PATENT DOCUMENT

Publication Number: US-8796555-B2
Application Number: US-201113013537-A
Country: US
Kind Code: B2

Title: Molded splitter structures and methods for making the same

Abstract:
Molded splitter structures and systems and methods for manufacturing molded splitter structures are disclosed.

Claims:
What is claimed is: 
     
       1. A cable structure, comprising:
 a plurality of cable structure legs, each leg having a splitter interface region that has a predetermined diameter; and 
 a tube-shaped splitter comprising:
 a plurality of leg interface regions, wherein each leg interface region is coupled to one of the splitter interface regions, wherein each leg interface region has a diameter that is substantially the same as the predetermined diameter of the splitter interface region to which it is coupled, and wherein the plurality of leg interface regions is a single molded shot of material that encapsulates the entire portion of a conductor bundle extending between two cable structure legs of the plurality of cable structure legs; and 
 another shot of material that encapsulates a first portion of the single molded shot and that abuts at least a first leg interface region of the plurality of leg interface regions. 
 
 
     
     
       2. The cable structure of  claim 1 , wherein the other shot has a maximum thickness that is substantially the same or less than the predetermined diameter of the splitter interface region of any leg. 
     
     
       3. The cable structure of  claim 1 , wherein the predetermined diameter of each splitter interface region is substantially the same, and wherein the other shot has a thickness that is substantially the same as the predetermined diameter. 
     
     
       4. The cable structure of  claim 1 , wherein the cable structure legs are extruded cable structure legs. 
     
     
       5. The cable structure of  claim 1 , wherein the diameter of at least one leg interface region provides a portion of an outer diameter of the cable structure. 
     
     
       6. The cable structure of  claim 1 , wherein the predetermined diameter of the splitter interface region of a first cable structure leg of the plurality of cable structure legs is different than the predetermined diameter of the splitter interface region of a second cable structure leg of the plurality of cable structure legs. 
     
     
       7. The cable structure of  claim 1 , wherein:
 the splitter provides a portion of an outer surface of the cable structure; and 
 the splitter does not overlap any portion of any cable structure leg of the plurality of cable structure legs. 
 
     
     
       8. A cable structure comprising:
 a first cable structure leg; 
 a second cable structure leg; 
 a singular molded splitter component comprising:
 a first ring region that abuts an end of the first cable structure leg; 
 a second ring region that abuts an end of the second cable structure leg; and 
 a non-ring region that extends between the first ring region and the second ring region, wherein an outer diameter of the non-ring region is smaller than an outer diameter of the first ring region; and 
 
 another molded splitter component that encapsulates the non-ring region. 
 
     
     
       9. The cable structure of  claim 8 , wherein an outer diameter of the other molded splitter component is the same as at least one of:
 the outer diameter of the first ring region; and 
 an outer diameter of the end of the first cable structure leg. 
 
     
     
       10. The cable structure of  claim 8 , wherein the singular molded splitter component encapsulates a conductor bundle that extends between the first cable structure leg and the second cable structure leg. 
     
     
       11. A cable structure comprising:
 a first cable sheath comprising a first cable sheath cavity that extends within the first cable sheath between a first end of the first cable sheath and a second end of the first cable sheath; 
 a second cable sheath comprising a second cable sheath cavity that extends within the second cable sheath between a first end of the second cable sheath and a second end of the second cable sheath; 
 a conductor bundle that extends out from the first cable sheath cavity through the first end of the first cable sheath and into the second cable sheath cavity through the second end of the second cable sheath; and 
 a splitter comprising:
 a first splitter component comprising:
 a first ring region that abuts the first end of the first cable sheath; 
 a second ring region that abuts the second end of the second cable sheath; and 
 a non-ring region that extends between the first ring region and the second ring region, wherein the first splitter component encapsulates the portion of the conductor bundle that extends between the first end of the first cable sheath and the second end of the second cable sheath; and 
 
 a second splitter component that encapsulates the non-ring region and that abuts each one of the first ring region and the second ring region. 
 
 
     
     
       12. The cable structure of  claim 11 , wherein the first splitter component is a single shot of molded material. 
     
     
       13. The cable structure of  claim 11 , wherein:
 the first splitter component is a single shot of a first molded material; and 
 the second splitter component is a single shot of a second molded material. 
 
     
     
       14. The cable structure of  claim 11 , wherein the splitter comprises a molded thermoplastic. 
     
     
       15. The cable structure of  claim 11 , wherein an outer diameter of the first ring region provides a first outer diameter of a first portion of the cable structure. 
     
     
       16. The cable structure of  claim 15 , wherein:
 an outer diameter of the first end of the first cable sheath provides a second outer diameter of a second portion of the cable structure; and 
 the first outer diameter is the same dimension as the second outer diameter. 
 
     
     
       17. The cable structure of  claim 11 , wherein an outer diameter of the non-ring region is less than an outer diameter of the first ring region. 
     
     
       18. The cable structure of  claim 11 , wherein:
 an outer diameter of the first ring region provides a first outer diameter of a first portion of the cable structure; and 
 an outer diameter of the second splitter component provides a second outer diameter of a second portion of the cable structure. 
 
     
     
       19. The cable structure of  claim 18 , wherein the first outer diameter is the same dimension as the second outer diameter. 
     
     
       20. The cable structure of  claim 11 , wherein:
 an outer diameter of the first end of the first cable sheath seamlessly blends with an outer diameter of the first ring region; and 
 an outer diameter of the first ring region seamlessly blends with an outer diameter of the second splitter component. 
 
     
     
       21. The cable structure of  claim 11 , wherein the conductor bundle comprises:
 a first conductor; and 
 a second conductor that is electrically connected to the first conductor within the splitter.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of previously filed U.S. Provisional Patent Application No. 61/298,087, filed Jan. 25, 2010, entitled “Small Diameter Cable with Splitter Assembly,” U.S. Provisional Patent Application No. 61/384,103, filed Sep. 17, 2010, entitled “Molded Splitter Structures and Systems and Methods for Making the Same,” U.S. Provisional Patent Application No. 61/319,772, filed Mar. 31, 2010, entitled “Thin Audio Plug and Coaxial Routing of Wires,” U.S. Provisional Patent Application No. 61/384,097, filed Sep. 17, 2010, entitled “Cable Structures and Systems Including Super-Elastic Rods and Methods for Making the Same,” U.S. Provisional Patent Application No. 61/326,102, filed Apr. 20, 2010, entitled “Audio Plug with Core Structural Member and Conductive Rings,” U.S. Provisional Patent Application No. 61/349,768, filed May 28, 2010, entitled “Molding an Electrical Cable Having Centered Electrical Wires,” U.S. Provisional Patent Application No. 61/378,311, filed Aug. 30, 2010, entitled “Molded Cable Structures and Systems and Methods for Making the Same,” and U.S. Provisional Application No. 61/378,314, filed Aug. 30, 2010, entitled “Extruded Cable Structures and Systems and Methods for Making the Same.” Each of these provisional applications is incorporated by reference herein in their entireties. 
     BACKGROUND 
     Wired headsets are commonly used with many portable electronic devices such as portable music players and mobile phones. Headsets can include non-cable components such as a jack, headphones, and/or a microphone and one or more cables that interconnect the non-cable components. The cables can be joined together at a bifurcation region—that is a region where three cable legs join together. Because cables can be manufactured using different approaches, different splitter structures may be required to join the cable legs together. 
     SUMMARY 
     Splitter structures and systems and methods for manufacturing splitter structures of a cable structure are disclosed. 
     A cable structure can interconnect various non-cable components of a headset such as, for example, a plug, headphones, and/or a communications box to provide a headset. The cable structure can include several legs (e.g., a main leg, a left leg, and a right leg) that each connect to a non-cable component, and each leg may be connected to one another at a bifurcation region (e.g., a region where the main leg appears to split into the left and right legs). Cable structures according to embodiments of this invention provide aesthetically pleasing interface connections between the non-cable components and legs of the cable structure, for example such that the interface connections appear to have been constructed jointly as a single piece, thereby providing a seamless interface. 
     In addition, because the dimensions of the non-cable components typically have a dimension that is different than the dimensions of a conductor bundle being routed through the legs of the cable structure, one or more legs of the cable structure can have a variable diameter. The change from one dimension to another can exhibit a substantially smooth variation in diameter along the length of the legs of the cable structure. 
     The interconnection of the three legs at the bifurcation region can vary depending on how the cable structure is manufactured. In one approach, the cable structure can be a single-segment unibody cable structure. In this approach, all three legs are jointly formed, for example using an extrusion process, and no additional processing is required to electrically couple the conductors contained therein. In another approach, the cable structure can be a multi-segment unibody cable structure. In this approach, the legs may be manufactured as discrete segments, but require additional processing to electrically couple conductors contained therein. In some embodiments, the segments can be joined together using a splitter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and advantages of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIGS. 1A and 1B  illustrate different headsets having a cable structure that seamlessly integrates with non-cable components in accordance with some embodiments of the invention; 
         FIGS. 1C and 1D  show illustrative cross-sectional views of a portion of a leg in accordance with some embodiments of the invention; 
         FIGS. 2A-C  show illustrative progressive stages of how an overmold splitter can be applied to a single-segment cable structure in accordance with an embodiment of the invention; 
         FIG. 3A  shows a multi-segment cable structure with an overmold splitter in accordance with an embodiment of the invention; 
         FIG. 3B  shows an illustrative schematic view of successive steps for connecting legs with an overmold splitter in accordance with an embodiment of the invention. 
         FIGS. 4A-G  show illustrative views of a cable structure having a tube-shape splitter in accordance with an embodiment of the invention; 
       FIGS.  5 A-C- 2  show illustrative systems for producing a tube-shaped splitter in accordance with an embodiment of the invention; 
         FIG. 6  shows an illustrative view of a shut off insert that may used to produce a tube-shaped splitter in accordance with an embodiment of the invention; 
         FIGS. 7A-E  show illustrative views of a cable structure having another tube-shaped splitter in accordance with an embodiment of the invention. 
         FIG. 8  shows an illustrative system for producing a portion of a tube-shaped splitter in accordance with an embodiment of the invention; 
         FIGS. 9-9B  show an illustrative system for producing a portion of a tube-shaped splitter in accordance with an embodiment of the invention; 
         FIGS. 10-11  show flowcharts of illustrative steps that may be performed to manufacture tube-shaped splitters in accordance with embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Cable structures for use in headsets are disclosed. The cable structure interconnects various non-cable components of a headset such as, for example, a plug, headphones, and/or a communications box to provide a headset. The cable structure can include multiple legs (e.g., a main leg, a left leg, and a right leg) that each connect to a non-cable structure, and each leg may be connected to each other at a bifurcation region (e.g., a region where the main leg appears to split into the left and right legs). Cable structures according to embodiments of this invention provide aesthetically pleasing interface connections between the non-cable components and legs of the cable structure. The interface connections between a leg and a non-cable component are such that they appear to have been constructed jointly as a single piece, thereby providing a seamless interface. 
     In addition, because the dimensions of the non-cable components typically have a dimension that is different than the dimensions of a conductor bundle being routed through the legs of the cable structure, one or more legs of the cable structure can have a variable diameter. The change from one dimension to another is accomplished in a manner that maintains the spirit of the seamless interface connection between a leg and the non-cable component throughout the length of the leg. That is, each leg of the cable structure exhibits a substantially smooth surface, including the portion of the leg having a varying diameter. In some embodiments, the portion of the leg varying in diameter may be represented mathematically by a bump function, which requires all aspects of the variable diameter transition to be smooth. In other words, a cross-section of the variable diameter portion can show a curve or a curve profile. 
     The interconnection of the three legs at the bifurcation region can vary depending on how the cable structure is manufactured. In one approach, the cable structure can be a single-segment unibody cable structure. In this approach, all three legs are jointly formed and no additional processing is required to electrically couple the conductors contained therein. Construction of the single-segment cable may be such that the bifurcation region does not require any additional support. If additional support is required, an over-mold can be used to add strain relief to the bifurcation region. 
     In another approach, the cable structure can be a multi-segment unibody cable structure. In this approach, the legs may be manufactured as discrete segments, but require additional processing to electrically couple conductors contained therein. The segments can be joined together using a splitter. Many different splitter configurations can be used, and the use of some splitters may be based on the manufacturing process used to create the segment. 
     The cable structure can include a conductor bundle that extends through some or all of the legs. The conductor bundle can include conductors that interconnect various non-cable components. The conductor bundle can also include one or more rods constructed from a superelastic material. The superelastic rods can resist deformation to reduce or prevent tangling of the legs. 
     The cable structure can be constructed using many different manufacturing processes. The processes include injection molding, compression molding, and extrusion. In injection and compression molding processes, a mold is formed around a conductor bundle or a removable rod. The rod is removed after the mold is formed and a conductor bundle is threaded through the cavity. In extrusion processes, an outer shell is formed around a conductor bundle. 
       FIG. 1A  shows an illustrative headset  10  having cable structure  20  that seamlessly integrates with non-cable components  40 ,  42 ,  44 . For example, non-cable components  40 ,  42 , and  44  can be a male plug, left headphones, and right headphones, respectively. Cable structure  20  has three legs  22 ,  24 , and  26  joined together at bifurcation region  30 . Leg  22  may be referred to herein as main leg  22 , and includes the portion of cable structure  20  existing between non-cable component  40  and bifurcation region  30 . In particular, main leg  22  includes interface region  31 , bump region  32 , and non-interface region  33 . Leg  24  may be referred to herein as left leg  24 , and includes the portion of cable structure  20  existing between non-cable component  42  and bifurcation region  30 . Leg  26  may be referred to herein as right leg  26 , and includes the portion of cable structure  20  existing between non-cable component  44  and bifurcation region  30 . Both left and right legs  24  and  26  include respective interface regions  34  and  37 , bump regions  35  and  38 , and non-interface regions  36  and  39 . 
     Legs  22 ,  24 , and  26  generally exhibit a smooth surface throughout the entirety of their respective lengths. Each of legs  22 ,  24 , and  26  can vary in diameter, yet still retain the smooth surface. 
     Non-interface regions  33 ,  36 , and  39  can each have a predetermined diameter and length. The diameter of non-interface region  33  (of main leg  22 ) may be larger than or the same as the diameters of non-interface regions  36  and  39  (of left leg  24  and right leg  26 , respectively). For example, leg  22  may contain a conductor bundle for both left and right legs  24  and  26  and may therefore require a greater diameter to accommodate all conductors. In some embodiments, it is desirable to manufacture non-interface regions  33 ,  36 , and  39  to have the smallest diameter possible, for aesthetic reasons. As a result, the diameter of non-interface regions  33 ,  36 , and  39  can be smaller than the diameter of any non-cable component (e.g., non-cable components  40 ,  42 , and  44 ) physically connected to the interfacing region. Since it is desirable for cable structure  20  to seamlessly integrate with the non-cable components, the legs may vary in diameter from the non-interfacing region to the interfacing region. 
     Bump regions  32 ,  35 , and  38  provide a diameter changing transition between interfacing regions  31 ,  34 , and  37  and respective non-interfacing regions  33 ,  36 , and  39 . The diameter changing transition can take any suitable shape that exhibits a fluid or smooth transition from any interface region to its respective non-interface region. For example, the shape of the bump region can be similar to that of a cone or a neck of a wine bottle. As another example, the shape of the taper region can be stepless (i.e., there is no abrupt or dramatic step change in diameter, or no sharp angle at an end of the bump region). Bump regions  32 ,  35 , and  38  may be mathematically represented by a bump function, which requires the entire diameter changing transition to be stepless and smooth (e.g., the bump function is continuously differentiable). 
       FIGS. 1C and 1D  show illustrative cross-sectional views of a portion of main leg  22  in accordance with embodiments of the invention. Both  FIGS. 1C and 1D  show main leg  22  with a center axis (as indicated by the dashed line) and symmetric curves  32   c  and  32   d . Curves  32   c  and  32   d  illustrate that any suitable curve profile may be used in bump region  32 . Thus the outer surface of bump region  32  can be any surface that deviates from planarity in a smooth, continuous fashion. 
     Interface regions  31 ,  34 , and  37  can each have a predetermined diameter and length. The diameter of any interface region can be substantially the same as the diameter of the non-cable component it is physically connected to, to provide an aesthetically pleasing seamless integration. For example, the diameter of interface region  31  can be substantially the same as the diameter of non-cable component  40 . In some embodiments, the diameter of a non-cable component (e.g., component  40 ) and its associated interfacing region (e.g., region  31 ) are greater than the diameter of the non-interface region (e.g., region  33 ) they are connected to via the bump region (e.g., region  32 ). Consequently, in this embodiment, the bump region decreases in diameter from the interface region to the non-interface region. 
     In another embodiment, the diameter of a non-cable component (e.g., component  40 ) and its associated interfacing region (e.g., region  31 ) are less than the diameter of the non-interface region (e.g., region  33 ) they are connected to via the bump region (e.g., region  32 ). Consequently, in this embodiment, the bump region increases in diameter from the interface region to the non-interface region. 
     The combination of the interface and bump regions can provide strain relief for those regions of headset  10 . In one embodiment, strain relief may be realized because the interface and bump regions have larger dimensions than the non-interface region and thus are more robust. These larger dimensions may also ensure that non-cable portions are securely connected to cable structure  20 . Moreover, the extra girth better enables the interface and bump regions to withstand bend stresses. 
     The interconnection of legs  22 ,  24 , and  26  at bifurcation region  30  can vary depending on how cable structure  20  is manufactured. In one approach, cable structure  20  can be a single-segment unibody cable structure. In this approach all three legs are manufactured jointly as one continuous structure and no additional processing is required to electrically couple the conductors contained therein. That is, none of the legs are spliced to interconnect conductors at bifurcation region  30 , nor are the legs manufactured separately and then later joined together. Some single-segment unibody cable structures may have a top half and a bottom half, which are molded together and extend throughout the entire unibody cable structure. For example, such single-segment unibody cable structures can be manufactured using injection molding and compression molding manufacturing processes (discussed below in more detail). Thus, although a mold-derived single-segment unibody cable structure has two components (i.e., the top and bottom halves), it is considered a single-segment unibody cable structure for the purposes of this disclosure. Other single-segment unibody cable structures may exhibit a contiguous ring of material that extends throughout the entire unibody cable structure. For example, such a single-segment cable structure can be manufactured using an extrusion process. 
     In another approach, cable structure  20  can be a multi-segment unibody cable structure. A multi-segment unibody cable structure may have the same appearance of the single-segment unibody cable structure, but the legs are manufactured as discrete components. The legs and any conductors contained therein are interconnected at bifurcation region  30 . The legs can be manufactured, for example, using any of the processes used to manufacture the single-segment unibody cable structure. 
     The cosmetics of bifurcation region  30  can be any suitable shape. In one embodiment, bifurcation region  30  can be an overmold structure that encapsulates a portion of each leg  22 ,  24 , and  26 . The overmold structure can be visually and tactically distinct from legs  22 ,  24 , and  26 . The overmold structure can be applied to the single or multi-segment unibody cable structure. In another embodiment, bifurcation region  30  can be a two-shot injection molded splitter having the same dimensions as the portion of the legs being joined together. Thus, when the legs are joined together with the splitter mold, cable structure  20  maintains its unibody aesthetics. That is, a multi-segment cable structure has the look and feel of single-segment cable structure even though it has three discretely manufactured legs joined together at bifurcation region  30 . Many different splitter configurations can be used, and the use of some splitters may be based on the manufacturing process used to create the segment. 
     Cable structure  20  can include a conductor bundle that extends through some or all of legs  22 ,  24 , and  26 . Cable structure  20  can include conductors for carrying signals from non-cable component  40  to non-cable components  42  and  44 . Cable structure  20  can include one or more rods constructed from a superelastic material. The rods can resist deformation to reduce or prevent tangling of the legs. The rods are different than the conductors used to convey signals from non-cable component  40  to non-cable components  42  and  44 , but share the same space within cable structure  20 . Several different rod arrangements may be included in cable structure  20 . 
     In yet another embodiment, one or more of legs  22 ,  24 , and  26  can vary in diameter in two or more bump regions. For example, the leg  22  can include bump region  32  and another bump region (not shown) that exists at leg/bifurcation region  30 . This other bump region may vary the diameter of leg  22  so that it changes in size to match the diameter of cable structure at bifurcation region  30 . This other bump region can provide additional strain relief. 
     In some embodiments, another non-cable component can be incorporated into either left leg  24  or right leg  26 . As shown in  FIG. 1B , headset  60  shows that non-cable component  46  is integrated within leg  26 , and not at an end of a leg like non-cable components  40 ,  42  and  44 . For example, non-cable component  46  can be a communications box that includes a microphone and a user interface (e.g., one or more mechanical or capacitive buttons). Non-cable component  46  can be electrically coupled to non-cable component  40 , for example, to transfer signals between communications box  46  and one or more of non-cable components  40 ,  42  and  44 . 
     Non-cable component  46  can be incorporated in non-interface region  39  of leg  26 . In some cases, non-cable component  46  can have a larger size or girth than the non-interface regions of leg  26 , which can cause a discontinuity at an interface between non-interface region  39  and communications box  46 . To ensure that the cable maintains a seamless unibody appearance, non-interface region  39  can be replaced by first non-interface region  50 , first bump region  51 , first interface region  52 , communications box  46 , second interface region  53 , second bump region  54 , and second non-interface region  55 . 
     Similar to the bump regions described above in connection with the cable structure of  FIG. 1A , bump regions  51  and  54  can handle the transition from non-cable component  46  to non-interface regions  50  and  55 . The transition in the bump region can take any suitable shape that exhibits a fluid or smooth transition from the interface region to the non-interface regions. For example, the shape of the taper region can be similar to that of a cone or a neck of a wine bottle. 
     Similar to the interface regions described above in connection with the cable structure of  FIG. 1A , interface regions  52  and  53  can have a predetermined diameter and length. The diameter of the interface region is substantially the same as the diameter of non-cable component  46  to provide an aesthetically pleasing seamless integration. In addition, and as described above, the combination of the interface and bump regions can provide strain relief for those regions of headset  10 . 
     In some embodiments, non-cable component  46  may be incorporated into a leg such as leg  26  without having bump regions  51  and  54  or interface regions  52  and  53 . Thus, in this embodiment, non-interfacing regions  50  and  55  may be directly connected to non-cable component  46 . 
     Cable structures  20  can be constructed using many different manufacturing processes. The processes discussed herein include those that can be used to manufacture the single-segment unibody cable structure or legs for the multi-segment unibody cable structure. In particular, these processes include injection molding, compression molding, and extrusion. 
     A more detailed explanation of compression molded cable structures can be found, for example, in commonly assigned U.S. patent application Ser. No. 13/013,540 (now U.S. Patent Application Publication No. 2011/0180302) and Ser. No. 13/013,542 (now U.S. Patent Application Publication No. 2011/0180303), both filed concurrently herewith, the disclosures of which are incorporated by reference herein in their entireties. In one embodiment, a cable structure can be manufactured by compression molding two urethane sheets together to form the sheath of the cable structure. In another embodiment, a cable structure can be manufactured by compression molding at least one silicon sheet to form the sheath of the cable structure. Both sheaths may be constructed to have a hollow cavity extending throughout so that a conductor bundle can be routed through the cavity. 
     A more detailed explanation of extruded cable structures can be found, for example, in commonly assigned U.S. patent application Ser. No. 13/013,553 (now U.S. Patent Application Publication No. 2011/0180321) and Ser. No. 13/013,556 (now U.S. Patent Application Publication No. 2011/0182460), both filed concurrently herewith, the disclosures of which are incorporated by reference herein in their entireties. 
     A more detailed explanation of injection molded cable structures can be found in commonly assigned U.S. patent application Ser. No. 13/013,557 (now U.S. Patent Application Publication No. 2011/0180962) filed concurrently herewith, the disclosure of which is incorporated by reference herein in its entirety. 
     Regardless of how cable structure  20  is constructed, the outer portion is referred to herein as the sheath or cable sheath. The sheath can be stripped away to expose conductors and anti-tangle rods. Stripping the sheath off of a portion of one or more cable legs may be required to electrically couple conductors of one leg to a non-cable component and/or to conductors in a different leg of cable structure  20 . 
       FIGS. 2A-C  show illustrative progressive stages of how an overmold splitter can be applied to a jointly formed multi-leg cable structure in accordance with an embodiment of the invention. Starting with  FIG. 2A , the bifurcation region of jointly formed multi-leg cable structure  200  is shown.  FIG. 2B  shows inner mold  210  disposed around the sheath of cable structure  200 . Inner mold  210  can be applied using an injection mold process. The manner in which inner mold  210  is disposed around cable structure  200  can vary. In one embodiment, inner mold  210  can have any suitable thickness and can vary in cable structure coverage. In another embodiment, inner mold  210  can vary in shape. For example, inner mold  210  can conform to the shape of the sheath at the bifurcation region, in which case inner mold  210  may resemble the tube shape of structure  200 . As another example, the inner mold  210  can resemble a wedge shape, as shown. 
       FIG. 2C  shows outer mold  220  disposed around inner mold  210  and cable structure  200 . Outer mold  220  can be applied using an injection mold process. Outer mold  220  can have any suitable thickness and shape. For example, outer mold  220  may be thicker than inner mold  210 . The shape of outer mold may mimic the shape of inner mold  210 . 
     The material used for inner mold  210  and outer mold  220  may be different. Inner mold  210  may be constructed from a material that is harder than the sheath of cable structure. In addition, inner mold  210  may have a higher melting temperature than the sheath to ensure the sheath bonds to inner mold  210 . Outer mold  220  may be constructed from a material having a higher melting temperature than inner mold  210  to ensure that inner mold  210  bonds to outer mold. 
     Although,  FIGS. 2A-C  show that an overmold splitter may be applied to a jointly formed multi-leg cable structure, an overmold splitter may also be used to interconnect two or more independently formed legs, as illustrated in  FIGS. 3A and 3B .  FIG. 3A  shows multi-segment cable structure  300  having legs  302 ,  304 , and  306  joined together at a bifurcation region. The bifurcation region shows how legs  302 ,  304 , and  306  have been spliced to electrically connect conductors  307 . Anti-tangle rods  308  (sometimes referred to herein as superelastic rods) can also be seen in the bifurcation region. 
     Inner mold  310  and outer mold  320  may exhibit many of the same properties of inner and outer molds  210  and  220  discussed above in connection with  FIG. 2 . That is, inner and outer molds  310  and  320  may have any suitable thickness and shape, and can be constructed from different materials. In addition, both molds  310  and  320  can be applied using an injection molding process. Dimensions  332 ,  334 ,  335 , and  338  may be selected to define the shape of outer mold  320 . In one embodiment, dimensions  332 ,  334 ,  335 , and  338  may be selected to minimize the size of outer mold  320 —to promote the seamless appearance of the cable structure—and to provide sufficient structural integrity to hold legs  302 ,  304 , and  306  together. 
     Minimal sizing of the overmold splitter (as shown in  FIGS. 2 and 3A ) may be achieved because no insert or “chicken foot” is used to provide structural stability. The inner mold/outer mold combination provides sufficient structural stability in lieu of any insert. 
       FIG. 3B  shows an illustrative schematic view of successive steps for connecting legs  340 ,  350 , and  360  with an overmold splitter in accordance with an embodiment of the invention. Each leg can have any suitable number of wires. For example, leg  340  can include six wires, leg  350  can include four wires, and leg  360  can include two wires. The wires can be connected using any suitable approach. In one embodiment, the wires can be connected to printed circuit board  370 , which has traces coupling wires in leg  340  to wires in either leg  350  or leg  360 . 
     The wires of the cables can be coupled to circuit board  370  using any suitable approach. For example, the wires can be coupled to the board using soldering or surface mount technology, tape, or combinations of these. In  FIG. 3B , each wire can be coupled to circuit board  370  via solder joints  372 . In some embodiments, an additional fastening mechanism (e.g., Kevlar ties) can be used to further secure the wires to the circuit board. 
     After the wires have been connected, first injection mold material  380  can be overmolded to cover circuit board  370  and the soldered wires. Any suitable material can be molded over the circuit board, including for example a plastic (e.g., polypropylene, polyethylene, or a polymer). In some embodiments, first material  380  can be selected specifically based on structural or stress and strain resistant characteristics. First material  380  can extend over any suitable portion of board  370  and legs  340 ,  350 , and  360 . 
     After first material  380  has been applied, any excess portion of circuit board  370  extending beyond material  380  can be removed. A cosmetic material  390  can be placed over first material  380  and circuit board  370  to provide an aesthetically pleasing interface. Any suitable material may be selected for cosmetic material  390 , and it may applied with any suitable thickness or shape. 
     The construction nature of the overmold splitter will cause a user to notice a tactile difference between a leg and the bifurcation region where the overmold splitter resides. This tactile difference is eliminated in the splitter embodiments discussed in connection with  FIGS. 4-11 . 
       FIGS. 4-11  use variations of a two-shot injection molding process to produce a tube-shaped splitter that has the same dimensions as the legs being joined together at the bifurcation region. This results in a multi-segment cable structure having a unibody look and feel even though it is constructed with several discrete parts. Referring now to  FIGS. 4-6 , a splitter structure for connecting several discrete legs produced from an extrusion process is discussed. 
       FIG. 4A  shows a bifurcation region of cable structure  400  having stripped legs  401 ,  402 , and  403  in accordance with an embodiment of the invention. Legs  401 - 403  may have been formed from an extrusion process. Conductors  405  and anti-tangle rods  406  are secured and ready to receive the first shot of a tube-shaped splitter. 
       FIG. 4B  shows a bifurcation region of cable structure  400  having first shot  410  of a tube-shaped splitter applied thereto in accordance with an embodiment of the invention. First shot  410  includes ring regions  411 - 413  and non-ring region  414 , both of which encapsulate conductors  405  and anti-tangle rods  406 . Ring regions  411 - 413  can have the same diameter as legs  401 - 403 , respectively. Ring regions  411 - 413  can have a width, W, as shown. Ring regions  411 - 413  may provide structural integrity needed for use of a shut-off plate (not shown) during formation of the second shot. Non-ring region  414  can have a diameter smaller than ring regions  411 - 413 . The material of non-ring region  414  can be uniformly distributed around conductors  405  and anti-tangle rods  406 . In addition, non-ring region  414  is sufficiently thick to prevent conductor or rod pinching during application of the second shot. 
       FIG. 4C  shows a bifurcation region of cable structure  400  having second shot  420  of a tube-shaped splitter applied thereto in accordance with an embodiment of the invention. Second shot  420  encapsulates non-ring region  414  of first shot  410  and abuts ring regions  411 - 413 . Second shot  420  is dimensioned so that legs  401 - 403 , ring regions  411 - 413 , second shot  420  have a seamless unibody look and feel. For example, second shot  420  can have a diameter that is substantially the same as the diameter of ring regions  411 - 413  and legs  401 - 403 . 
       FIG. 4D  shows an alternative view of a bifurcation region of cable structure  400  having second shot  420  applied thereto in accordance with an embodiment of the invention. In contrast to  FIG. 4C , first shot  410 , conductors  405 , and anti-tangle rods  406  are shown as opaque structures, whereas the sheath of legs  401 - 403  and second shot  420  are shown as transparent structures. 
       FIG. 4E  shows an illustrative top view of cable structure  400  having second shot  420  applied thereto and  FIG. 4F  shows an illustrative side view of structure  400  in accordance with embodiments of the invention. The outer diameter, OD, of cable structure  400  is substantially constant throughout, including legs  401 - 403  and tube-shaped splitter  409 . 
       FIG. 4G  shows an illustrative cross-sectional view of cable structure  400  taken along lines  4 G- 4 G of  FIG. 4E .  FIG. 4G  shows conductors  405  and anti-tangle rods  405  surrounded by first shot  410 , which is surrounded by second shot  420 . The combination of conductors  405  and anti-tangle rods  406  has a diameter, D 1 . The portion of first shot  410  shown has a diameter, D 2 . The thickness of second shot  420  (shown as a delta) is one-half the difference of OD and D 2 . 
       FIGS. 5A and 5B  show an illustrative system  500  for applying the first or second shots of a tube-shaped splitter to a cable structure in accordance with an embodiment of the invention. System  500  can include injectors  510 , which can be positioned in different locations depending on whether the first or second shot is being formed. In particular,  FIG. 5A  shows the position of injectors for forming the first shot. A clamping tool (not shown) may enclose a portion of cable structure  400  to provide the pressure needed for thermoplastic or other material to form the first shot. In addition, a shut off insert (shown in  FIG. 6 ) may be used as part of the clamping tool. 
     Referring to  FIG. 6 , shut off insert  600  may prevent thermoplastic bleed off from causing the first shot (i.e., the ring regions) to have a diameter that exceeds the diameter of the legs. This may be accomplished by having the diameter of shut off insert  600  be less than the desired diameter of the leg. Three copies of shut off insert  600  may be used in system  500 , with each insert  600  clamped down on a portion of a leg adjacent to where the ring regions will be molded. 
     Referring back to  FIG. 5A , a cross-sectional view of system  500  taken along lines  5 A- 1 - 5 A- 1  is shown in dashed box  520  of  FIG. 5A-1 .  FIG. 5B  shows the position of injectors  510  for molding the second shot of a tube shaped splitter. Similar to  FIG. 5A , a clamping tool and a shut off insert (e.g., shut off insert  600 ) are used in the formation of the second shot. The shut off inserts may be positioned on the ring regions of the first shot. 
       FIG. 5C  shows an alternative injector arrangement to that shown in  FIG. 5B  for forming the second shot in accordance with an embodiment of the invention. As shown, injectors  510  are positioned to provide equal distribution of pressure to mitigate any movement of the first shot during formation of the second shot. Again, as discussed above in connection with  FIG. 5B , a clamping tool and shut off inserts are used in the formation of the second shot.  FIGS. 5C-1  and  5 C- 2  also show cross-sectional views of system  500  taken along lines  5 C- 1 - 5 C- 1  and  5 C- 2 - 5 C- 2  in dashed boxes  530  and  540 , respectively. 
     Referring now to  FIGS. 7-9 , a splitter structure for use with molded cable structures is discussed. The molded cable structures can be formed from a compression molding process or an injection molding process. The molded cable structures used with the splitter in  FIGS. 7-9  can be hollow. That is, the molded cable structures have cavities that pass through their entire length, thereby providing a pathway for routing a conductor bundle. As will be apparent in the discussion below, three hollow legs (e.g., a main leg, a right leg, and a left leg) interface with the splitter such the legs and the splitter appear to be a one-piece construction. Thus, the visible portions of the cable leg and splitter have substantially the same dimensions. 
       FIG. 7A  shows a bifurcation region of cable structure  700  having first shot  720  of a tube-shaped splitter applied to a bundle of conductors and/or anti-tangle rods  710  in accordance with an embodiment of the invention. Bundle  710  can be any suitable arrangement of conductors and/or anti-tangle rods. A more detail discussion of bundles can be found in U.S. Provisional Patent Application No. 61/384,097, filed Sep. 17, 2010, entitled “Cable Structures and Systems Including Super-Elastic Rods and Methods for Making the Same. 
     First shot  720  is applied to bundle  710 , and in particular to the bifurcation region of bundle  710 . First shot  720  can be applied using a high pressure injection mold or a lower pressure compression mold. First shot  720  can include extension regions  721 - 723 , lip regions  724 - 726  (i.e., lip  726  is shown in more detail in detail view  950 ), and u-shaped region  728 . The dimensions of first shot  720  are smaller than the outer dimension of the finished cable structure. In particular, the dimensions of extension regions  721 - 723  are sized to permit hollow cable structures to be slid over the bundle and extension region. The lip regions  724 - 726  serve as a stop for hollow cable structure insertion. U-shaped region  728  may be dimensioned larger than extension regions to provide added rigidity to the cable structure so that it will not be moved during application of the second shot. 
       FIG. 7B  shows a bifurcation region of cable structure  700  of second shot  730  of a tube-shaped splitter applied to first shot  720  in accordance with an embodiment of the invention.  FIG. 7B  also shows hollow cable structures  741 - 743 , which abut second shot  730  at lip regions  724 - 726 . Second shot  730  has the same diameter as cable structures  741 - 743  and can be applied using a high pressure injection mold. After second shot  730  is applied, the cable structure has a unibody look and feel because the tube-shaped splitter seamlessly blends with the hollow cable structures. 
       FIG. 7C  shows an alternative view of a bifurcation region of cable structure  700  having second shot  730  applied thereto in accordance with an embodiment of the invention. In particular cable structures  741 - 743  are shown as wire frames whereas the other components are shown as opaque. Glue  745  may be applied to a portion of first shot  720  to secure cable structures  741 - 743  in place. 
       FIG. 7D  shows an illustrative top view of cable structure  700  and  FIG. 7E  shows an illustrative side view of cable structure  700 .  FIGS. 7D and 7E  show that the diameters of hollow cable structure  741 - 743  are the same as the outer diameter D of the tube-shaped splitter. 
       FIG. 8  shows an illustrative system  800  for applying the first shot of a tube-shaped splitter to a cable structure in accordance with an embodiment of the invention. System  800  can include injectors  810  that can inject a thermoplastic material onto bundle  710  to form first shot  720 . A clamping tool (not shown) may be used to apply the pressure needed to form the mold for first shot  720 . 
       FIG. 9  shows an illustrative system  900  for applying the second shot of a tube-shaped splitter to a cable structure in accordance with an embodiment of the invention. System  900  includes injectors  910  that are positioned to prevent movement of the first shot when the thermoplastic material is injected. A clamping tool and a shut off insert may be used in the formation of second shot  730 . The shut off insert may be dimensioned to prevent bleed off from affecting the outer diameter sizing of the cable structure. Cross-sectional views taken along lines  9 A- 9 A and  9 B- 9 B are shown in dashed-line boxes  950  and  960  of  FIGS. 9A and 9B , respectively. 
       FIG. 10  illustrates steps that may be performed to mold a splitter onto a cable structure in accordance with an embodiment of the invention. These steps may be performed to produce cable structure  400  of  FIGS. 4A-4G . Starting at step  1010 , a plurality of extruded cable structure segments are provided. Each cable structure segment has an exposed bundle interconnected at a bifurcation region. At step  1020 , a first material is applied to the exposed bundle to form a first shot that encapsulates the exposed bundle. The first shot having ring regions and a non-ring region, wherein the ring regions have substantially the same diameter as the portion of the extruded cable structure segments interfacing with the bifurcation region. An example of a first shot is shown in  FIG. 45 . At step  1030 , a second material is applied to the non-ring region to form a second shot that encapsulates the non-ring region. The second shot has a diameter substantially the same diameter as the portion of the extruded cable structure segments interfacing with the bifurcation region. 
       FIG. 11  illustrates steps that may be performed to mold a splitter onto a cable structure in accordance with an embodiment of the invention. These steps may be performed to produce cable structure  700  of  FIGS. 7A-C . Starting at step  1110 , a bundle arranged in a predetermined configuration is provided. The bundle can have three legs joined together at a bifurcation region. At step  1120 , a first material is applied to the bundle at the bifurcation region to form a first shot that encapsulates a portion of the bundle. The first shot can have extension regions, lip regions, and a u-shaped region. At step  1130 , a hollow cable structure segment is inserted over each leg so that the hollow cable structure segment covers one of the extension regions and abuts one of the lip regions. At step  1140 , a second material is applied to at least the u-shaped region to form a second shot. The second shot having a diameter that is substantially the same as a diameter of any one of the hollow cable structure segments. 
     It should be understood that processes of  FIGS. 10-11  are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added, without departing from the scope of the invention. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20110125
Publication Date: 20140805
Grant Date: 20140805
Priority Date: 20100125
Inventors: AASE JONATHAN
FRAZIER CAMERON
RUSSELL-CLARKE PETER
CHOINIERE PAUL
DUNHAM GREG
STIEHL KURT
Assignee: APPLE INC
CPC Classifications: [{"code": "B29C2043/3665", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3621", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14131", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/1409", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C33/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02G15/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2105/256", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2105/256", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C33/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3621", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14073", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29L2031/3462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3665", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C39/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C39/42", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 44308097