PATENT DOCUMENT

Publication Number: US-9331438-B2
Application Number: US-201414185133-A
Country: US
Kind Code: B2

Title: Split jack assemblies and methods for making the same

Abstract:
Split jack assemblies are constructed with a tubeless pin block. Elimination (or split) of the tube, or more particularly, a tube that is an integrally formed part of the pin block form the pin block allows for the use of a tubeless pin block design that results in a jack assembly having smaller overall dimensions than a conventional jack assembly constructed to accommodate a plug of the same dimensions. The tubeless pin block can be used in conjunction with a tube sleeve or with a curved surface of a housing for an electronic device, or both to provide a plug receptacle of the split jack assembly.

Claims:
What is claimed is: 
     
       1. A jack assembly comprising:
 a pin block including a plurality of curved abutting members; 
 a tube positioned adjacent to the pin block such that the curved abutting members abut an outer surface of the tube; 
 a plurality of conductive pins interspersed with the plurality of curved abutting members; and 
 a housing with a curved side wall, wherein the tube is positioned against the curved side wall. 
 
     
     
       2. The jack assembly defined in  claim 1  wherein the tube includes a plurality of holes, wherein the plurality of conductive pins protrude through the plurality of holes. 
     
     
       3. The jack assembly defined in  claim 1  wherein a curved portion of the plurality of curved abutting members contacts an outer surface of the tube. 
     
     
       4. The jack assembly defined in  claim 1  wherein the pin block further comprises a tube-stop abutting member that contacts an end of the tube. 
     
     
       5. The jack assembly defined in  claim 1  wherein the plurality of curved abutting members and the tube are non-conductive. 
     
     
       6. A jack assembly comprising:
 a pin block including a plurality of curved abutting members; 
 a tube positioned adjacent to the pin block; and 
 a plurality of conductive pins interspersed with the plurality of curved abutting members, wherein the pin block comprises a retention pin adjacent to a tube-stop abutting member. 
 
     
     
       7. The jack assembly defined in  claim 1 , wherein the pin block and the housing form an opening. 
     
     
       8. The jack assembly defined in  claim 1  wherein the housing comprises a first surface member and a second surface member integrally formed with the curved side wall, wherein the first surface member, the second surface member, and the curved side wall at least partially surround the tube and the pin block. 
     
     
       9. An electronic device, comprising:
 a housing having first and second surface members joined by a curved side member; and 
 a pin block in the housing adjacent to the curved side member, wherein the pin block and the curved side member form an opening, and wherein the pin block comprises a plurality of curved abutting members and a plurality of spring-loaded pins interposed between each of the plurality of curved abutting members. 
 
     
     
       10. The jack assembly defined in  claim 7 , wherein the tube is positioned in the opening formed by the pin block and the housing. 
     
     
       11. An electronic device, comprising:
 a housing having first and second surface members joined by a curved side member; and 
 a pin block in the housing adjacent to the curved side member, wherein the pin block and the curved side member form an opening, wherein the pin block comprises a plurality of curved abutting members, wherein the curved side member comprises an inner surface with a radius, and wherein the plurality of curved abutting members comprises curved surfaces with radii that are the same as the radius of the inner surface of the curved side member. 
 
     
     
       12. The electronic device defined in  claim 9  wherein the opening is circular. 
     
     
       13. An electronic device, comprising:
 a housing having first and second surface members joined by a curved side member; 
 a pin block in the housing adjacent to the curved side member, wherein the pin block and the curved side member form an opening; and 
 an insulation layer applied to an inner surface of the curved side member. 
 
     
     
       14. The electronic device defined in  claim 9  wherein the plurality of spring-loaded pins protrude beyond a curved plane formed by the curved abutting members. 
     
     
       15. The electronic device defined in  claim 9  wherein the opening forms at least a portion of a plug receptacle.

Description:
This application claims the benefit of U.S. Non-Provisional application Ser. No. 13/631,553 filed Sep. 28, 2012, U.S. Provisional Application No. 61/553,109, filed Oct. 28, 2011, and U.S. Provisional Application No. 61/555,131, filed Nov. 3, 2011, the disclosures of which are incorporated by reference herein in their entireties. 
    
    
     BACKGROUND 
     This disclosure is directed to split jack assemblies and methods for making the same. 
     Electronic devices may include jacks into which plugs may be inserted. The jack can include a number of contacts that come into contact with the plug when it is inserted into the jack. When inserted, signals can be transmitted between the plug and the jack. For example, an electronic device can generate audio signals that are provided from the jack to the plug, or the jack can receive microphone signals from the plug. As the size of electronic devices continue to shrink, and more features requiring more circuitry are incorporated therein, an ever increasing premium is made on space. Since the jack is often a necessary component included in electronic devices, there is a need for jacks having a reduced footprint. 
     SUMMARY 
     This disclosure is directed to split jack assemblies and methods for making the same. Split jack assemblies according to embodiments of the invention are constructed with a tubeless pin block. Elimination (or split) of the tube, or more particularly, a tube that is an integrally formed part of the pin block form the pin block allows for the use of a tubeless pin block design that results in a jack assembly having smaller overall dimensions than a conventional jack assembly constructed to accommodate a plug of the same dimensions. The tubeless pin block can be used in conjunction with a tube sleeve or with a curved surface of a housing for an electronic device, or both to provide a plug receptacle region of the split jack assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIGS. 1A-1C  show several illustrative views of a conventional integrated-tube jack assembly; 
         FIGS. 2A-2C  shows several views of a split jack assembly in accordance with an embodiment of the invention. in accordance with an embodiment; 
         FIGS. 3A-3C  show several illustrative views of tubeless pin block in accordance with an embodiment; 
         FIGS. 4A-4B  show two illustrative views of a tube in accordance with one embodiment; 
         FIG. 5  shows a partial cut-away view of a split jack assembly incorporated inside housing in accordance with an embodiment; 
         FIG. 6  shows an illustrative flowchart for making a jack assembly in accordance with an embodiment; and 
         FIGS. 7A-7B and 8A-8B  show illustrative interlocking features that can be incorporated into the tube and pin block according to various embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     Split jack assemblies according to various embodiments are constructed with a tubeless pin block. Elimination (or split) of the tube, or more particularly, a tube that is an integrally formed part of the pin block form the pin block allows for the use of a tubeless pin block design that results in a jack assembly having smaller overall dimensions than a conventional jack assembly constructed to accommodate a plug of the same dimensions. The tubeless pin block can be used in conjunction with a tube sleeve or with a curved surface of a housing for an electronic device, or both to provide a plug receptacle region of the split jack assembly. 
     Referring to  FIGS. 1A-1C , several illustrative views of a conventional integrated-tube jack assembly are shown.  FIG. 1A  shows an illustrative partial cut-way and isometric view of integrated-tube jack assembly  100  incorporated into housing  150 .  FIG. 1B  shows a side view and  FIG. 1C  shows a top view of jack assembly  100  in housing  150 , respectively. Reference will be made to  FIGS. 1A-1C  collectively. As shown, jack assembly  100  includes a non-conductive component and several conductive components. The non-conductive component includes integrally formed body  106  and tube  110 . For example, the non-conductive component can be injected molded as a single integrated component. The conductive components can include electrical contacts  120  that are mounted to body  106 . The integral nature of body  106  and tube  110  requires a certain minimum thickness of the non-conductive component in order to form tube  110  of assembly  100 . This minimum thickness for tube  110  limits the ability to reduce the size of housing  150 . For example, a reduction of z-height thickness of housing  150  is limited due to the minimum thickness needed to form  110 . 
       FIGS. 2A-2C  shows several views of a split jack assembly in accordance with an embodiment of the invention.  FIG. 2A  shows an illustrative partial cut-way and isometric view of split jack assembly  200  incorporated into housing  250 .  FIG. 2B  shows a side view and  FIG. 2C  shows a top view of split jack assembly  200  in housing  250 , respectively. Reference will be made to  FIGS. 2A-2C  collectively. As shown, split jack assembly  200  can include tubeless pin block  210 , tube  220 , spring-loaded pins  230 , and retention pin  232 . Tubeless pin block  210  and tube  220  are separate components and are not integrally formed, which is in direct contrast to conventional integrated-tube jack assembly  100  of  FIG. 1 . Pins  230  and  232  are conductive, but the other parts of pin block  210  are non-conductive. Tube  220  is also non-conductive. 
     Split jack assembly  200  eliminates the integrated housing of assembly  100 , and as a result, is able to reduce its footprint, compared to assembly  100 . The reduced footprint can be realized in that the separate pin block  210  and tube  220  construction allows for a thinner housing  250  in the z-height than housing  150 . The two part construction of assembly  200  does not require pin block to envelope tube  220 , thus eliminating the minimum thickness requirement needed to form tube  110 . 
     Referring briefly to  FIGS. 3A-3C , several illustrative views of tubeless pin block  210  are shown. Tubeless pin block  210  includes curved abutting members  240  that are aligned along curved plane  242  and are interspersed with spring-loaded pins  230 . A portion of each spring-loaded pin  230  can protrude beyond curved plane  242 . Curved abutting members  240  are curved according to a predetermined radius. The predetermined radius can vary on a few factors such as the diameter of the plug to be inserted in the split jack assembly and/or whether a separate tube (e.g., tube  220 ) is used. 
     Block  210  can include tube-stop abutting member  212 , which can provide an anchor point for tube  220  if tube  220  is fixed to block  210 . Retention pin  232  can hold a plug (not shown) in place when it is inserted into the split jack assembly. 
     Referring now to  FIGS. 4A-4B , two illustrative views of tube  220 . As shown, tube  220  can include one or more holes  222 . Each hole  222  permit a spring-loaded pin  230  to pass through so that it can come into contact with a region of a plug (not shown). Tube  220  has a predetermined diameter and wall thickness. The wall thickness can range between 50 and 200 um, 75 and 125 um, or be about 100 um. Tube  220  may be an extruded material having non-conductive properties. 
     Referring back to  FIGS. 2A-2BC , tube  220  is shown fixed to tubeless pin block  210 . When tube  220  is fixed to block  210 , curved abutting members  240  abut the outer surface of tube  220 , the edge of tube  220  abuts tube-stop abutting member  212 , and each one of spring-loaded pins  230  protrude through one of holes  222 . Tube  220  may be fixed to block  210  using any suitable approach, such as, for example, adhesive (e.g., PSA), glue, or press fit. In another approach, block  210  and tube  220  can be subject to elevated temperatures that cause both to partially melt and bond together. 
     Jack assembly  200  can be positioned adjacent to a side of housing  250 . In some embodiments, block  210 , tube  220 , or both may be secured to housing  250  using glue, adhesive, or other suitable bonding agent or technique. Use of glue, for example, can assist in enhanced strength of jack assembly  200  and can help eliminate ingress of water or debris into the housing  250 . Housing  250  can be any multi-walled structure that encloses various components of an electronic device. Some of the walls may be curved, as shown. In particular, side wall  253  is curved and can be integrally formed with first surface member  251  and second surface member  252 . The interior surface of sidewall  253  can be curved according to a predetermined radius. Moreover, in some embodiments, the interior surface may be dimensioned so that tube  220  fits snuggly against it when jack assembly  200  is installed in housing  250 . In other embodiments, the interior surface of housing  250  may be dimensioned to accommodate a tubeless design (as shown in  FIG. 5 ). 
     The wall thickness of side wall  253  relative to wall thickness of tube  220  may be substantially greater. For example, the wall thickness of side wall  253  may be 2-10 times greater than the wall thickness of tube  220 . Enhanced wall thickness may be necessary because it bears some the lateral load exerted by the plug as it is inserted and retained within jack assembly  200 . 
       FIG. 5  shows a partial cut-away view of split jack assembly  500  incorporated inside housing  550  in accordance with an embodiment of the invention. Jack assembly  500  can include tubeless pin block  510  and curved inner surface  553 . Pin block  510  can be the same or similar to pin block  210 , as discussed above. The difference with jack assembly  500 , compared to jack assembly  200 , is that no separate tube is used as a receptacle for a plug. Rather, inner surface  553  and pin block  510  form the plug receptacle by being appropriately sized and placed together in appropriate proximity of each other. Thus, the radii of curvature of both inner surface  553  and curved abutting members  540  can be substantially the same so that a receptacle of uniform diameter is provided for receiving a plug (not shown). 
     In some embodiments, depending on the material composition of housing  550 , an insulation layer may be applied to inner surface  553 . If housing is constructed from metal, the insulation layer will prevent shorts when the plug is inserted. If an insulation layer is applied, then the dimensions of the inner surface are made so that the desired diameter is obtained for the plug receptacle. 
     The insulation layer may be constructed from any suitable material and applied using any suitable process. For example, a material may be applied using spraying, painting, plasma vapor deposition (PVD), chemical vapor deposition (CVD), plasma enhanced chemical vapor deposition (PECVD), UV curing, high bake curing, thin tube extrusion (e.g., coupled to the housing an adhesive, tape, bonding, or press fit), oxidation, electrolytic deposition, electrostatic deposition, plasma electrolytic oxide (PEO) process, a thermal spray coating, or any other suitable process. Different materials may be used for each of the processes, including for example polyetheretherketone (PEEK), alumina, nitride (e.g., aluminum titanium nitride or silicon nitride), polyphenyl ether (PPE), diamond-like carbon coating (DLC), a plastic, polymer, composite material, or any other suitable material. In some embodiments, thin tube extrusion (e.g., using PEEK), coatings applied by oxidation of the base metal (e.g., oxidation of the housing metal around the periphery of the port), or electrostatic deposition of ceramic coatings may provide adequate insulation on inner surface  653 . 
     The material and process may be selected based on any suitable criteria. In particular, the material may be selected to be isolating (e.g., otherwise, it does not reduce undesired contacts between the connector and housing). Other criteria may include, for example, selecting the material and process based on the appearance of the resulting layer or film (e.g., select a material that is substantially clear or transparent, or a material that is substantially the same color as the housing). As another example, the material and process may be selected based on resistance to cracking, abrasive wear, or other failure (e.g., select a material and process that provide a layer operative to resist to a particular number of cycles of placing and removing a connector within the connector housing, or pulling a connector against the edges of the housing port). As still another example, the material and process may be selected for its applicability to different geometries (e.g., select a process and material that may be applied to ports in flat housings and curved housings). 
       FIG. 6  shows an illustrative process for assembling a jack assembly in accordance with an embodiment. Beginning at step  610 , a tubeless pin block is secured within a housing, the tubeless pin block including a plurality of curved abutting members and a plurality of spring-loaded pins. For example, the tubeless pin block can be block  210  of  FIGS. 2 and 3 . At step  620 , a hollow tube comprising a plurality of holes is fixed to the pin block such that the curved abutting members abut an outer surface of the hollow tube and the spring-loaded pins protrude through respective ones of the holes. The tube can be tube  220  of  FIGS. 4A-4B , for example. 
     The tube can be secured to the pin block by being inserted into the housing and rotated such that the spring-loaded pins protrude through their respective holes in the tube. The tube may also be inserted into the housing until it abuts a tube-stop abutting member. 
       FIGS. 7A-7B and 8A-8B  show interlocking features that can be incorporated into the tube and pin block according to various embodiments. Interlocking features may be useful in securing the tube to the pin block and further enhancing ease of assembly. Referring now to  FIG. 7A , tube  700  includes tab  710  and holes  722 . Tab  722  can fit into a corresponding slot contained within the pin block (neither of which are shown). The tab/slot combination can assist in preventing tube  700  from rotating after it is installed. If desired, an adhesive can be used to glue tab  710  within the slot. 
       FIG. 7B  shows tube  750  including tab  760 , ribs  762 , and holes  772 . Tab  760  can fit into a corresponding slot in a manner similar to tab  710  (of  FIG. 7A ). Ribs  762  can run along the length of tube  750 , and in some embodiments, can also run along tab  760 . Any number of ribs can be incorporated into tube  750 . Thus, although three ribs are shown in the FIG., fewer or additional ribs can be incorporated. Ribs  762  can fit into channels that run along the pin block (both of which are not shown). When ribs  762  are engaged with their respective channels in the pin block, the rib/channel combination is effective in preventing tube  750  from rotating, and it can facilitate ease of assembly. In some embodiments, use of tab  760  can be omitted and the tube can rely on use of ribs  762  to prevent rotation of tube  750 . 
     It is understood that the interlocking features can be reversed. For example, the slot can exist on the tube and the tab member can exist in the pin block. As another example, the channels can exist on the tube and the ribs can exist on the pin block. 
       FIG. 8A  shows an illustrative perspective view of pin block  800  with tube  820  attached thereto in accordance with an embodiment.  FIG. 8B  shows an illustrative cross-sectional view taken along line B-B of  FIG. 8A . Reference will be made to  FIGS. 8A-8B  collectively. Pin block  800  includes, among other features, curved member  810 , tab member  812 , and pins  814 . Tube  820  can includes holes (not shown) and slot  823 . Tab member  812  is part of curved member  810  and is constructed to fit into slot  823  when tube  820  is positioned next to pin block  800 . The combination of tab member  812  and slot  823  can prevent tube  820  from rotating and sliding in the y-axis direction. In some embodiments, curved member  810  is can be attached to the outer surface of tube  820  with an adhesive. 
     Referring specifically to  FIG. 8B , the surface of tab member  812  is dimensioned to match the radius of tube  820 . Thus, even though tab member  812  is inserted into a slot (not shown) contained within tube  820 , the inner diameter of tube  820  remains substantially constant. 
     It is understood that the tab member and slot can be reversed. For example, the tube can include a tab member operative to fit into a slot contained in the curved member. 
     The above described embodiments of the invention are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20140220
Publication Date: 20160503
Grant Date: 20160503
Priority Date: 20111028
Inventors: ROTHKOPF FLETCHER R.
SHEDLETSKY ANNA-KATRINA
COLAHAN IAN P.
DE IULIIS DANIELE
DO TRENT K.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/187", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 47221532