. The accessory device set forth in  claim 14  wherein the second housing includes a raised portion around the plurality of openings. 
     
     
       16. The accessory device set forth in  claim 10  further comprising an exterior layer that extends along an exterior surface of the cover and folds over the attachment feature. 
     
     
       17. The accessory device set forth in  claim 10  wherein the attachment feature has an elongated shape with a convexly curved back portion and concavely curved front portion, and wherein the contact structure is exposed at a center location within the front portion. 
     
     
       18. An accessory device suitable for use with an electronic device, the accessory device comprising: an enclosure;
 one or more electrical components positioned within or attached to the enclosure; an attachment feature connected to the enclosure and configured to magnetically couple the accessory device with the electronic device, the attachment feature comprising a housing and an opening formed through the housing; 
 a contact structure positioned within the opening at an exterior surface of the attachment feature, the contact structure including: a contact housing; 
 a cover attached to a top of the contact housing, the cover including a raised portion sized and shaped to fit within the device housing opening; a plurality of openings formed in the cover; 
 a plurality of movable contacts corresponding in number to the plurality of openings, each of the plurality of movable contacts having a contacting portion; and 
 a plurality of biasing members positioned within the contact housing and corresponding in number to the plurality of contacts, each biasing member operatively coupled to one of the plurality of movable contacts to bias the contact such that the contacting portion protrudes outside of the enclosure through its respective opening; and an alignment feature positioned within the housing and comprising first and second arrays of magnets positioned on opposing sides of the plurality of movable contacts. 
 
     
     
       19. The accessory device set forth in  claim 18  wherein the attachment feature has an elongated shape with the contact structure centered along a length of the attachment feature. 
     
     
       20. The accessory device set forth in  claim 1  wherein the plurality of openings are formed in a surface that is substantially flush with a surrounding exterior surface of the attachment feature and each contact in the plurality of contacts protrudes above the exterior surface of the attachment feature by no more than 1 mm.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of priority of U.S. Provisional Patent Application 62/215,707 filed on Sep. 8, 2015; U.S. Provisional Patent Application 62/215,714 filed on Sep. 8, 2015; U.S. Provisional Patent Application 62/254,033 filed on Nov. 11, 2015; U.S. Provisional Patent Application 62/215,592 filed on Sep. 8, 2015; and U.S. Provisional Patent Application 62/214,671 filed on Sep. 4, 2015; each of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     There are many different types of electronic devices including laptop computers, tablet computers, smart phones, among others. Such devices can work in cooperation with one or more accessory devices (e.g., a keyboard, a game controller, a clock radio, etc.) to expand the capabilities and functionality of the primary or host electronic device. To do so, a connection can be established between the host electronic device and the accessory electronic device. 
     Connections can be established with a variety of conventional physical connectors that adhere to pre-defined formats, such as USB 2.0, USB 3.0, Firewire, and the like, or connections can be established wirelessly using protocols such as Bluetooth, WiFi, etc. In some instances, a physical, wired connection can be beneficial to exchange power and exchange data. 
     Wired connections require some amount of real estate within the device. As an example, a USB receptacle connector typically requires a certain amount of surface area at an exterior surface of a host device along with a certain amount of volume within the host device for the cavity of the receptacle connector into which a plug connector can be inserted and for the associated contacts and circuitry of the receptacle connector. Physical connectors can also become a potential source of corrosion and may detract somewhat from the aesthetic appearance of the device. 
     BRIEF SUMMARY 
     Embodiments of the disclosure pertain to an electronic device, such as an accessory electronic device, that includes a physical connector having one or more contacts positioned at an exterior surface of the device. Each of the one or more contacts can be positioned within an opening that corresponds in size and shape to the contact such that there is essentially no gap or a minimal gap between the sides of the contact and surfaces surrounding the opening where a contacting portion of each contact protrudes out of the opening. The one or more contacts can be biased by a biasing element, such as a spring, to protrude from the opening, and are movable in a direction perpendicular to the surrounding housing such that when the contacts are mated with an appropriate connector on another device, each contact depresses slightly inward within its respective opening. The biasing element applies a sufficient normal force to the contacts to maintain a strong electrical connection between each contact and its corresponding contact in the mating connector. 
     Some embodiments the connector does not include an exposed cavity or other open area in which dirt or debris, such as lint, can collect. Additionally, connectors according to embodiments of the disclosure take up minimal real estate, including minimal surface area, depth and volume, on the electronic device in which they are incorporated. As such, connectors according to the disclosure can be small and barely noticeable contributing to the overall aesthetic appearance of the device. 
     In some embodiments, an accessory device suitable for use with an electronic device is provided. The accessory includes: an enclosure; one or more electrical components positioned within or attached to the enclosure; an attachment feature connected to the enclosure and configured to magnetically couple the accessory device with the electronic device, the attachment feature comprising: an exterior surface; a corresponding plurality of openings formed through the exterior surface; a plurality of movable contacts corresponding in number to the plurality of openings, each movable contact extending out of one of the plurality of openings; one or more biasing members operatively coupled to the plurality of movable contacts to bias the contacts such that a contacting portion of each contact protrudes beyond the exterior surface of the attachment feature through its respective opening; and an alignment feature comprising at least one magnet positioned adjacent to the plurality of openings. 
     In some embodiments an accessory device suitable for use with an electronic device is provided that includes: an enclosure; one or more electrical components positioned within or attached to the enclosure; an attachment feature connected to the enclosure and configured to magnetically couple the accessory device with the electronic device, the attachment feature comprising a housing and an opening formed through the housing; a contact structure positioned within the opening at an exterior surface of the attachment feature. The contact structure can include: a contact housing; a cover attached to a top of the contact housing, the cover including a raised portion sized and shaped to fit within the device housing opening; a plurality of openings formed in the cover; a plurality of movable contacts corresponding in number to the plurality of openings, each of the plurality of movable contacts having a contacting portion; and a plurality of biasing members positioned within the contact housing and corresponding in number to the plurality of contacts, each biasing member operatively coupled to one of the plurality of movable contacts to bias the contact such that the contacting portion protrudes outside of the enclosure through its respective opening. And the accessory can further include an alignment feature positioned within the housing and having first and second arrays of magnets positioned on opposing sides of the contact area. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system according to an embodiment of the disclosure; 
         FIG. 2  is a simplified isometric view of a host electronic device shown in  FIG. 1  according to some embodiments of the disclosure; 
         FIG. 3  illustrates a contact structure in a device enclosure according to some embodiments of the disclosure; 
         FIG. 4A  is a simplified top plan view of an accessory electronic device that includes multiple contacts that can be mated with the contact structure shown in  FIG. 3  according to some embodiments of the disclosure; 
         FIG. 4B  is a simplified top plan view of the contact structure shown in  FIG. 4A  according to some embodiments of the disclosure; 
         FIG. 4C  is a simplified side plan view of the contact structure shown in  FIG. 4B ; 
         FIG. 4D  is a simplified side plan view of a portion of the accessory electronic device shown in  FIG. 4A  according to some embodiments of the disclosure; 
         FIG. 5  is a simplified isometric view of an accessory electronic device having a keyboard attached to a cover that includes multiple contacts that can mate with the contact structure shown in  FIG. 3  according to some embodiments of the disclosure; 
         FIG. 6  is a simplified perspective view of the contact structure shown in  FIG. 5  according to some embodiments of the disclosure; 
         FIG. 7  is a simplified a side cross-sectional view of the contact structure shown in  FIG. 6  according to some embodiments of the disclosure; 
         FIG. 8  illustrates an exploded view of various components of the attachment feature shown in  FIG. 2  according to some embodiments of the disclosure; 
         FIG. 9  illustrates a cross sectional view of the attachment feature shown in  FIGS. 2 and 8  through the dashed line shown in  FIG. 8 ; 
         FIG. 10  illustrates a side view of the accessory device shown in  FIG. 5  coupled with the electronic device shown in  FIG. 2 , with the accessory device in a folded configuration to allow use of the keyboard assembly with the electronic device; 
         FIGS. 11-13  illustrate an enlarged view of the portion of  FIG. 10  shown in dotted lines, with the attachment feature of the accessory positioned in a retention feature of the accessory; 
         FIGS. 14-19  illustrate a method of assembling a contact structure according to an embodiment of the present disclosure; 
         FIG. 20  illustrates another contact structure in a device enclosure according to an embodiment of the present disclosure; 
         FIG. 21  illustrates a contact structure according to an embodiment of the present disclosure; 
         FIG. 22  illustrates a contact structure in a device enclosure according to an embodiment of the present disclosure; 
         FIG. 23  is an exploded view of a contact structure according to an embodiment of the present disclosure; 
         FIG. 24  illustrates a spring-biased contact according to an embodiment of the present disclosure; and 
         FIG. 25  is an exploded view of a spring-biased contact of  FIG. 24 . 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments of the disclosure illustrated in the accompanying drawings. 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. To the contrary, the present disclosure is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments. It is to be understood that other embodiments may be used and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to electronic devices, such as accessory electronic devices, that include a physical connector having one or more contacts positioned at an exterior surface of the electronic device. Each of the one or more contacts can be positioned within an opening that corresponds in size and shape to the contact such that there is essentially no gap or a minimal gap between the sides of the contact and surfaces surrounding the opening through which a contacting portion of each contact protrudes. The one or more contacts can be biased by a biasing element (for example, a spring) to protrude from the opening, and the contacts are movable such that when the contacts are mated with an appropriate connector on another device, each contact depresses slightly inward within its respective opening against the biasing member. During the mating process, the biasing element applies a sufficient normal force to the contacts to maintain a strong electrical connection between each contact and its corresponding contact in the mating connector. 
     In some embodiments the connector does not include an exposed cavity or other open area in which dirt or debris, such as lint, can collect. Additionally, connectors according to embodiments of the disclosure take up minimal real estate, including minimal surface area, depth and volume, on the device in which they are incorporated. As such, connectors according to the disclosure can be small and barely noticeable contributing to the overall aesthetic appearance of the device. 
       FIG. 1  illustrates an electronic system  100  according to some embodiments of the present disclosure. System  100  includes a host electronic device  110  that can be connected to an accessory electronic device  120  in order to share data, power, or both between the accessory and the host. Specifically, one or more contacts  112  on host device  110  can be electrically connected to one or more contacts  122  on accessory device  120  by, for example, a cable connector  130 . In other embodiments of the present disclosure, contacts  112  on host device  110  can be directly and electrically connected to contacts  122  on accessory device  120  using connectors different than cable connector  130 . In still other embodiments of the present disclosure, one or more optical contacts supporting one or more optical connections between host device  110  and accessory device  120  can be included. 
     To facilitate a direct connection between contacts  112  on host electronic device  110  and contacts  122  on accessory electronic device  120 , contacts  122  can be part of a surface mount connector incorporated into accessory device  120  that includes a housing supporting one or more movable contacts at an external surface of device  120 . Each movable contact can include a contact portion that emerges from a corresponding opening in the housing. Some examples of a surface mount connector that includes contacts  122  are shown in the following figures and discussed below. 
     Some embodiments of the disclosure pertain to accessory electronic device  120  and contacts  122  that are incorporated within the accessory electronic device. The accessory contacts  122  are sized and shaped to mate with contacts  112  of host electronic device  110 . Thus, prior to describing various embodiments of accessory electronic device  120  and accessory contacts  122  in detail, reference is made to  FIG. 2 , which illustrates an isometric view of an electronic device  200  that is representative of one the many different types of electronic devices that can be host electronic device  110  shown in  FIG. 1 . In some embodiments, electronic device  200  is a mobile communications device, such as a smartphone. In the embodiment shown in  FIG. 2 , electronic device  200  is a tablet computing device. Electronic device  200  can vary in shape and size. Also, electronic device  200  can include an enclosure  202  that forms a cavity and is designed to enclose and protect various internal components of device  200  within the cavity, such as a battery, one or more processors, one or more computer-readable memories, wireless interfaces, etc. In some embodiments, enclosure  202  is formed from a metal, such as aluminum, or another electrically conductive material. 
     Electronic device  200  can also include a display assembly  204  designed to present visual content. In some embodiments, display assembly  204  includes a touch sensitive layer designed to receive a touch input and generate commands, in accordance with the touch input, to the electronic device  200 . Further, in some embodiments, display assembly  204  includes a capacitive touch sensitive layer designed to generate an input based upon a capacitive coupling with the display assembly  204 . An outer protective layer  206  made from a transparent material, can overlay display assembly  204  and be attached to enclosure  202  with an adhesive or other means thereby covering the display and the cavity formed by the enclosure. Outer protective layer  206  can be made from glass or similar materials and is sometimes referred to as a cover glass. In some embodiments, electronic device  200  can further include a force detection sensor (not shown) designed to detect an amount of force applied to display assembly  204  and/or outer protective layer  206 . 
     Electronic device  200  can include one or more input buttons, such as button  208 , designed to receive an input corresponding to a command to the electronic device (for example, to change the visual content shown on display assembly  204 ). Further, in some embodiments, electronic device  200  includes a receptacle connector  210  designed to receive power and/or data from another device. For example, power from a power source (not shown) can be supplied to device  200  through connector  210  in order to power internal components of electronic device  200  and/or power one or more power sources (not shown) disposed in electronic device  200 . Receptacle connector  210  can include a cavity in which the contacts of the receptacle connector are located. 
     Separate from connector  210 , electronic device  200  can further include one or more electrical contacts  212  within a contact area  211  located at an exterior surface of device  200 . Electrical contacts are designed to electrically couple with corresponding contacts associated with an accessory device, such as one of accessory device  400  or  500  (shown in  FIGS. 4 and 5 ). Contacts  212  can allow for electrical communication between electronic device  200  and accessory device  400  or  500  just as contacts  112  can allow electrical communication between devices  110  and  120 . For example, in some embodiments contacts  212  can include one or more data contacts that enable the exchange of data between device  200  and device  400  or  500 . Contacts  212  can also include one or more power contacts that enable an accessory device to provide power to electronic device  200  or enable an accessory device to draw power from device  200  and/or ground contacts. 
     Contacts  212  can be substantially flush with an exterior surface of housing  202 . That is, in some embodiments contacts  212  are not formed within an exposed opening or other type of cavity in housing  202  that is typically required by a receptacle connector, such as connector  210 , and that might otherwise be a source for dust or other debris to collect. Instead, contacts  212  are part of a continuous exterior surface of the device housing  202  making the contacts less noticeable than when standard connectors are incorporated into housing  202 , which can be beneficial to the aesthetic appearance of electronic device  200 . As used herein, contacts  212  can be said to be “substantially flush” with an exterior surface of housing  202  when the exterior surface of the contacts is flush with (e.g., in the same plane as) the surrounding housing surface as well as when an exterior surface of each individual contact  212  is recessed a limited amount, such as 1 millimeter or less, from the surface of the exterior housing  202  that surrounds the contact. In other embodiments contacts  212  are recessed 0.5 mm or less and in still other embodiments, contacts  212  are recessed 0.25 mm or less from the surrounding exterior housing surface. When the contacts are substantially flush with the surrounding exterior surface of housing  202 , the contact and exterior housing can combine such that there is a continuous smooth transition between the portion of the housing exterior surface surrounding the contact and the exterior surface of the contact. 
     Since contacts  212  are not positioned within a cavity of housing  202  or other exposed opening of housing  202  that can provide alignment for a corresponding connector to mate and electrically connect to contacts  212 , in some embodiments electronic device  200  includes an alignment feature to facilitate connector mating. In some particular embodiments, the alignment feature can include a first array  214  of alignment magnets and a second array  216  of alignment magnets disposed along a sidewall of enclosure  202  on opposite sides of contacts area  211 . Each of first array  214  and second array  216  of magnets can include several magnets having a magnetic polarity arrangement to magnetically couple the arrays with corresponding arrays of magnets in the accessory electronic device as explained below. The magnetic circuits formed by multiple magnetic couplings can allow electronic device  200  to magnetically couple with an accessory electronic device, such as accessory devices  400  and  500  shown in  FIGS. 4 and 5 , respectively, and align contacts  212  with contacts of the accessory electronic device. In other embodiments, the alignment feature can include fewer or more magnets or magnetic components or other types of alignment structures. 
       FIG. 3  illustrates one example of a contact area  300  in a device enclosure according to an embodiment of the present disclosure. Contact area  300  can be, for example, contact area  211  shown in  FIG. 2 . In this example, contact area  300  includes three individual contacts  312  (labeled as contacts  312   a ,  312   b  and  312   c ) each of which is located at and substantially flush with a surrounding exterior surface of a device enclosure  310 . Embodiments of the disclosure are not limited to any particular number of contacts, however, and other embodiments can include fewer or more than three contacts within contact area  300 . Each of contacts  312  can be similar to or identical to contacts  212  while device enclosure  310  can be, for example, housing  202  of electronic device  200 . 
     In some embodiments device enclosure  310  can be made from a metal or similar electrically conductive material in which case an insulating ring  320  can surround an outside edge of each individual contact  312  between each contact  312  and device enclosure  310 . The insulating rings  320  can be made from plastic or another nonconductive material and can electrically isolate contacts  312  from device enclosure  310 . In these and other embodiments of the present disclosure, contacts  312  and insulating rings  320  can be substantially flush with a surrounding surface of device enclosure  310 . 
     In some embodiments, each contact  312  is positioned within and fills an opening in device enclosure  310  with an insulating ring  320  located between its respective contact  312  and the portion of device enclosure  310  surrounding the contact. The insulating ring  320  can closely abut both device enclosure  310  and contact  312  such that no gaps are formed between the three components. Further, as evident from the figure, the exterior surface of the electronic device within contact area  300  (including the relevant portions of enclosure  310 , contacts  312  and insulating rings  320 ) can essentially be a continuous, smooth (to a user&#39;s touch) surface along lines A-A′ and B-B′. Additionally, the exterior surfaces of enclosure  310 , each contact  312  and each insulating ring  320  can be curved, they can be substantially flat, or they can have other contours. In some embodiments the exterior surfaces of contacts  312  and surrounding insulating rings  320  can combine such that, when the contacts and insulating ring are recessed a limited amount as described herein, the exterior surfaces of the contact, insulating ring and device housing all combine to form a continuous smooth exterior surface that can be slightly recessed in the areas of the contact and/or insulating ring, forming three side-by-side dimples in the contact area as shown in  FIG. 3 . 
       FIG. 4A  illustrates a top plan view of an accessory electronic device  400  that is representative of one the many different types of electronic devices that can be accessory electronic device  120  shown in  FIG. 1 . Accessory electronic device  400  can include one or more electrical components, such as components  402 ,  404 ,  406  and  408  that can be electrically coupled to a host electronic device, such as one of host devices  110  or  200 , via a surface mount connector  415 , which can include one or more contacts, such as contacts  122 . Components  402 - 408  can be housed within, positioned at an exterior surface of, or otherwise connected to, an enclosure  410 . In some embodiments, such as those discussed with respect to  FIG. 5 , enclosure  410  can be a cover sized and shaped to overlay and cover another electronic device, such as device  200 . In some embodiments where enclosure is a cover, the one or more of components  402 - 408  can be embedded within the cover. Alternatively, or in addition to such, one or more of components  402 - 408  can be attached to the cover (for example, as keyboard assembly  504  is attached to cover  502  in the embodiment discussed in conjunction with  FIG. 5 ) or positioned on the cover. 
     Components  402 - 408  can be any of a wide variety of electrical components such as a computer-readable memory, a processor, a display, a keyboard, a touch pad, input buttons, a battery and/or any of a variety of different sensors, such as force sensors, biometric sensors, temperature sensors, light sensors, proximity sensors and/or accelerometers to name a few. The one or more components  402 - 408  can be incorporated into accessory  400  enabling the accessory, which can communicate with a host electronic device, via surface mount connector  415 , to augment or expand the capabilities or functionality of the host electronic device to which it is connected. 
     In the embodiment shown in  FIG. 4 , accessory electronic device  400  further includes an attachment feature  414  that is connected to enclosure  410  by a flexible member  412 . Attachment feature  414  enables accessory electronic device  400  to be operatively attached to a host electronic device, such as device  200 . Flexible member  412  enables the attachment feature to rotate with respect to enclosure  410  around an axis that is parallel to a length of the attachment feature. Such rotation enables the attachment feature, and surface mount connector  415  that is incorporated into the attachment feature, to be positioned at many different angles with respect to enclosure  410  providing a variety of attachment positions between accessory device  400  and the host device to which connector  415  is to be mated. In other embodiments, attachment feature  414  can be part of enclosure  410  and can be included at an exterior surface of the enclosure. For example, in some embodiments attachment feature  414  can be in a permanent fixed position with respect to other portions of enclosure  410 . In other embodiments, attachment feature  414  can be connected to enclosure  410  by a hinge or other rigid element that allows the attachment feature to be moved into different positions relative to the enclosure. 
     Attachment device  414  can include one or more magnets for aligning and securing surface mount connector  415  to the corresponding connector of another electronic device. For example, as shown in  FIG. 4A , attachment feature  414  includes a first array of magnets  420  on one side of connector  415  and a second arrays of magnets  422  on the opposing side. First and second arrays of magnets  420 ,  422  can be aligned to magnetically couple to corresponding arrays of magnets disposed in the host electronic device to accessory device  500  is to be attached. For example, when accessory device  400  is designed to be operatively attached to host electronic device  200 , first array of magnets  420  can align with and magnetically couple to first array  214  of alignment magnets in device  200  while second array of magnets  422  can align with and magnetically couple to second array  216  of alignment magnets in device  200 . Attachment feature  414  includes an enclosure (not shown) in which the first and second arrays of magnets, along with other components, can be housed. 
       FIG. 4B  illustrates a top view of surface mount connector  415  while  FIG. 4C  illustrates a side plan view. As shown in these figures, connector  415  can include one or more electrical contacts designed to electrically couple with electrical contacts of a host electronic device, such contacts  312  of host device  200 . Generally the number of electrical contacts in connector  415  will equal the number of contacts in the corresponding contact area  300  that accessory  400  is manufactured to be paired with. In some embodiments, for example as shown in  FIGS. 4B and 4C , surface mount connector  415  includes three contacts  416   a ,  416   b , and  416   c  that align with and can be electrically coupled to contacts  312   a ,  312   b ,  312   c , respectively. Embodiments of the disclosure are not limited to any particular number of contacts within connector  415 , however, and can include more or fewer than three contacts in various embodiments. 
     Surface mount connector  415 , or a portion thereof, can fit within an opening (not labeled) of the enclosure portion of attachment feature  414  such that there is essentially no gap between a top surface  420  of connector  415  and an exterior surface  430  of attachment feature  414  that surrounds the exposed portion of the surface mount connector. In some embodiments, exterior surface  430  and top surface  420  can be part of a continuous flush exterior surface of electronic device  400 , while in other embodiments top surface  420  is raised a small distance (less than 1 mm in some embodiments, less than 0.5 mm in other embodiments) above surrounding surface  430 . 
     Surface mount connector  415  can include multiple openings  418   a - 418   c  that correspond in number to the number of contacts within the connector. Thus, as shown in  FIG. 4B , each contact  416   a - 416   c  sits within its respective opening  418   a - 418   c . A very narrow, almost imperceptible gap can exist between each contact and an inner surface of the surface mount connector that defines the contact&#39;s respective opening. As shown in  FIGS. 4B and 4C , each opening  418   a - 418   c  can be formed in top surface  420 . In other embodiments the openings  418   a - 418   c  can be formed directly in surface  430 . In some embodiments of the disclosure the openings are in a surface that is in the same plane as the surrounding exterior surfaces of device  400  or is slightly raised from the surrounding surfaces as described above. Thus, in such embodiments, no portion of the exterior surfaces of device  400  that surround the openings in the X or Y planes is above the openings in the Z plane and the openings  418 - 418   c  can be said to be formed in a surface that is substantially flush with the surrounding exterior surfaces. 
     Further, as shown in  FIG. 4C , the contacts  416   a - 416   c  can be low-profile contacts that protrude slightly above the top of the opening and thus protrude slightly above the surrounding exterior surfaces of attachment feature  414 . In some embodiments, contacts  416   a - 416   c  protrude less than 1 mm above the surface of attachment feature  414 . In still other embodiments, the contacts protrude 0.5 mm or less above the surface of attachment feature  414 , and in still other embodiments, the contacts protrude 0.25 mm or less above the surface of the attachment feature. 
     Attachment feature  414  can be connected to the bulk of enclosure  410  by a flexible connector  412 . Flexible connector  412  can be, for example, one or more layers of flexible material such as a polymer-based, low modulus elastomeric material that allows attachment feature  414  to be positioned at different angles with respect to enclosure  410 . For example, as shown in  FIG. 4C , flexible connector  412  allows attachment feature (and thus contact structure  415 ) to be moved between a first position in which attachment feature faces parallel to device  400 , a second position in which attachment feature  414  faces perpendicularly and up from device  400 , and a third position in which attachment feature  414  faces perpendicularly and down from device  400 . Connector  412  also allows the attachment feature to be positioned at any angle in between the three positions shown in  FIG. 4C  as well as at additional angles. 
     Reference is now made to  FIG. 5 , which illustrates an isometric view of an embodiment of an electronic device that is representative of accessory electronic device  120  and accessory electronic device  400 . As such, electronic device  500  can be electrically connected to and physically attached to a host electronic, such as host electronic device  110  shown in  FIG. 1  or host electronic device  200  shown in  FIG. 2 . Accessory device  500  includes a cover  502  coupled with a keyboard assembly  504 . Cover  502  can be sized and shaped to overlay and cover an electronic device, such as device  110  or device  200 , that can be used with accessory device  500 . In some embodiments, cover  502  includes multiple sections, which can also be referred to as panels or segments. For example, as shown in  FIG. 5 , cover  502  can include a first segment  506 , a second segment  508 , and a third segment  510 . Each of first segment  506 , second segment  508 , and third segment  510  can be moveable or rotatable with respect to the remaining segment. In this regard, cover  502  may be referred to as a foldable cover. Further, as shown in  FIG. 5 , third segment  510  can be raised or elevated with respect to first segment  506  and second segment  508  such that when the keyboard assembly  504  is folded over and onto first segment  506  and second segment  508 , keyboard assembly  504  is generally co-planar, or flush, with respect to third segment  510 . 
     Each of the first, second and third segments can be covered or overlaid by a fabric layer  512 , such as a microfiber, or generally any material that provides a cosmetic enhancement while also not causing damage to a display assembly (e.g., display  204  shown in  FIG. 2 ) of the host electronic device that accessory keyboard  500  is designed to operate with. Also, each of the segments can include a rigid panel formed from a material, such as glass fiber, disposed below fabric layer  512 . Further, the segments previously described can be folded to define a folded configuration of cover  502  in which the electronic device that the accessory keyboard is designed to cooperate with can be positioned in a propped-up position. 
     Cover  502  can further include an attachment feature  514 , similar to attachment feature  414  described above and designed to receive and secure a host electronic device, such host electronic device  110  or host electronic device  200 , with accessory device  500 . In this regard, attachment feature  514  can include one or more magnets, or arrays of magnets, (not shown in  FIG. 5 ) that can be aligned to magnetically couple to several magnets disposed in the host electronic device to accessory device  500  is to be attached as described above. Further, accessory device  500  can include one or more electrical contacts within an accessory contact structure  515  designed to electrically couple with electrical contacts  312  of a host electronic device, such as host device  110  or  200 , as also described above. Accessory contact structure  515  can be, for example, surface mount connector  415  described with respect to  FIG. 4 . Further details of an embodiment of accessory contact structure  515  are also discussed later in this application with respect to at least  FIGS. 6-7 and 14-25 . 
     Attachment feature  514  can be coupled with cover  502  by way of an exterior layer  518 , or outer layer, that extends along an exterior surface of cover  502  and wraps around the attachment feature  514  to define a top, or upper, surface of attachment feature  514 . In some embodiments, exterior layer  518  includes a polymer-based, low modulus elastomeric material that allows some flexibility of attachment feature  514  and cover  502 . Further, exterior layer  518  can include a mixture of polyurethane and coal tar and can come in a variety of colors. Also, the material forming exterior layer  518  can further include relatively high adhesion to other components and can further be abrasion-resistant. In this regard, exterior layer  518  can include a relatively high coefficient of friction, which can limit movement of the electronic device when engaged with attachment feature  514 . In order to lower the coefficient of friction, attachment feature  514  can include a first layer  522  and a second layer  524  surrounding the electrical contact. First layer  522  and second layer  524  can include a lower coefficient of friction relative to attachment feature  514 , which can facilitate alignment and coupling between an electronic device and attachment feature  514 . 
     Keyboard assembly  504  can include keys  526  disposed according to a QWERTY configuration commonly known in the art for a keyboard. However, in other embodiments, the keys  526  can include a different configuration according to a language or dialect. Keyboard assembly  504  can include a printed circuit board (not shown) that receives the keys  526 . Keyboard assembly  504  can further include a retention feature  528  disposed across, and protruding from, a top surface  530  of the keyboard assembly  504 . Retention feature  528  can be designed to receive attachment feature  514 , or at least a portion of attachment feature  514 , when cover  502  is in a particular folded configuration. Retention feature  528  can provide a mechanical stop for attachment feature  514  and an electronic device secured with attachment feature  514 . 
     As shown in  FIG. 5 , retention feature  528  includes a ring-like configuration protruding from a top surface  530 . However, in other embodiments, retention feature  528  includes two or more discontinuous features that provide the mechanical stop previously described. Still, in other embodiments, top surface  530  include a trough or “valley” in a location within retention feature  528  that positions a portion of attachment feature  514  below top surface  530 . Also, retention feature  528  can include an array of magnets designed to magnetically couple with magnets in attachment feature  514  that combines with the mechanical stop to further limit movement of attachment feature  514 . Further details of attachment feature  514  are discussed below with respect to  FIGS. 8-9 . 
     Reference is now made to  FIG. 6 , which is a simplified perspective view of accessory contact structure  515  according to some embodiments of the disclosure. As shown in  FIG. 6 , contact structure  515  can include a contact housing  605  (also shown in  FIG. 7 ) that includes a raised portion  610 . The raised portion  610  is sized and shaped to be positioned within and extend through an opening in a device enclosure, such as enclosure  625  shown in  FIG. 7 , which can be part of the housing of the accessory device or can be, for example, an exterior surface of attachment feature  514 . In this example, accessory contact structure  515  includes three individual contacts  516   a ,  516   b  and  516   c , each of which can be made from metal or another conductive material. The raised portion  610  of the contact structure can include separate openings for each of the individual contacts  516   a ,  516   b  and  516   c . While  FIG. 6  illustrates that each of the contacts  516   a - 516   c  are located in a single raised portion  610 , in other embodiments of the disclosure, more than one raised portion  610  can be employed, and one or more contacts  516   a - 516   c  can be located in portions of contact structure  515  other than the one or more raised portions  610 . Also, while the three contacts  516   a - 516   c  are shown as being in spaced apart from each other in a single row or line, in other embodiments of the disclosure, the contacts of contact structure  515  can be arranged in other patterns. 
     Contacts  516   a - 516   c  can be low-profile contacts that allow contact structure  515  to provide contacts for a connector without consuming a large volume in the electronic device. In various embodiments, contacts  516   a - 516   c  are movable towards the accessory electronic device and can be, for example, spring-biased contacts. For example, contacts  516   a - 516   c  can be biased by a spring, flexible arm, or other flexible structure such that they can be pushed or depressed and may return to their original position once released. Spring-biased contacts can provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  516   a - 516   c  and corresponding contacts of a second connector on a second device, such as contacts  312   a - 312   c  of host electronic device  200 . 
       FIG. 7  is a simplified side cross-sectional view of contact structure  515  according some embodiments of the present disclosure taken along the dotted plane, shown in  FIG. 6 . In the described embodiment, contact structure  515  can be located within a housing or enclosure  625  of attachment feature  514 . In other embodiments, contact structure  515  can be located within a portion of a housing or enclosure of an accessory electronic device different from the described attachment feature. As noted above, raised portion  610  of cover  620  of contact structure  515  can be located in an opening in device enclosure  625 . Contact housing  605  of contact structure  515  can support contacts  516   a ,  516   b ,  516   c  (e.g., opening  548  shown in  FIG. 8 ) having contacting portions  622   a ,  622   b , and  622   c , respectively. These contacting portions  622   a - 622   c  can be attached to ends of flexible lever arms  624   a ,  624   b , and  624   c , respectively. Each flexible arm may terminate in a second end and can include a barb, which may be inserted into notches or grooves in contact housing  605 . Specifically, flexible lever arm  624   a  can include barb  626   a , flexible lever arm  624   b  can include barb  626   b , and flexible lever arm  624   c  can include barb  626   c . In some embodiments, the center contact can have contact housing  605  insert molded around it and barb  626   b  may not be needed. 
     During assembly, the central contact including contact portion  622   b  can be inserted through an opening in a bottom of connector housing  605 . Without more, contacting portion  622   b  could be pushed deep into connector housing  605 . In some instances, contacting structure  622   b  could be pushed below a top surface of raised portion  610 . If contacting portion  622   b  were to be laterally offset at this time, contacting portion  622   b  may not emerge from its opening in contact housing  605 . Accordingly, a bottom stop portion  630  can be located under contacting portion  622   b . Bottom stop portion  630  can limit a depth to which contacting portion  622   b  can be depressed, thereby preventing possible damage to contact structure  515 . In other embodiments, the center contact can have contact housing  605  insert molded around it and bottom stop portion  630  may not be needed. 
     Various techniques of forming contact structure  515  are described below with respect to  FIGS. 14-19 . Additionally, other embodiments of contact structures according to the present disclosure are also described with respect to  FIGS. 20-25 . 
     Before discussing further details and embodiments of various contact structures according of the present disclosure, however, reference is now made to  FIG. 8 , which illustrates an exploded view of various components of attachment feature  514  according to some embodiments of the disclosure. For example, attachment feature  514  can include a first array  532  of magnets and a second array  534  of magnets. In some embodiments, first array  532  and second array  534  include several magnets (such as neodymium magnets) aligned together prior to assembly. In the embodiment shown in  FIG. 8 , first array  532  and second array  534  are formed form a composition of non-magnetized material and magnetized prior to an assembly of attachment feature  514 . First array  532  and second array  534  can be placed under a camera/sensor assembly (not shown) and aligned with a magnetizer (not shown) according to a desired alignment between electrical contacts  516   a - c  and an electronic device (not shown). This allows for a custom magnetization that improves a magnetic alignment of an electronic device. 
       FIG. 8  further shows first array  532  and second array  534  having several magnetized regions. For example, first array  532  can include a first magnetized region  536  and a second magnetized region  538  adjacent to first magnetized region  136 . Also, the magnetized regions can include dissimilar magnetic regions, or magnetic region of different sizes. As known by one of ordinary skill in the art, a magnet generally includes magnetic polarity arrangement having a “North” facing polarity, or North Pole, and a region of a “South” facing polarity, or South Pole, with magnetic field lines extending in a direction from the North Pole to the South Pole. Also, it is also understood by one of ordinary skill in the art that a North Pole of a magnet can be magnetically attracted to a South Pole of a magnet, and that two North poles, or two South poles, can magnetically repel one another. In this regard, adjacent magnetic regions of first array  532  and second array  534  can include magnet polarity arrangements designed to produce magnetic field lines in opposite directions. For example, as shown in  FIG. 8 , first magnetized region  536  includes magnetic field lines (shown as dotted lines) extending in a first direction, indicative of a top surface have a North polarity and a bottom surface (not shown) opposite the top surface having a South polarity. Conversely, second magnetized region  538  includes magnetic field lines (shown as dotted lines) extending in a second direction opposite the first direction, indicative of a top surface have a South polarity and a bottom surface (not shown) opposite the top surface having a North polarity. This pattern can be representative of magnetized regions of first array and the second array. Further, in other embodiments, the pattern is reversed such that first magnetized region  536  and second magnetized region  538  include magnetic field lines in the opposite direction as those shown in  FIG. 8 . Also, first magnetized region  536  can be smaller than that of second magnetized region  538 . Similar, but complementary, magnet polarity arrangements can be employed in magnet arrays  214  and  216  of device  200  to facilitate magnet coupling of the attachment feature to device  200 . 
     Also, as shown in  FIG. 8 , electrical contact structure  515  can be disposed on a flexible circuit assembly  535 , and a magnetic shunt  537  can be disposed below first array  532  and second array  534 . Magnetic shunt  537  can be formed from a metal, including soft steel, magnetically attracted to first array  532  and second array  534 . Also, magnetic shunt  537  can alter the direction of the magnetic fields of the first and second arrays in a direction towards magnets in a host electronic device, such as magnet arrays  214  and  216  in electronic device  200 , to which attachment feature secures accessory  500 . Attachment feature  514  can further include a protective component  540  that include a metal layer (not shown) that can include stainless steel. An outer coating  542  can cover the metal layer and provide an aesthetic finish. In some embodiments, outer coating  542  includes a photothermolplastic (“PTP”) material that includes polyurethane plus a thermoplastic. 
     Attachment feature  514  can further include or receive several additional features. For example, an electrically conductive fabric  544  designed to carry electrical signals from an electronic device to a connector (not shown) of keyboard assembly  504  (shown in  FIG. 5 ), or vice versa. Electrically conductive fabric  544  can wrap around protective component  540  electrically couple with flexible circuit assembly  535 , and electrically conductive fabric  544  can be electrically coupled with one or more of the individual electrical contacts  516  within contact structure  515  (i.e., one or more of contacts  516   a - 516   c ). In some embodiments, electrically conductive fabric  544  is electrically conductive throughout (the electrically conductive fabric  544 ). In the embodiment shown in  FIG. 8 , electrically conductive fabric  544  includes an electrically conductive region  546  that includes three electrically independent signal traces (not shown) that electrically couple to respective ones of contacts  516   a - 516   c . Exterior layer  518  can also wrap around attachment feature  514  and combine with first layer  522  and second layer  524  to define a top surface of the attachment feature. As shown, exterior layer  518  can include an opening  548  that allows the raised portion  610  of contact structure  515  to protrude through couple with an electrical contact of an electronic device. 
       FIG. 9  illustrates a cross-sectional view of attachment feature  514  through the dashed line shown in  FIG. 8  and with the various components shown in  FIG. 8  assembled together. As shown, metal layer  552 , surrounded by outer coating  542 , is generally U-shaped, but can vary according to a desired shape of attachment feature  514 . Also, exterior layer  518  and electrically conductive fabric  544  generally wrap around protective component  540 , with exterior layer  518  extending over a magnet  554  (of either first array  532  or second array  534 , shown in  FIG. 8 ) and electrically conductive fabric  544  extending below magnet  554 , between magnet  554  and magnetic shunt  537 . Also, electrically conductive fabric  544  can be covered by a cosmetic layer  556 , which further provides a protective cover to the electrically conductive fabric  544 . The cosmetic layer  556  can include PTP. 
     Also, cosmetic layer  556  can be adhesively secured with an upper portion of attachment feature  514 . For example, an adhesive layer  558  between cosmetic layer  556  and outer coating  542  can extend only along a fraction (less than half) of outer coating  542 . This allows for better ease of movement of the attachment feature in a clockwise and/or counterclockwise manner (denoted by arrow  560 ). Also, although not specifically shown, several features shown and described in  FIG. 9  can be adhesively secured together. 
     Referring now to  FIG. 10 , which illustrates a side view of accessory device  500  resting on a surface  1000  (e.g., a desktop) and coupled with electronic device  200 . As shown in  FIG. 5 , accessory device  500  is in a folded configuration to allow use of keyboard assembly  504  with electronic device  200 . In the folded configuration, attachment feature  514  of accessory device  500  couples cover  502  to the retention feature  128  portion of keyboard assembly  504 . At the same time, attachment feature  514  also couples accessory device  500  to host electronic device  200  such that contact area  300  in host device  200  is mated with and electrically connected to contact structure  515  in accessory device  500 . As shown, the folded configuration can include first segment  506 , second segment  508 , and third segment  510  folded to form a triangular support for the electronic device  200 . Further, the electronic device  200  can abut against third segment  510 . 
     In the configuration shown in  FIG. 10 , keyboard assembly  504  can be used as an input device in order to generate input or command to electronic device  200  and change the visual content (denoted as several diagonal lines) of display assembly  204  (shown in  FIG. 2 ) of electronic device  200 . This is due in part to electrically conductive fabric  544 , shown in the enlarged view, folding with cover  502 , and extending through cover. 
     While not shown in  FIG. 10 , one or more arrays of magnets are disposed below retention feature  528  of keyboard assembly  504  and couple with the magnets in the first array  532  and second array  534  of attachment feature  514  when attachment feature  114  is positioned, or nearly positioned, in retention feature  128 . In this regard, each magnet in first array  532  and second array  534  can include a magnetic polarity arrangement to magnetically couple with a magnet in one or more arrays of magnets (not shown) under retention feature  528 . This allows retention feature  528  to simultaneously secure attachment feature  514  and electronic device  200  coupled with attachment feature  514 . In some embodiments, the combined number of magnets in the one or more magnet arrays under retention feature  528  is equal to the combined number of magnets in first array  532  and second array  534 . 
     To more clearly illustrate the magnetic coupling associated with attachment feature  514  and both retention feature  528  and electronic device  200 , reference is made to  FIG. 11 , which illustrates an enlarged partial cross-sectional view of a portion of  FIG. 10  shown in dotted lines taken through portions of attachment feature  514  and retention feature  528  that include alignment magnets as discussed. As shown in  FIG. 11 , attachment feature  514  is positioned in retention feature  528  and the retention feature is used as a mechanical stop for attachment feature  514 . Also, as shown, attachment feature  514  can include a magnet  554  that can be part of first array  532  of magnets or second array  534  of magnets (shown in  FIG. 8 ) magnetically coupled with a magnet  1102  that can be part of the first array  214  or the second array  216  of magnets, respectively (shown in  FIG. 2 ). The magnetic field lines are shown as dotted lines having arrows. Magnet  554  in attachment feature  514  can further be magnetically coupled with a magnet  1104  that is part of an array of magnets in the keyboard assembly  504 . This magnetic coupling can, in combination with the retention feature  528 , maintain the attachment feature  514  and the electronic device  200  in a stationary position. 
     As discussed above, when accessory device is in the folded position shown in  FIG. 10  such that attachment feature  514  is properly aligned with and secured within retention feature  528 , each contact  516  is accessible to be electrically coupled to a respective contact  212  that is part of host device  200 . This connection sequence is illustrated in  FIGS. 12 and 13 , each of which represents the same enlarged partial cross-sectional view of  FIG. 10  that is shown in  FIG. 11  but through a pair mating contacts, a contact  212  (from electronic device  200 ) and a contact  516  (e.g., one of contacts  516   a - 516   c  from accessory device  500 ) instead of through the alignment magnets. Specifically,  FIG. 12  depicts host electronic device  200  in a position in which contact  212  is spaced apart from, and thus not yet mated with, contact  516 . As shown in  FIG. 12 , contact  516  protrudes slightly above an exterior surface  1202  of attachment feature  514 . 
     As shown in  FIG. 13 , as electronic device  200  is moved closer to attachment feature  514  and magnets  1102  and  554  pull device  200  into the attachment feature, contact  516  becomes physically and electrically connected to contact  212 . Contact  516  is attached to a flexible lever arm (e.g., one of lever arms  624   a - 624   c  discussed with respect to  FIG. 7 ) and is thus pushed into the enclosure  625  of the attachment feature by contact  212  (as shown by arrow  1302 ) until device  200  reaches its fully mated position in which exterior surface  1204  of device  200  is in physical contact with exterior surface  1202  of attachment feature  514  at an interface  1205 . 
     Reference is now made to  FIGS. 14-19 , which illustrate a method of assembling a contact structure, such as contact structure  515  shown in  FIG. 6 , according to an embodiment of the present disclosure. In  FIG. 14 , contacts for a contact structure according to an embodiment of the present disclosure, such as contact structure  515 , may be formed. These contacts may include contacting portions  622   a ,  622   b , and  622   c . Ends of contacting portions  622   a ,  622   b , and  622   c  may be attached to flexible lever arms  624   a ,  624   b , and  624   c . Flexible lever arm  624   a  may terminate in a first barb  626   a  and include a surface-mount contact portion  1402 . Flexible lever arm  624   b  may include barb  626   b  and may terminate in surface-mount contacting portion  1404 . Flexible lever arm  624   c  may include barb  626   c  and may terminate in surface-mount contacting portion  1406 . In other embodiments of the present disclosure, the center contact may have housing  605  insert molded around it and barb  626   b  may not be needed. 
     Contacting portions  622   a ,  622   b , and  622   bc  may be riveted to flexible lever arms  624   a ,  624   b , and  624   c . Specifically, contacting portion  622   a  may include a narrowed tail portion  1408  below ledge  1407 . Narrowed end portion  1408  may be inserted into opening  1405  in flexible lever arm  624   a . Ledge  1407  may rest on a top surface of flexible lever arm  624   a  around opening  1405 . Narrowed end  228  may have a force applied such that it widens, for example, by riveting. In this way, contacting portion  622   a  may be secured to flexible arm  624   a  by ledge  1407  and the widened portion of narrowed tail  1408 . When contacting structure  515  is mounted on a board or other appropriate substrate, surface-mount contacting portions  1402 ,  1404 , and  1406  may be soldered to contacts on the board thereby forming interconnect paths from contacting portions  622   a ,  622   b , and  622   bc  to interconnect traces on the board. 
     In  FIG. 15 , a central contact including contacting portion  622   a  may be inserted through an opening in a bottom of housing  605 . At least some of contacting portion  622   a  may emerge from a top surface of housing  605 . In other embodiments, housing  605  may be insert molded around the central contact. 
     In  FIG. 16 , central contact  516   b  is shown inserted through a bottom opening in housing  605 . Since central contact  622   b  is inserted through a bottom opening in housing  605 , central contacting portion  622   b  could inadvertently be pushed all the way to the bottom of housing  605 . To prevent this, embodiments of the present disclosure may attach a bottom stop portion  630  to a bottom of housing  605 . Bottom stop portion  630  may include a raised portion  1610  below contacting portion  622   b . This raised portion  1610  may restrict the travel range of contacting portion  622   b . This may prevent contacting portion  622   b  from being pushed all the way into housing  605 , thereby damaging contacting structure  515 . In other embodiments of the present disclosure, the center contact may have housing  605  insert molded around it and bottom stop portion  630  may not be needed. 
     In  FIG. 17 , side contacts including contacting portions  622   a  and  622   c  may be inserted into housing  605  using slots  1710  and  1712 , respectively. Flexible lever arm  624   a  may be pushed into housing  605  until barb  626   a  is inserted into a groove or notch in housing  605 . Similarly, flexible lever arm  624   c  may be pushed into housing  605  until barb  624   c  is inserted into a groove or notch in housing  605 . 
     In  FIG. 18 , a piece of insulating tape  1810  may be wrapped around a portion of the top, sides, and bottom of housing  605 . Insulating tape  1810  may include openings  1812  for surface-mount contacting portions  1402 ,  1404 , and  1406  of the contacts in housing  605 . Insulating tape  1810  may include top surface tabs  1814 . Top surface tabs  1814  may be sandwiched between top cover  620  and housing  605 , thereby helping to maintain insulating tape  1810  in place. In various embodiments of the present disclosure, insulating tape  1810  may be Mylar tape or other type of tape or insulating layer. 
     In  FIG. 19 , a cover  620  may be placed over housing  605 . Again, top surface tabs  1814  of insulating tape  1810  may be placed between top cover  620  and housing  605 , thereby holding insulating tape  1810  in place. Top cover  620  may include a raised portion  610  having three openings  613 , one for each of contacts  516   a - 516   c.    
     A completed contact structure  515  according to an embodiment of the present disclosure is shown in  FIG. 6  and discussed above. 
     In various embodiments of the present disclosure, different portions of contact structure  515  and other contact structures may be formed of various materials. For example, housing  605  and cover  620  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions  622   a ,  622   b , and  622   bc , may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Flexible lever arms  624   a ,  444 , and  624   c  may be formed of spring metal, sheet-metal, copper alloy, or other complaint material. 
     In various embodiments of the present disclosure, different portions of contact structure  515  and other contact structures may be formed in various ways. For example, housing  605  and cover  620  may be formed using injection or other molding, printing, or other technique Contact portions  622   a ,  622   b , and  622   bc  and flexible lever arms  624   a ,  624   b , and  624   c  may be machined, stamped, coined, forged, printed, or formed in different ways. Contact portions  622   a ,  622   b , and  622   bc  may be attached to flexible lever arms  624   a ,  624   b , and  624   c  by riveting, soldering, spot-welding, or other technique, or they may be formed as a single unit. Housing  605  and cover  620  may be formed around contacts  516   a - 516   c  using injection molding. 
       FIG. 20  illustrates another contact structure in a device enclosure according to an embodiment of the present disclosure. In this example, a raised portion  2010  of a contact structure may be fit in an opening in device enclosure  2000 . Raised portion  2010  may include contacts  2020  each surrounded by an individual raised portion  2012 . 
     Contacts  2020  may be low-profile contacts. Such contacts may allow a contact structure to provide contacts for a connector without consuming a large volume in the electronic device housed by enclosure  2000 . In various embodiments the present disclosure, contacts  2020  may be spring-biased contacts. For example, contacts  2020  may be biased by a spring, flexible arm, or other flexible structure such that they may be pushed or depressed and may return to their original position once released. Spring-biased contacts may provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  2020  and corresponding contacts of a second connector on a second device (not shown.) 
     Accordingly, embodiments of the present disclosure may provide contact structures having low-profile, spring-biased contacts. An example is shown in the following figure. 
       FIG. 21  illustrates a contact structure according to an embodiment of the present disclosure. This contact structure may include housing  2120  having a number of slots for contact portions  2022 . Contact portions  2022  may connect to contacting portions  2020  via flexible arms  2024 . 
     This contact structure may further include a top plate or cover  2110  having a raised portion  2010 . Raised portion  2010  may include further raised portions  2012  around each opening  2013 . Each opening  2013  may allow a connection to be made to contacting portion  2020 . 
     This contact structure may further include a bottom plate  2130 . Bottom plate  2130  may include tabs  2150  to fit in notch  2152  in top plate or cover  2110  and notch  2154  in housing  2120  to secure top plate or cover  2110 , housing  2120 , and bottom plate  2130  together as a unit. 
     In various embodiments of the present disclosure, different portions of this contact structure and other contact structures may be formed of various materials. For example, housing  2120 , cover  2110 , and bottom plate  2130  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions  2020  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Flexible lever arms  2024  and contact portions  2022  may be formed of spring metal, sheet-metal, copper alloy, or other complaint material. 
     In various embodiments of the present disclosure, different portions of this contact structure and other contact structures may be formed in various ways. For example, housing  2120 , cover  2110 , and bottom plate  2130  may be formed using injection or other molding, printing, or other technique Contacting portions  2020 , flexible lever arms  2024 , and contact portions  2022  may be machined, stamped, coined, forged, printed, or formed in different ways. Contact portions  2020  may be attached to flexible lever arms  2024  by riveting, soldering, spot-welding, or other technique, or they may be formed as a single unit. Housing  2120 , cover  2110 , and bottom plate  2130  may be formed around contacts  2020  using injection molding. 
       FIG. 22  illustrates a contact structure in a device enclosure according to an embodiment of the present disclosure. In this example, a raised portion  2210  of a contact structure may be fit in an opening in a device enclosure. Raised portion  2210  may include contacts  2220 . This contact structure may include bracket  2230 . Bracket  2230  may be fixed to a lid, device enclosure, or other structure by inserting fasteners into threaded inserts  2232 . 
     Contacts  2220  may be low-profile contacts. Such contacts may allow a contact structure to provide contacts for a connector without consuming a great deal of volume in the electronic device housed by the enclosure. In various embodiments the present disclosure, contacts  2220  may be spring-biased contacts. For example, contacts  2220  may be biased by a spring, flexible arm, or other flexible structure such that they may be pushed or depressed and may return to their original position once released. Spring-biased contacts may provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  2220  and corresponding contacts of a second connector on a second device (not shown.) 
     This contact structure may be assembled in various ways. An example is shown in the following figure. 
       FIG. 23  is an exploded view of a contact structure according to an embodiment of the present disclosure. In this example, a flexible circuit board  2350  may include a number of openings for terminals of spring-biased contacts  2220 . Spring-biased contacts  2220  may be attached to flexible circuit board  2350  by inserting terminals of spring-biased contacts  2220  into the openings in flexible circuit board  2350  and soldering. A cap  2210  having openings for contacts  2220  may be placed over contacts  2220 . Cap  2210  may further include gaskets  2320  in openings in cap  2210 . An additional gasket  2330  may be placed or formed between contacts  2220  and inside edges of openings in cap  2210 . Gaskets  2320  and  2330  may be formed of silicone or other sealing material. Cap  2210  may be formed as a two shot injection molded process, where the main part of cap  2210  is formed in a first shot and gaskets  2320  are formed in a second shot. Cap  2210  may be attached to flexible circuit board  2350  using a double-sided adhesive layer  2340 . Adhesive layer  2340  may be a heat activated film or adhesive layer. Bracket  2230  may be attached using a second adhesive layer  2360  to a bottom of flexible circuit board  2350 . Adhesive layer  2360  may also be a heat activated film or adhesive layer. Lid  2310  may be placed over cap  2210 . Lid  2310  may be a portion of a device enclosure for a device housing this contact structure. The enclosure may be conducive or nonconductive. Gasket  2330  may be placed around a raised surface of cap  2210  and be located between cap  2210  and lid  2310 . Threaded inserts  2232  may be press-fit into openings at ends of bracket  2230 . Fasteners, such as screws  2312 , may be inserted into openings at ends of lid  2310  and screwed into threaded inserts  2232  in bracket  2230 . In other embodiments of the present disclosure, the threaded inserts may be replaced by threaded opening in bracket  2230 . 
     In this example, the contact structure may include three contacts  2220 . In other embodiments of the present disclosure, the contact structure may include one, two, or more than three contacts  2220 . Also, while in this example each of the contacts  2220  are located in a single raised portion, in other embodiments of the present disclosure, more than one raised portion may be employed, and one or more contact  2220  may be located in portions of the contact structure other than the one or more raised portions. Also, while the three contacts  2220  are shown as being in a line, in other embodiments of the present disclosure, contacts  2220  may be arranged in other patterns. 
     Various spring-biased contacts  2220  may be used in contacting structures according to embodiments of the present disclosure. An example is shown in the following figures. 
       FIG. 24  illustrates a spring-biased contact according to an embodiment of the present disclosure. This spring-biased contact may include a contacting portion  2220  supported by housing  2410 . Terminal structure  2420  may include legs that may be inserted into openings in a flexible circuit board, printed circuit board, or other appropriate substrate. 
       FIG. 25  is an exploded view of a spring-biased contact of  FIG. 24 . In this example, housing  2410  may include a central opening  2412 . A first end of spring  2510  may be inserted into central opening  2412 . Housing  2410  may further include notches  2416  and  2418 , as well as corner notches  2414 . 
     A contacting portion  2220  may have a backside cavity (not shown.) A second end of spring  2510  may be inserted into the backside cavity of contacting portion  2220 . 
     Terminal structure  2420  may be fit over contacting portion  2220  such that contacting portion  2220  passes through central opening  2422  of terminal structure  2420 . Terminal structure  2420  may include legs which may fit in corner notches  2414 . Tabs  2428  and  2426  may fit in notches  2418  and  2416  in housing  2410  to secure terminal structure  2420  in place relative to housing  2410 . Contacting portion  2220  may include tabs  2222 , which may fit under terminal structure  2420  near portion  2424  to hold contacting portion  2220  in place. Tabs  2428  may include raised portions  2429 , which may fit in the back side cavity of contacting portion  2220 . Tabs  2429  may help to ensure that electrical contact remains between contacting portion  2220  and terminal  2420  as the contacting portion  2220  is depressed towards housing  2410 . 
     In various embodiments of the present disclosure, different portions of this contact structure and other contact structures may be formed of various materials. For example, cap  2210  and gaskets  2320  may be formed of the same or different materials, such as plastic, LPS, or other non-conductive material. Contacting portions of spring-biased contacts  2220  may be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Bracket  2230  may be formed of sheet metal or other material. 
     In various embodiments of the present disclosure, different portions of this contact structure and other contact structures may be formed in various ways. For example, cap  2210  and gaskets  2320  may be formed using injection or other molding, printing, or other technique. Contact portions and other conductive portions of contacts  2220  may be machined, stamped, coined, forged, printed, or formed in different ways. 
     Embodiments of the present disclosure may provide contact structures that may be located in various types of devices, such as portable computing devices, tablet computers, desktop computers, laptops, all-in-one computers, wearable computing devices, cell phones, smart phones, media phones, storage devices, keyboards, covers, cases, portable media players, navigation systems, monitors, power supplies, adapters, remote control devices, chargers, and other devices. These devices may include contact structures that may provide pathways for signals and power compliant with various standards such as one of the Universal Serial Bus (USB) standards including USB Type-C, HDMI, DVI, Ethernet, DisplayPort, Thunderbolt, Lightning, JTAG, TAP, DART, UARTs, clock signals, power signals, and other types of standard, non-standard, and proprietary interfaces and combinations thereof that have been developed, are being developed, or will be developed in the future. In one example, the contact structures may be used to convey a data signal, a power supply, and ground. In various embodiments of the present disclosure, the data signal may be unidirectional or bidirectional and the power supply may be unidirectional or bidirectional. 
     The above description of embodiments of the disclosure has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure 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 disclosure and its practical applications to thereby enable others skilled in the art to best utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the disclosure is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20160902
Publication Date: 20171003
Grant Date: 20171003
Priority Date: 20150904
Inventors: ESMAEILI HANI
ROSS OLIVER
DEGNER BRETT
WAGMAN DANIEL
JOL ERIC S.
KAMEI IBUKI
AMINI MAHMOUD R.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2407", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F2200/1634", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1669", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/2407", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2201/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1669", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F2200/1634", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F2200/1633", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1684", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1684", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1662", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 58191052