PATENT DOCUMENT

Publication Number: US-9363343-B2
Application Number: US-201414473781-A
Country: US
Kind Code: B2

Title: Audio jack connector integrated into enclosure

Abstract:
An electronic device enclosure that includes a housing and a frame and an integrally formed connector shell. The connector shell includes a first portion integrally formed with the housing and a second portion integrally formed with the frame. The first and second portions of the connector shell are joined at first and second mating surfaces, respectively, forming a cavity therebetween in which a plurality of receptacle connector contacts are positioned.

Claims:
What is claimed is: 
     
       1. An electronic device enclosure, comprising:
 a housing having a back portion and an outer sidewall extending from the back portion around an outer periphery of the electronic device enclosure; 
 an opening in the outer sidewall that communicates with a cavity; 
 a frame coupled to the housing and configured to receive a display cover; 
 a first section of a connector shell integrally formed with the back portion and outer sidewall and extending from the back portion towards the frame, the first section having a first mating surface and a first interior surface, the first mating surface extending around a periphery of the first section and surrounding the first interior surface except at the opening; 
 a second section of the connector shell integrally formed with the frame and extending from the frame towards the back portion, the second section including a second mating surface and a second interior surface, the second mating surface extending around a periphery of the second section and surrounding the second interior surface except at the opening, wherein the second mating surface is aligned with the first mating surface and the first and second interior surfaces combining to form the cavity; and 
 a plurality of contacts positioned in the cavity. 
 
     
     
       2. The electronic device enclosure set forth in  claim 1  wherein the connector shell is an audio jack connector shell configured to receive an audio jack plug inserted through the opening. 
     
     
       3. The electronic device enclosure set forth in  claim 2  wherein each of the first and second sections comprise approximately half a depth of the audio jack connector shell. 
     
     
       4. The electronic device enclosure set forth in  claim 1  wherein the first section includes a first plurality of slots formed in or adjacent to the first mating surface, the second section includes a second plurality of slots formed in or adjacent to the second mating surface, and the plurality of contacts include portions that mate with one or more of the plurality of slots. 
     
     
       5. The electronic device enclosure set forth in  claim 1  wherein the first and second mating surfaces are joined together by an ultrasonic weld. 
     
     
       6. The electronic device enclosure set forth in  claim 1  wherein a joint is formed along at least one of the first and second mating surfaces to form a more water-tight seal between the surfaces. 
     
     
       7. The electronic device enclosure set forth in  claim 1  wherein the outer sidewall includes an upper edge around its periphery and a seat extending along an interior surface of the outer sidewall proximate to the edge, and wherein the frame is supported by the seat. 
     
     
       8. The electronic device enclosure set forth in  claim 7  wherein the outer sidewall and back are part of the housing that includes one or more cutouts or bores and wherein the frame includes one or more projections that align with the one or more cutouts or bores. 
     
     
       9. The electronic device enclosure set forth in  claim 8  wherein the one or more projections from the frame are joined to the housing by a press-fit connection in the one or more cutouts or bores. 
     
     
       10. An electronic device enclosure, comprising:
 a housing having a back portion and an outer sidewall extending from the back portion around an outer periphery of the electronic device enclosure, the outer sidewall including an upper edge around its periphery and a seat extending along an interior surface of the outer sidewall proximate to the edge; 
 an opening in the outer sidewall that communicates with a cavity; 
 a frame supported by the seat and having a window for a display cover; 
 a connector shell including a first section integrally formed with the housing and extending from the back portion towards the frame and a second section integrally formed with the frame and extending from the frame towards the back portion, the first section having a first mating surface and a first interior surface, the first mating surface extending around a periphery of the first section and surrounding the first interior surface except at the opening, the second section including a second mating surface and a second interior surface, the second mating surface extending around a periphery of the second section and surrounding the second interior surface except at the opening, wherein the second mating surface is aligned with the first mating surface and the first and second interior surfaces combining to form the cavity; and 
 a plurality of contacts positioned in the cavity. 
 
     
     
       11. The electronic device enclosure set forth in  claim 10  wherein the connector shell is configured to receive an audio jack plug inserted through the opening and the plurality of contacts include first, second, third and fourth contacts spaced apart along a depth of the cavity. 
     
     
       12. The electronic device enclosure set forth in  claim 10  wherein the opening is formed in a bottom sidewall of the enclosure. 
     
     
       13. The electronic device enclosure set forth in  claim 10  wherein the back portion and outer sidewall of the housing are formed from an injection molding process. 
     
     
       14. The electronic device enclosure set forth in  claim 10  wherein the first section of the connector shell is also formed from an injection molding process. 
     
     
       15. The electronic device enclosure set forth in  claim 10  wherein the back portion and outer sidewall of the housing are formed from a first shot of an injection molding process and the first section of the connector shell is formed integral with the back and outer sidewall from a second shot of an injection molding process. 
     
     
       16. The electronic device enclosure set forth in  claim 15  wherein the back portion and outer sidewall of the housing are formed from a non-glass filled resin material and the first section of the connector shell is formed from a glass filled LCP plastic. 
     
     
       17. The electronic device enclosure set forth in  claim 10  wherein the back portion, outer sidewall and the first section are formed from a single piece of metal with a nonconductive coating covering at least the first interior surface of the first section. 
     
     
       18. The electronic device enclosure set forth in  claim 10  wherein the back portion and outer sidewall are formed from a single piece of metal and the first section is formed with an injection molding process.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to enclosures for electronic devices, and in particular enclosures including electrical connectors such as a receptacle connector for receiving an audio connector or plug. 
     Many electronic devices include electrical connectors that receive data and, in some cases, receive and provide power and data. These electrical connectors are typically receptacle connectors and are designed to receive a male plug connector. The male plug connector may be on the end of a cable or part of an accessory, such as a docking station or stereo receiver. The plug connector may plug into the receptacle connector, thereby forming one or more conductive paths for signals and/or power. 
     Receptacle connectors often have a shell that surrounds and provides mechanical support for contacts of the receptacle connector. Receptacle connector shells are typically made from a dielectric material such as plastics. The contacts may be arranged to mate with corresponding contacts on the plug connector, e.g., an audio plug, to form portions of electrical paths between devices. 
     These receptacle connectors, e.g., audio jacks, are often manufactured separately from the enclosure and sometimes by a manufacturer different than the enclosure manufacturer. These off-the-shelf receptacle connectors may be attached with screws or otherwise fixed to an enclosure of an electronic device. Some receptacle connectors are customized for use within a specific electronic device or a group of electronic devices. These custom receptacle connectors may also be manufactured separately from the enclosure and inserted into the enclosure during the assembly process of the electronic device. 
     As electronic devices continue to become smaller and thinner, the housing of an off-the-shelf or custom receptacle connector may take up an undesirably high percentage of the overall limited internal space within the enclosure and/or be a limit on how thin the enclosure can be made. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates generally to enclosures for electronic devices, and in particular enclosures integrally formed with a receptacle connector shell for receiving electrical connectors such as audio plug connectors. In some embodiments, the receptacle connector shell is formed from first and second sections that are integrally formed with bottom and top portions of an enclosure, respectively. The first and second sections can be aligned so that when the bottom and top portions of the enclosure are joined together, the first and second sections form a receptacle connector shell integral with the enclosure. In this manner, the overall amount of space the receptacle connector takes up within the enclosure can be reduced and the enclosure can be thinner than a similar enclosure that includes a separate receptacle connector shell instead. Additionally, enclosure designs according to some embodiments of the present invention may provide excellent sealing between the receptacle connector shell and the enclosure thus protecting against liquid ingress and may also provide a structurally robust receptacle connector shell having reduced material requirements and reduced assembly time. 
     According to one embodiment, an electronic device enclosure is provided. The electronic device enclosure includes a housing having a back portion and an outer sidewall extending from the back portion around an outer periphery of the electronic device enclosure. An opening is formed in the outer sidewall that communicates with a cavity in which a plurality of contacts are positioned. The enclosure further includes a frame coupled to the housing and configured to receive a display cover. A first section of a connector shell is integrally formed with the back portion and outer sidewall and extends from the back portion towards the frame. The first section includes a first mating surface and a first interior surface, the first mating surface extending around a periphery of the first section and surrounding the first interior surface except at the opening. A second section of the connector shell is integrally formed with the frame and extends from the frame towards the back portion. The second section includes a second mating surface and a second interior surface. The second mating surface extends around a periphery of the second section and surrounds the second interior surface except at the opening and is aligned with the first mating surface so that the first and second interior surfaces combine to form the cavity. 
     According to another embodiment, an electronic device enclosure is provided. The electronic device enclosure can include a housing having a back portion, an outer sidewall extending from the back portion around an outer periphery of the electronic device enclosure, and an opening in the outer sidewall that communicates with a cavity in which a plurality of receptacle connector contacts are positioned. The outer sidewall includes an upper edge around its periphery and a seat extending along an interior surface of the outer sidewall proximate to the edge. The enclosure further includes a frame supported by the seat and having a window for a display cover, and a connector shell that includes a first section integrally formed with the housing and a second section integrally formed with the frame. The first section includes a first mating surface and a first interior surface where the first mating surface extends around a periphery of the first section and surrounds the first interior surface except at the opening. The second section includes a second mating surface and a second interior surface. The second mating surface extending around a periphery of the second section and surrounding the second interior surface except at the opening, and where the first and second mating surfaces are aligned with each other and the first and second interior surfaces combine to form the cavity. 
     Although aspects of the invention are described herein primarily in relation to enclosures integrally formed with an audio jack, it is appreciated that the described features, aspects and methods can be used in a variety of different environments, regardless of receptacle connector size or type. For example, the enclosures described herein may be integrally formed with a variety of different electrical connector shells, which may use a variety of different connector technologies including standard Universal Serial Bus (USB), High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), DisplayPort, Thunderbolt, FireWire, power, Ethernet connectors, as well as various proprietary connectors, such as Apple&#39;s proprietary 30-pin connector or Lightening connector, used with common electronics. The invention may also apply to internal connectors or other connections between components within the enclosure of an electronic device. Additionally, while the invention is primarily described with respect to an enclosure for portable media devices, the invention may apply to devices such as tablets, laptops, netbooks, desktops, all-in-one computers, storage devices, navigation systems, monitors, among other electronic devices. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a simplified illustrative block diagram representing an electronic media device that includes an audio receptacle connector according to embodiments of the present invention; 
         FIG. 2  illustrates a rendering of one particular electronic media device; 
         FIGS. 3A-B  illustrate examples of audio plugs having three and four conductive portions, respectfully; 
         FIG. 4A  illustrates a sectional perspective view of a traditional electronic device enclosure having an audio jack mounted thereon; 
         FIG. 4B  illustrates a cross-sectional view of a section of a traditional enclosure having an audio jack mounted thereon and having a cover glass frame and a cover glass assembled therewith; 
         FIG. 5  illustrates a simplified perspective view of a partially formed electronic device enclosure having an integrally formed audio jack shell according to one embodiment of the invention; 
         FIG. 6A  is a partial perspective view of a housing portion of an electronic device enclosure integrally formed with a first portion of an audio jack connector shell according to an embodiment of the invention; 
         FIG. 6B  is a partial perspective view of a front cover portion of an electronic device enclosure integrally formed with a second portion of an audio jack shell integrally according to an embodiment of the invention; 
         FIG. 7A  illustrates a perspective sectional view of an audio jack shell according to an embodiment of the invention prior to assembly; and 
         FIG. 7B  illustrates a cross-sectional view of the audio jack shell shown in  FIG. 6A  within an enclosure according to an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to certain embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known details have not been described in detail in order not to unnecessarily obscure the present invention. 
     Before describing the present invention, electronic devices in which the invention may be implemented and examples of audio connectors or plugs corresponding to receptacle connectors for which embodiments of the invention are particularly useful are first described. 
       FIG. 1  is a simplified illustrative block diagram representing an electronic media device  100  that includes an audio receptacle connector  105  according to embodiments of the present invention. Electronic media device  100  may also include, among other components, connector receptacle  110 , one or more user input components  120 , one or more output components  125 , control circuitry  130 , graphics circuitry  135 , a bus  140 , a memory  145 , a storage device  150 , communications circuitry  155  and POM (position, orientation or movement sensor) sensors  160 . Control circuitry  130  may communicate with the other components of electronic media device  100  (e.g., via bus  140 ) to control the operation of electronic media device  100 . In some embodiments, control circuitry  130  may execute instructions stored in a memory  145 . Control circuitry  130  may also be operative to control the performance of electronic media device  100 . Control circuitry  130  may include, for example, a processor, a microcontroller and a bus (e.g., for sending instructions to the other components of electronic media device  100 ). In some embodiments, control circuitry  130  may also drive the display and process inputs received from input component  120 . 
     Memory  145  may include one or more different types of memory that may be used to perform device functions. For example, memory  145  may include cache, flash memory, ROM, RAM and hybrid types of memory. Memory  145  may also store firmware for the device and its applications (e.g., operating system, user interface functions and processor functions). Storage device  150  may include one or more suitable storage mediums or mechanisms, such as a magnetic hard drive, flash drive, tape drive, optical drive, permanent memory (such as ROM), semi-permanent memory (such as RAM) or cache. Storage device  150  may be used for storing media (e.g., audio and video files), text, pictures, graphics, advertising or any suitable user-specific or global information that may be used by electronic media device  100 . Storage device  150  may also store programs or applications that may run on control circuitry  130 , may maintain files formatted to be read and edited by one or more of the applications and may store any additional files that may aid the operation of one or more applications (e.g., files with metadata). It should be understood that any of the information stored on storage device  150  may instead be stored in memory  145 . 
     Electronic media device  100  may also include input component  120  and output component  125  for providing a user with the ability to interact with electronic media device  100 . For example, input component  120  and output component  125  may provide an interface for a user to interact with an application running on control circuitry  130 . Input component  120  may take a variety of forms, such as a keyboard/keypad, trackpad, mouse, click wheel, button, stylus or touch screen. Input component  120  may also include one or more devices for user authentication (e.g., a smart card reader, a fingerprint reader or an iris scanner) as well as an audio input device (e.g., a microphone) or a video input device (e.g., a camera or a web cam) for recording video or still frames. Output component  125  may include any suitable display, such as a liquid crystal display (LCD) or a touch screen display, a projection device, a speaker or any other suitable system for presenting information or media to a user. Output component  125  may be controlled by graphics circuitry  135 . Graphics circuitry  135  may include a video card, such as a video card with 2D, 3D or vector graphics capabilities. In some embodiments, output component  125  may also include an audio component that is remotely coupled to electronic media device  100 . For example, output component  125  may include a headset, headphones or ear buds that may be coupled to electronic media device  100  with a wire or wirelessly (e.g., Bluetooth headphones or a Bluetooth headset). 
     Electronic media device  100  may have one or more applications (e.g., software applications) stored on storage device  150  or in memory  145 . Control circuitry  130  may be configured to execute instructions of the applications from memory  145 . For example, control circuitry  130  may be configured to execute a media player application that causes full-motion video or audio to be presented or displayed on output component  125 . Other applications resident on electronic media device  100  may include, for example, a telephony application, a GPS navigator application, a web browser application and a calendar or organizer application. Electronic media device  100  may also execute any suitable operating system, such as Mac OS, Apple iOS, Linux or Windows and can include a set of applications stored on storage device  150  or memory  145 , which applications may be compatible with the operating system running on the device. 
     In some embodiments, electronic media device  100  may also include communications circuitry  155  to connect to one or more communications networks. Communications circuitry  155  may be any suitable communications circuitry operative to connect to a communications network and to transmit communications (e.g., voice or data) from electronic media device  100  to other devices within the communications network. Communications circuitry  155  may be operative to interface with the communications network using any suitable communications protocol such as, for example, Wi-Fi (e.g., a 802.11 protocol), Bluetooth, high frequency systems (e.g., 900 MHz, 2.4 GHz and 5.6 GHz communication systems), infrared, GSM, GSM plus EDGE, CDMA, quadband and other cellular protocols, VOIP or any other suitable protocol. 
     In some embodiments, communications circuitry  155  may be operative to create a communications network using any suitable communications protocol. Communications circuitry  155  may create a short-range communications network using a short-range communications protocol to connect to other devices. For example, communications circuitry  155  may be operative to create a local communications network using the Bluetooth protocol to couple with a Bluetooth headset (or any other Bluetooth device). Communications circuitry  155  may also include a wired or wireless network interface card (NIC) configured to connect to the Internet or any other public or private network. For example, electronic media device  100  may be configured to connect to the Internet via a wireless network, such as a packet radio network, an RF network, a cellular network or any other suitable type of network. Communication circuitry  145  may be used to initiate and conduct communications with other communications devices or media devices within a communications network. 
     Electronic media device  100  may also include any other component suitable for performing a communications operation. For example, electronic media device  100  may include a power supply, an antenna, ports or interfaces for coupling to a host device, a secondary input mechanism (e.g., an ON/OFF switch) or any other suitable component. 
     Electronic media device  100  may also include POM sensors  160 . POM sensors  160  may be used to determine the approximate geographical or physical location of electronic media device  100 . As described in more detail below, the location of electronic media device  100  may be derived from any suitable trilateration or triangulation technique, in which case POM sensors  160  may include an RF triangulation detector or sensor or any other location circuitry configured to determine the location of electronic media device  100 . 
     POM sensors  160  may also include one or more sensors or circuitry for detecting the position orientation or movement of electronic media device  100 . Such sensors and circuitry may include, for example, single-axis or multi-axis accelerometers, angular rate or inertial sensors (e.g., optical gyroscopes, vibrating gyroscopes, gas rate gyroscopes or ring gyroscopes), magnetometers (e.g., scalar or vector magnetometers), ambient light sensors, proximity sensors, motion sensors (e.g., a passive infrared (PIR) sensor, active ultrasonic sensor or active microwave sensor) and linear velocity sensors. For example, control circuitry  130  may be configured to read data from one or more of POM sensors  160  in order to determine the location orientation or velocity of electronic media device  100 . One or more of POM sensors  160  may be positioned near output component  125  (e.g., above, below or on either side of the display screen of electronic media device  100 ). 
       FIG. 2  depicts an illustrative rendering of one particular electronic media device  200  that may include an enclosure having an integral receptacle connector according to embodiments of the invention. Device  200  includes a multipurpose button  205  as an input component, a touch screen display  210  as both an input and output component, and a speaker  215  as an output component, all of which are housed within a device housing  220 . Device  200  also includes a primary receptacle connector  230  and an audio receptacle connector  235  or audio jack within device housing  220 . Each of the receptacle connectors  230  and  235  can be positioned within housing  220  such that an opening of the receptacle connectors  230 ,  235  into which a corresponding plug connector is inserted is located at an exterior surface of the device housing. In some embodiments, these openings may be located at an exterior side surface of device  200 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 2 . 
     Electronic media device  200  may be a portable computing device, a tablet, a smart or media phone, or a portable media player. However, as discussed earlier, embodiments of the present invention may be implemented in laptops, desktops, all-in-one computers, cell phones, storage devices, navigation systems, monitors and other electronic devices. 
     Embodiments of the invention disclosed herein pertain to an enclosure  220  that is integrally formed with audio receptacle connector  235 , but in other embodiments the enclosure may be integrally formed with receptacle connector  230 , such as Apple&#39;s Lightning receptacle connector. Additionally, in some embodiments, enclosure  220  may only include a single receptacle connector  230  (as opposed to the two receptacle connectors  230 ,  235  shown in  FIG. 2 ) that is used to connect to other electronic devices. In these embodiments, the enclosure may be integrally formed with just receptacle connector  230 . 
     Embodiments of the present invention may include a receptacle connector for receiving an audio connector or plug, e.g., a standard audio connector or plug. Standard audio plugs are available in three sizes according to the outside diameter of the plug: a 6.35 mm (¼″) plug, a 3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. The plugs include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions between the tip and sleeve resulting in the connectors often being referred to as TRS (tip, ring and sleeve) connectors. 
       FIGS. 3A and 3B  illustrate examples of audio plugs  310  and  320  having three and four conductive portions, respectfully. As shown in  FIG. 3A , plug  310  includes a conductive tip  312 , a conductive sleeve  316  and a conductive ring  314  electrically isolated from the tip  312  and the sleeve  316  by insulating rings  317  and  318 . The three conductive portions  312 ,  314 ,  316  are for left and right audio channels and a ground connection, respectively. Plug  320 , shown in  FIG. 3B , includes four conductive portions: a conductive tip  322 , a conductive sleeve  326  and two conductive rings  324 ,  325  and is thus sometime referred to as a TRRS (tip, ring, ring, sleeve) connector. The four conductive portions  322 ,  324 ,  325  and  326  are electrically isolated by insulating rings  327 ,  328  and  329  and are typically used for left and right audio, ground and microphone signals, respectively. 
     When plugs  310  and  320  are 3.5 mm miniature connectors, the outer diameter of conductive sleeve  316 ,  326  and conductive rings  314 ,  324 ,  325  is 3.5 mm and the insertion length of the connector is 14 mm. For 2.5 mm subminiature connectors, the outer diameter of the conductive sleeve is 2.5 mm and the insertion length of the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MP3 players and smart phones as well as other electronic devices. Electronic devices such as MP3 players and smart phones are continuously being designed to be thinner and smaller and/or to include video displays with screens that are pushed out as close to the outer edge of the devices as possible. The diameter and length of current 3.5 mm and even 2.5 mm audio connectors are limiting factors in making such devices smaller and thinner and in allowing the displays to be larger for a given form factor. 
     The sizes of corresponding receptacle connectors or audio jacks for the standard audio plugs connectors described above are also limiting factors in making portable electronic devices smaller. An example of traditional 3.5 mm audio jacks mounted within an enclosure of an electronic device is shown in the following figures. 
       FIG. 4A  illustrates a perspective view of a section of a traditional electronic device enclosure  400  having an audio jack  405  mounted thereon. Enclosure  400  includes a back portion  410  having bottom and left walls  415 ,  420  as well as top and right walls (not shown in  FIG. 4A ). Bottom wall  415  includes an opening (opening  465  shown in  FIG. 4B ) for access to audio jack  405 . 
     Audio jack  405  is assembled on back portion  410 , adjacent to an opening (opening  465  in  FIG. 4B ) on bottom wall  415 . Audio jack  405  is mounted to back portion  410  via a screw (not shown in  FIG. 4B ) that is threaded through audio jack bracket  425  and threaded opening  430 . Audio jack  405  also includes contacts  435 - 439  for mating with corresponding contacts on a standard audio plug. 
       FIG. 4B  illustrates a cross-sectional view of a section of traditional electronic device enclosure  400  having audio jack  405  mounted thereon and having a cover glass frame  440  and a cover glass  445  assembled therewith. Cover glass frame  440  and cover glass  445  are held in position by shelf  450  and other interlocking features (not shown in  FIG. 4B ). As shown in  FIG. 4B , an opening  470  of audio jack  405  is registered with opening  465  of bottom wall  415 . Trim gasket  455  surrounds opening  470  and is intended to seal gaps between enclosure  400  and audio jack  405  in order to limit liquid ingress. A trim  460  may be included that surrounds opening  465 . A standard audio plug may be inserted through opening  465  and into opening  470  in order for its contacts to mate with corresponding contacts  435 - 439  (not shown in  FIG. 4B ) of audio jack  405 . The inclusion of separate audio jack  405  within enclosure  400  results in enclosure  400  having a depth or thickness of T 1 . 
       FIG. 5  illustrates a simplified perspective view of an electronic device enclosure  500  having an integrally formed audio jack shell according to an embodiment of the present invention. Enclosure  500  includes a housing  510  and a front cover portion  540 . In  FIG. 5 , housing  510  is depicted as being spaced apart from front cover portion  540  prior to the two components being assembled together. The audio jack shell is integrally formed with enclosure  500  and includes a first section  502  integrally formed with housing  510  and a second section  504  integrally formed with front cover portion  540 . Once components  510  and  540  are assembled, sections  502  and  504  are joined together to form audio jack shell  505  as shown in  FIG. 7B . 
     Housing  510  includes a back portion  520  and an outer sidewall  525  that extends from back portion  520  around an outer periphery of device enclosure  500 . Since enclosure  500  has a generally rectangular shape, sidewall  525  defines a generally rectangular opening  515  into which front cover portion  540  fits as described below. Sidewall  525  includes top and bottom opposing walls  525 A,  525 B and left and right opposing walls  525 C,  525 D that surround and define opening  515 . A seat  522  extends along an interior surface of sidewall  525  proximate to an upper edge  524  of the sidewall. A circular opening  535  for receiving a plug connector, e.g., a standard audio plug, is shown in wall  525 B but in other embodiments opening  535  can be formed in one or more of the other walls  525 A,  525 C,  525 D in addition to or instead of wall  525 B. Opening  535  communicates with a cavity  536  formed within audio jack shell  505  in which receptacle connector contacts (e.g., contacts  530  shown in  FIG. 7A ) that correspond to contacts on the plug connector are positioned. 
     Front cover portion  540  includes a frame  545  and a cover glass  550  assembled therewith. In addition to supporting cover glass  550 , frame  545  can support a display (not shown) positioned underneath and visible through cover glass  550  along with other components of an electronic device housed within enclosure  500 . An outer perimeter of front cover portion  540  is sized and shaped similar to, but slightly smaller than, opening  515  in housing  510  such that it fits within opening  515  and is supported by seat  522  and other interlocking features, such as projections configured to fit within bores  526  shown in  FIG. 6A ). 
     First section  502  of the audio jack shell is integrally formed with both back portion  520  and bottom wall  525 B of housing  510 , and second section  504  of the audio jack shell is integrally formed with frame  545  of front portion  540 . First and second sections  502  and  504  combine to form a complete audio jack shell  505  having a cavity  536  in which audio jack contacts  530  can be positioned or formed (see  FIG. 7B ). In the embodiment depicted in  FIG. 5 , each of sections  502  and  504  make up approximately one half the height of the audio jack. Such a design makes it easy to install contacts  530  within the audio jack and makes it easy to seal the two portions of the audio jack together to create a water tight enclosure. In other embodiments, however, one of sections  502  or  504  may make up more than half the height of the audio jack with the other of sections  502  making up the difference. In still other embodiments, a dividing line between sections  502  and  504  is not planar. For example, in one embodiment mating surfaces  506  and  508  may have one or more complimentary steps. In another embodiment, one side of mating surface  506  may be lower or higher than the other with the corresponding side of mating surface  508  being higher or lower, respectively. 
     As shown in  FIG. 6A , first section  502  includes a first mating face  504  around a perimeter of section  502 . A first interior surface  512  lies within section  502  and defines a bottom portion of cavity  536 . A plurality of slots  507  are formed along the perimeter of section  502  and configured to accept portions of contacts  530  such that the contacts can be securely attached to audio jack  505  and positioned within cavity  536 . As also shown in  FIG. 6A , housing  510  further includes various bores and/or cutouts  526  that align with projections formed on front cover  540  (not shown) to securely attach the front cover to the housing. 
     In one embodiment, housing  510  is formed from a single piece of polymer or metal and the various features formed in the housing, including first section  502 , sidewall  525 , openings  515  and  535 , slots  507  and bores/cutouts  526  are formed by milling the single piece of polymer metal using known milling techniques (e.g., using computer numerical control (CNC) of a machining tool). In another embodiment, housing  510  including first section  502  may be formed by injecting molten polymer, e.g., thermoplastics, or glass filled resin, e.g., glass reinforced nylon, into a mold, i.e., injection molding, so as to form a single piece of polymer. Alternatively, enclosure  500  may be formed by molding Liquidmetal or a metal injection molding process (MIM) to form a single piece of metal, e.g., stainless steel. It is desirable for the interior portions of section  502 , including surface  512  and the surfaces within slots  507 , to be nonconductive so that each individual contact in contacts  530  is electrically isolated from other contacts in contacts  530 . Thus, when housing  510  and section  502  are milled from a single piece of metal or formed by molding Liquidmetal or in a MIM process, in some embodiments of the invention the interior surface of the entire housing or portions of the housing including section  502  can be covered with a nonconductive coating. 
     In another embodiment, back  520  and sidewall  525  can be formed from a single piece of polymer or metal and section  502  can be integrally formed with back  520  and sidewall  525  using an injection molding process. For example, one or more grooves (not shown) can be formed in back  520  and/or sidewall  525 , and section  502  may then be injection molded from a plastic material that flows into the grooves thereby forming a unified body for housing  510  and first section  502 . In one embodiment, the grooves may have an opening at the interior surface of back  520  or sidewall  525  that is narrower than a channel or main portion of the groove thereby locking the injection plastic material to be securely locked to back  520  and/or sidewall  525 . In some embodiments, back  520  and sidewall  525  are formed with milling techniques as discussed above. In still other embodiments, a two shot injection molding process can be used to form housing  510 . For example, a first shot of the process can be used to form back  520  and sidewall  525  and a second shot of the process can be used to form section  502 . A two shot process allows the materials for each shot to be selected for specific properties that are desirable for the individual components being formed. For example, if the first shot is used to form back  520  and sidewall  525 , a polycarbonate or similar non-glass filled resin or plastic material can be selected for the first shot that has excellent cosmetic features and is highly scratch resistant. A hard and stiff plastic material (e.g., a glass-filled LCP material) can then be selected based on its structural properties for the second shot and used form section  502 . 
     Referring now to  FIG. 6B , second section  504  includes a second mating face  508  around a perimeter of section  504 . A second interior surface  514  lies within section  504  and defines a top portion of cavity  536 . Multiple second slots  509  are formed along the perimeter of section  504  and configured to accept portions of contacts  530 . Slots  507  and  509  thus combine to anchor contacts  530  to audio jack  505  securing the contacts within cavity  536 . Font cover  540  may also include one or more projections (not shown) that align with one or more of bores and/or cutouts  526  formed in housing  510  to securely attach the front cover to the housing. In one embodiment, front cover  540  is formed from plastic using an injection molding process. 
     Sections  502  and  504  can be joined together when front cover  540  is joined to housing  510  to form audio jack shell  505 . In one embodiment ultrasonic welding techniques can be used to join face  506  to face  508 . To improve the strength of the joined sections and to form a more water-tight seal, various joints (not shown) can be formed along mating faces  506 ,  508 . For example, a tongue and groove joint, a step joint, a shear joint, or other appropriate joint designs can be incorporated into mating faces  506 ,  508 . In other embodiments, an adhesive can be applied to one or both of mating faces  506  and  508  and/or a sealant or gasket can be employed between the two mating faces, for example in a groove, or around the two mating faces to improve the water resistance of the audio jack shell  505  and prevent liquid from passing from cavity  536  into an interior of enclosure  500  housing electronic components and other portions of the electronic device formed within enclosure  500 . In still other embodiments, other known and appropriate bonding techniques can be used. Also, while not shown in the figures, sections  502  and  504  can be formed with projections and holes along the perimeter of each that align with each other and facilitate a stronger bond or connection between the parts, for example, by using a press-fit connection or similar technique. 
     As shown in  FIG. 7A , metal contacts  530  are positioned within cavity  536  formed by sections  502  and  504  by aligning various legs or cutouts of the contacts with slots  507  and  509  in first and second sections  502  and  504 , respectively. In one embodiment, audio jack shell  505  houses four separate contacts  530  (left audio, right audio, ground and microphone) spaced apart along a depth of the cavity for coupling to a TRRS connector as shown in  FIG. 3B . In one embodiment, contacts  530  can be integrally formed within audio jack shell  505  and insert molded within shell  505  by, for example, an overmolding process applied to one of sections  502  or  504  prior to or after the sections are joined. In another embodiment, before sections  502  and  504  are joined the contacts can be assembled within slots  507  and  509  using a press-fit or similar connection. In either case, contacts  530  can be bonded to wires or leads that connect the contacts to appropriate circuitry to the electronic device formed within enclosure  500 . 
     Referring now to  FIG. 7B , once housing  510  and front cover portion  540  are joined together, the overall height of enclosure  500  can be made thinner than enclosure  400  shown in  FIG. 4B  (e.g., by having a thickness T 2  that is less than T 1 ), and the total amount of space audio jack shell  505  takes up within enclosure  500  can be less than the space jack  405  takes up within enclosure  400 , because audio jack  505  can have the same or even a stronger structural integrity as compared to audio jack  405  with walls that are considerably thinner. Additionally, no screws or other attachment mechanisms are necessary to attach audio jack  505  to enclosure  500 . Instead, the audio jack is integrated directly into enclosure  500  which makes the entire enclosure and the audio jack more robust. Additionally, as compared to traditional enclosure  400  (shown in  FIGS. 4A-B  and discussed above), the overall depth in which audio jack shell  505  extends towards top wall  515  may be reduced by not including a trim (e.g., trim  460  as shown in  FIG. 4B ) or a trim gasket (e.g., gasket  455  as shown in  FIG. 4B ). Not including a trim eliminates cosmetic gaps between an enclosure and the trim. However, the potential for liquid ingress at the interface of the enclosure  500  and the audio jack  505  is also eliminated by virtue of the elimination of the cosmetic gaps. Hence, trim gaskets may not be needed for enclosure  500  to fill gaps at seams between parts to prevent liquid ingress. 
     In some embodiments, it may be desirable to include a trim, as discussed with regards to the prior art in the enclosure embodiments described above in order to prevent wear caused by inserting and extracting plug connectors, e.g., TRRS audio plug connectors, into and from opening  535  of enclosure  500 . The trim, which may be made from a metallic material, may be assembled with the enclosure and surround opening  535 . Cosmetic gaps between the enclosure and the metal trim can be removed by virtue of an insert molding process that may fill in potential gaps at the seams between the enclosure and the metal trim. 
     Although not shown in  FIG. 5, 6A-6B or 7A-7B , in some embodiments, enclosure  500  may also include one or more additional openings (in addition to opening  535 ) for providing access to more than one receptacle connector. For example, enclosure  500  may include openings for two receptacle connectors such as receptacle connectors  230  and  235  (as shown in  FIG. 2 ). Furthermore, one or more of the additional receptacle connectors may be integrated with embodiments of enclosure  500  in addition to or instead of audio jack  505 . 
     Other components described herein may be integrally formed with an audio jack shell that is integrally formed with an enclosure, according to embodiments of the present invention. That is, components adjacent to audio jack shells could share one or more walls with the audio jack shell. Other components could also be formed integrally within the enclosure regardless of their proximity to the audio jack housing. For example, components could be integrated with walls of the enclosure or just the back portion of the enclosure. 
     Also, while a number of specific embodiments were disclosed with specific features, a person of skill in the art will recognize instances where the features of one embodiment can be combined with the features of another embodiment. For example, some specific embodiments of the invention set forth above were illustrated with audio jacks. A person of skill in the art will readily appreciate that any of the types of receptacle connectors described herein may be integrally formed with an enclosure, as well as other internal components specifically mentioned herein and not specifically mentioned herein. Also, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the inventions described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20140829
Publication Date: 20160607
Grant Date: 20160607
Priority Date: 20140829
Inventors: RAO MATTHEW P.
MAG STEFAN C.
DO TRENT K.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B2001/3894", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04B1/3888", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04B2001/3894", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55403960