PATENT DOCUMENT

Publication Number: US-8435081-B2
Application Number: US-201113077027-A
Country: US
Kind Code: B2

Title: Thin plug assembly and methods for making the same

Abstract:
Thin plug assemblies and methods for constructing the same are disclosed. The plug assembly can include a plug portion, a cable portion, and an interfacing portion between the plug portion and the cable portion. The plug portion can include several conductive regions each connected to a conductor of the cable portion to form conductor/plug member coupling(s), for example via a plug extension member associated with each conductive region. The plug assembly is constructed such that a diameter of the plug portion, interface portion, and at least part of the cable portion have substantially the same diameter. Ring structures enhance one or more of the conductor/plug member couplings by providing a press or interference fit directly to the coupling(s). Ring structures are constructed to slide axially over at least one conductor and at least one plug member.

Claims:
What is claimed is: 
     
       1. A plug assembly comprising:
 a cable portion comprising a plurality of conductors; 
 a plug portion comprising a plurality of conductive regions each associated with a plug extension member, wherein each of the plug extension members is coupled to one of the plurality of conductors; and 
 an interfacing portion between the cable portion and the plug portion at which each of the plurality of conductive regions is coupled to one of the plurality of conductors via the plug extension members, the interfacing portion comprising:
 a ring positioned around at least one plug extension member and the one of the plurality of conductors coupled to the at least one plug extension member; and 
 a shell member that encompasses the ring to form an exterior surface of the plug assembly, wherein a diameter of the shell member is substantially the same as a diameter of at least one of the conductive regions. 
 
 
     
     
       2. The plug assembly of  claim 1 , wherein the plug portion further comprises:
 a plurality of dielectric rings separating each of the plurality of conductive regions. 
 
     
     
       3. The plug assembly of  claim 1 , wherein:
 the ring is secured to at least one conductor and to at least one plug extension member. 
 
     
     
       4. The plug assembly of  claim 1 , wherein:
 the ring is constructed from a dielectric material. 
 
     
     
       5. The plug assembly of  claim 1 , the interfacing portion further comprising:
 a spring arm having a secured end and a free end, the spring arm in contact with an inner surface of one of the plurality of conductive regions. 
 
     
     
       6. The plug assembly of  claim 5 , wherein:
 the one of the plurality of conductive regions comprises the conductive region nearest the interfacing portion. 
 
     
     
       7. The plug assembly of  claim 5 , wherein:
 the secured end of the spring arm is adjacent to the plug portion; and 
 the free end of the spring arm is adjacent to the cable portion. 
 
     
     
       8. The plug assembly of  claim 5 , wherein:
 one of the plurality of conductors is coupled to the spring arm. 
 
     
     
       9. The plug assembly of  claim 5 , wherein:
 the spring arm is constructed from a conductive material. 
 
     
     
       10. The plug assembly of  claim 5 , wherein:
 the secured end of the spring arm is secured within the ring.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of previously filed 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.” Each of these provisional applications is incorporated by reference herein in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     Connectors are commonly used to connect one electronic device to another electronic device or an accessory such as a headset. These connectors exist in all sorts of different configurations and enable passage of data and/or power. Examples of such connectors include USB connectors, Firewire connectors, audio plugs, video plugs, headset plugs, optical plugs, and magnetic connectors. 
     The connector typically interfaces with one or more conductors in an interfacing region that can be covered with an overmold or a protective jacket. The overmold can reinforce the physical coupling of the conductor(s) and connector, and provide strain relief. The overmold is sized to have dimensions that are greater than the dimensions of the connector because it covers a portion of the connector. This can create a visible and tactile discontinuity (e.g., a step change) between the outer surface of the connector and overmold that can be regarded as a cosmetic blemish. Accordingly, connectors are needed that have more aesthetically pleasing overmolds. 
     SUMMARY OF THE INVENTION 
     Thin plug assemblies and methods for constructing the same are disclosed. The plug assembly can include a plug portion, a cable portion, and an interfacing portion between the plug portion and the cable portion. It will be understood that the term plug can encompass any suitable type of connector. The plug portion can include several conductive regions each connected to a conductor of the cable portion. The conductive regions can be isolated from each other using dielectric rings. One or more of the conductive regions can each be associated with a plug extension member extending towards the cable portion. Individual conductors can be coupled to the plug extension members to establish a path for transferring data and/or power to the conductive regions. 
     The plug assembly is constructed such that a diameter of the plug portion, interface portion, and at least part of the cable portion have substantially the same diameter. In other words, the plug assembly is constructed such that the diameter of the interfacing portion is no larger than the diameter of the plug portion. For example, if conductive regions of the plug portion are the 3.5 mm in diameter, the interface portion can have a diameter that is substantially the same. This provides for a plug assembly having a seamless and/or stepless transition from the plug portion to the cable portion. As a result, no part of the interfacing portion enshrouds or encompasses the plug portion in a manner that would result in a diameter that exceeds the diameter of the plug portion. Any potential for reduced reliability of the conductor/plug member couplings (due to use of such an interface portion) is mitigated through the use of ring structures according to embodiments of the invention. 
     Ring structures enhance one or more of the conductor/plug member couplings by providing a press or interference fit directly to the coupling(s). Ring structures are constructed to slide axially over at least one conductor and at least one plug member. As the ring is slid into position, it engages the conductor and plug extension member to provide an additional retaining force to that conductor/plug member coupling or interface. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1  shows an illustrative plug assembly  100  constructed in accordance with some embodiments of the invention 
         FIG. 2  is a partial sectional view of a plug assembly showing an interface between conductors in accordance with some embodiments of the invention; 
         FIG. 3  is a perspective view of a plug assembly having a ring supporting an interface between a plug portion and conductors in accordance with some embodiments of the invention; 
         FIG. 4  is a schematic view of a ring in accordance with some embodiments of the invention; 
         FIG. 5  is a schematic view of an illustrative plug assembly having a final conductive region in accordance with some embodiments of the invention; 
         FIG. 6  is a sectional view of a portion of plug assembly having a final conductive region in accordance with some embodiments of the invention; 
         FIG. 7  is a flowchart of an illustrative process for constructing a plug assembly in accordance with some embodiments of the invention; and 
         FIG. 8  shows a perspective view of an illustrative headset in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  shows an illustrative plug assembly  100  constructed in accordance with some embodiments of the invention. Plug assembly  100  is a tip, ring, sleeve (“TRS”) type of connector that has a cylindrical shape of a predetermined diameter and has two or more contacts. TRS type connectors can be manufactured with two, three, four, five or six contacts and typically have a diameter of 3.5 mm or 2.5 mm. Audio plugs can have three contacts (e.g., left channel, right channel, and ground) and Audio/Microphone or Audio/Video plugs can have four contacts (e.g., left channel, right channel, mic or video, and ground). TRS type plugs are sometimes referred to as audio jacks, audio plugs, phone jacks, phone plugs, jack plugs, stereo plugs, mini-stereo, mini-jacks, and headset plugs. In use, plug assembly  100  is inserted into a jacket, which may be contained in an electronic device such as a phone, computer, or media player. 
     Plug assembly  100  can have plug portion  110 , interfacing portion  120 , and cable portion  130  arranged in the manner shown, and the diameters of plug portion  110  and interfacing portion  120  can be substantially the same, as indicated by the diameter designation, D, in  FIG. 1 . Plug portion  100  can include conductive regions  102 , which are electrically isolated by dielectric rings  104 . Interfacing portion  120  is the region of plug assembly  100  where conductors (not shown) of cable portion  130  are coupled to plug extension members (not shown) of plug portion  100 . Each plug extension member is electrically coupled to a particular one of conductive regions  102 . Cable portion  130  can include any number of conductors and that number may equal the number of conductive regions  102  in plug region  110 . 
     Interfacing portion  120  can include shell member  121  that covers the plug extension members (not shown) and the portions of the conductors coupled thereto and fits flush against plug portion  110 . In some embodiments, shell member  121  can be part of cable portion  130  or it may be a component manufactured independent of cable portion  130 . The flush fit (of interface portion  120 ) provides a seamless and continuous union of plug portion  110  and cable portion  130 . That is, there is substantially no visible or tactile step change in the diameters of plug portion  110  and interfacing portion  120 . This can be accomplished using ring structures and/or spring arms according to embodiments of the invention. 
       FIG. 2  is a partial sectional view of a plug assembly showing an interface between conductors in accordance with some embodiments of the invention. Plug assembly  200  can include plug portion  210 , interfacing portion  220 , and cable portion  230  having some or all of the features described above in connection with plug assembly  100  ( FIG. 1 ). Cable portion  230  can include individual conductors  232  each coupled to a conductive region  202   a ,  202   b , and  202   c  within interfacing portion  220 . In particular, individual conductors  232  can each be coupled to one of plug extension members  222 ,  224 , and  226 . Plug extension members  222 ,  224 , and  226  can extend away from plug portion  210  towards cable portion  230 . So that the interface between the plug extension members and the conductors does not interfere with conductive regions  204 , the plug extension members can be extend beyond a surface of conductive region  202   c  that is nearest cable portion  230  (e.g., the surface of conductive regions  202   a ,  202   b , and  202   c  that is furthest from tip  250  of plug portion  210 ). 
     Each of plug extension members  222 ,  224 , and  226  can be coupled to a conductive region  202 . For example, conductive region  202   c  (e.g., the conductive region that is closest to interfacing portion  220 ) can be coupled to plug extension member  222 , or be constructed with an integrated plug extension member  222 . Middle conductive region  202   b  can be coupled to or include plug extension member  224 , and conductive region  202   a  (e.g., the conductive region that forms tip  250  of plug assembly  200 , and that is farthest from interfacing portion  220 ) can be coupled to or include plug extension member  226 . In some embodiments, plug assembly  200  can include additional conductive regions than those shown in  FIG. 2  and each of those additional conductive regions can have a corresponding plug extension member. 
     The plug extension members can have any configuration relative to each other to ensure that a conductor can be coupled to each plug extension member. In particular, at least a portion of each plug extension member may include an exposed contact pad to which a conductor can be coupled. For example, a conductor can be soldered to an exposed contact pad, or can be coupled using a surface mount technology process. In some cases, the plug extension members can be staggered or stepped relative to each other such that side walls of one or more plug extension members are exposed (e.g., such that the plug extension members have the appearance of a stepped tower). This may provide a larger surface area to which conductors can be coupled. 
     Different approaches can be used to provide staggered or stepped plug extension members. In some cases, each plug extension member can include an opening or hole sized to allow all taller plug extension members to pass through (e.g., plug extension member  222  includes an opening for receiving plug extension members  224  and  226 , and plug extension member  224  includes an opening for receiving plug extension member  226 ). In some cases, a plug extension member can include several distinct holes or openings, where different taller plug extension members can pass through each hole. For example, plug extension member  222  can include a first hole for plug extension member  224  and a second hole for plug extension member  226 , and plug extension member  224  can include a single hole for plug extension member  226 , where the hole of plug extension member  224  and the second hole of plug extension member  222  are aligned to receive plug extension member  226 . 
     To ensure that data or power transmitted through a particular conductive region  202  does not interfere with data or power transmitted through other conductive regions  202 , dielectric rings  204  provided between conductive regions  202  can also be provided between plug extension members  222 ,  224 , and  226 . For example, the material used to isolate adjacent conductive regions can extend within plug portion  210  towards interfacing portion  220  to isolate the plug extension members corresponding to each of the conductive regions. 
     During use, a user may apply forces to plug assembly  200  that tend to deform or damage the interface between conductors  232  and one or more of plug extension members  222 ,  224 , and  226 . For example, a user may pull at cable portion  230  to remove plug assembly  200  from a device. To strengthen the interface between the conductors and plug portion  210 , interfacing portion  220  can include shell member  221  to support conductors  232  and enclose the interface. For example, shell member  221  can include a molded component that adheres to conductors  232  and to plug extension members  222 ,  224 , and  226 . If the dimensions of shell member  221  are constricted such that the outer diameter of shell member  221  is substantially the same as the diameter of plug portion  210 , however, shell member  221  may provide insufficient support for the interface. 
     To add additional support, a ring can be press fit over the interface between the conductors and the plug extension members. In particular, the ring can be press fit around at least one conductor and at least plug extension member to reinforce the coupling between the conductor(s) and plug member(s). Because the plug extension members can have different sizes (e.g., different diameters, the ring can have a variable inner and/or outer diameter, for example to include a stepped inner diameter complementing the dimensions and distribution of the plug extension members. 
       FIG. 3  is a perspective view of a plug assembly having a ring supporting an interface between a plug portion and conductors in accordance with some embodiments of the invention. Plug assembly  300  can include plug portion  310 , interfacing portion  320 , and cable portion  330  having some or all of the features of corresponding components described above. Conductive regions  302 , separated by dielectric rings  304 , can include plug extension members (e.g., member  322 ) connected to conductors  332 . 
     To provide additional support to the interface between the conductors and the plug extension members, plug assembly  300  can include ring  340  positioned over the interface (e.g., over some or all of the contact pads or solder joints of the plug). Ring  340  can include opening  342  sized to receive at least conductors  332 , such that ring  340  can be assembled by sliding ring  340  axially over conductors  332  towards a distal end (e.g., tip  250 ,  FIG. 2 ) of plug assembly  310 . In some cases, ring  340  can be inserted over conductors  332  prior to coupling conductors  332  to plug portion  310  (e.g., by inserting the ring over the distal end of conductors  332  that will be coupled to the plug extension members), or ring  340  can be provided over conductors  332  after the conductors have been coupled to the plug portion (e.g., insert ring  340  from the proximal end of conductors  332 , and slide ring  340  over the entire length of the conductors). 
     The inner diameter of opening  342  can be selected relative to dimensions of one or more plug extension members, or relative to the position and size of contact pads on plug extension members (e.g., the distance of plug extension members from a centerline of plug assembly  300 ). In particular, ring  340  can be sized such that an inner surface of opening  342  comes into contact with at least one contact pad. Then, ring  340  can engage both a conductor and a plug extension member to secure the conductor and the plug extension member together. 
     In some cases, an inner surface of opening  342  may include a variable size or internal features (e.g., protrusions, bumps, tabs, indentations, or recesses).  FIG. 4  is a schematic view of a ring in accordance with some embodiments of the invention. Ring  400  can include opening  402  defining inner surface  410 , and outer surface  420 . Inner surface  410  can include internal features  412  recessed relative to or extending past surface  410  such that different portions of the inner surface  410  can engage or come into contact with different contact pads or different interfaces between plug extension members and conductors. For example, inner surface  410  can engage portions of a plug extension member within an interfacing portion (e.g., interfacing portion  320 ,  FIG. 3 ) that may be at different positions or distances relative to a centerline of the plug assembly, or relative to a plane perpendicular to the centerline such as a plane passing through a proximal surface of the contact region that is nearest the interfacing portion (e.g., the most proximal contact region). This may be beneficial, for example, when several plug extension members are stepped. 
     Alternatively, an inner surface  410  can include a recess or trench forming a channel within inner surface  410  (e.g., a channel forming an empty ring within ring  400 ). The channel can be positioned such that it is aligned with one or more contact pads of plug extension members. Other, non-channel portions of inner surface  410  can engage at least one plug extension member (e.g., distal portions  440  of inner surface  410 ), and other portions can engage one or more conductors (e.g., proximal portions  442  of inner surface  410 ). Using this approach, ring  400  may not come into contact with the joints between the plug extension members and the conductors, which may protect the interface from damage when ring  410  is positioned within the interfacing portion. 
     Ring  400  can be constructed from any suitable material. In some cases, ring  400  can be at least partially or entirely constructed from a non-conductive material to avoid shorting the different conductors or plug extension members. In particular, at least inner surface  410  (or other surfaces coming into contact with the plug extension members) can be coated with a non-conductive material. Such materials can include, for example, plastics, ceramic materials, organic materials, or combinations of these. 
     The material used for ring  400  can also be selected using structural criteria. In particular, the material of ring  400  may be selected to resist forces applied to the plug assembly. In some cases, ring  400  can be constructed such that portions that engage or come into contact with a conductor or a plug extension member are sufficiently hard or stiff to maintain the conductors coupled to the plug extension members. 
     Ring  400  can be secured within a plug assembly using any suitable approach. In some cases, ring  400  can be press fit over plug extension members. In such cases, inner surface  410  can be sized, or include features that create an interference fit. In some cases, ring  400  can be secured using an adhesive, tape, a fastener, a clip, or any other fastening mechanism. In some cases, inner surface  410  can include a particular feature that locks or engages a conductor, a plug extension member, or both. In still other cases, material used to create a shell member of an interfacing portion can be placed over ring  400  to secure the ring within the plug assembly (e.g., using an overmold). 
     Other approaches can be used to add strength to the interface between the conductors and plug portion while maintaining a small profile. In some cases, a final conductive region can be slid over the conductors toward the plug portion to enclose the interface.  FIG. 5  is a schematic view of an illustrative plug assembly having a final conductive region in accordance with some embodiments of the invention. Plug assembly  500  can include plug portion  510 , interfacing portion  520 , and cable portion  530  having some or all of the features of corresponding elements described above. In some cases, plug assembly  500  can include ring  540  placed over an interface between conductors  532  and plug extension members associated with each of conductive regions  502 , though ring  540  may not be present. 
     In addition, plug assembly  500  can include final conductive region  506  provided as a ring that is slid over conductors  532  towards distal end  550  until final conductive region  506  abuts the dielectric ring  504  that is nearest interfacing portion  520  (e.g., the most proximal dielectric ring  504 ). Conductive region  506  can have an opening  507  through which ring  540  and the interface between plug extension members and conductors  532  can reside without touching conductive region  506 . By providing a hard structure surrounding the interface, conductive region  506  can reduce the stress and strain applied to the interface in interfacing portion  520  during use of plug assembly  500 . 
     To conduct signals or power, conductive region  506  can be constructed from any suitable conductive material including, for example, the material used to create conductive regions  502  (e.g., a metal such as brass, silver, gold, or copper). In addition, one of conductors  532  can be connected to conductive region  506  to provide a path through which data and/or power signals can be transferred. Because some conductors  532  are already coupled to the plug extension members of conductive regions  502  when conductive region  506  is assembled to plug assembly  500 , it may be difficult to simply solder one more conductor to conductive region  506  within the space enclosed by opening  507 . Instead, another approach may be used (e.g., a conductive adhesive, or a surface mount technology process). 
       FIG. 6  is a sectional view of a portion of plug assembly  600  having a final conductive region in accordance with some embodiments of the invention. Plug assembly  600  can include plug portion  610 , interfacing portion  620 , and cable portion  630  having some or all of the features of corresponding elements described above. Conductors  632  can be coupled to plug extension members (not shown) of conductive regions  602 . Ring  640  can be placed over the interface between conductors  632  and conductive regions  602 . To complete the plug assembly, final conductive region  606  may be slid over conductors  632  towards tip  650  of plug assembly  600  until conductive region  606  abuts the dielectric ring  604  that is nearest interfacing portion  620  (e.g., furthest from tip  650  of plug portion  610 ). 
     Because it may be difficult to couple a conductor to final conductive region  606  once it has been positioned over plug extension members in interfacing region  620 , a different approach may be necessary. In particular, it may be beneficial to provide a mechanism by which simply positioning conductive region  606  over the plug extension members causes conductive region  606  to be coupled to a conductor. In some cases, plug assembly  600  can include a conductive spring arm  660  forming a cantilever spring. End  662  of spring arm  660  may be secured, for example in ring  640 , such that free end  664  of spring arm may be displaced. Spring  660  can be oriented such that end  662  is distal to end  664  (e.g., the free end of spring arm  660  extends towards cable portion  630 ). Spring arm  660  can be electrically connected to conductor  633 , for example by soldering or surface mount technology at contact pad  666 . 
     Spring arm  660  can be sized and oriented such that end  664  extends away from a centerline of plug assembly  600  and towards an outer surface of the plug assembly. In particular, spring arm  660  can be oriented such that, when it is undeformed, end  664  extends substantially to or beyond the outer diameter of plug portion  610 . When conductive region  606  is slid over conductors  632  towards tip  650 , an inner surface of conductive region  606  may come into contact with at least end  664  of spring arm  660  and cause end  664  to deflect towards a centerline of plug assembly  600 . The elastic deflection of spring arm  660 , however, may maintain a portion of spring arm  660  (e.g., contact portion  668 ) in contact with the inner surface of conductive region  606 . This may provide an electrical path from the outside of conductive region  606 , through conductive region  606  to the inner surface of the conductive region, into spring arm  660  via contact portion  668 , and into conductor  632  via contact pad  666 , thus connecting conductive region  606  in plug assembly  600 . 
     Spring arm can be constructed to have any suitable shape. In some cases, the shape can be selected to ensure that a minimum force required to maintain contact with conductive region  606  is applied. In some cases, end  664  may be partially redirected towards the centerline of plug assembly  600  to provide a lip over which conductive region  606  may slide during assembly. The material selected for spring arm  660  can be selected, in combination with the spring arm shape, to tune the force applied to conductive region  606 . Spring arm  660  can be constructed from a conductive material, or at least include a conductive path for transferring signals or power between contact region  668  and contact pad  666 . 
     In some cases, spring arm  660  can be retained within ring  640  (e.g., by construction, for example using an overmold, or using an adhesive or other connecting mechanism). Some plug assemblies, however, may not include ring  640 . To secure end  662  of spring arm  660 , shell member  621  can include two portions, for example two molded shots. A first portion, which can be relatively small, can serve to secure end  662 . For example, the first portion can have a shape and dimensions that are similar to ring  640 . A second portion, which can be larger than the first portion, can surround at least a portion of the first portion and can define an external surface for interfacing portion  620 . In some cases, the second portion can fill some or all of a volume enclosed within conductive region  606 . 
     Different approaches can be used to retain or secure conductive region  606 . In some cases, spring arm  660  can apply a large enough force to conductive region  606  that the contact between spring arm  660  and an inner surface of conductive region  606  retains conductive region  606 . In some cases, the plug assembly can include one or more additional spring arms distributed around a centerline of plug assembly  600  that apply similar forces to an inner surface of conductive region  606 . The additional spring arms may not be used to transfer power or data signals, as spring arm  660  is used for that. 
     To enhance the coupling between a spring arm and conductive region  606 , the inner surface of conductive region  606  can include one or more features operative to engage or receive spring arms. For example, the inner surface can include a receptacle, a tab, a channel, a flange, a hook, or any other feature that can engage a spring arm. In some cases, the spring arm can include a feature that is complimentary to the feature of conductive region  606 . The type of features used for a spring arm and the inner surface of conductive region  606  can be selected based on the securing force desired for conductive region  606 . For example, features that include hooks, overlapping, or returning features can provide larger region forces than features that include protrusions, flanges, or recesses. 
     In some cases, material used to form interfacing region  620  can instead or in addition be used to secure conductive region  606  to plug assembly  600 . For example, material (e.g., plastic) can be injected into the volume enclosed by conductive region  606  (e.g., as part of a molding process). When the material hardens, it can adhere to ring  640 , conductive region  606 , and other portions of plug assembly  606  to form a secure conductive region  606 . When a material is provided within the volume enclosed by conductive region  606 , the material may also maintain spring arm  660  in contact with conductive region  606 . 
     In some cases, conductive region  606  can instead or in addition be secure using other approaches. For example, an adhesive or tape can be used to couple conductive region  606  to a portion of plug assembly  600  (e.g., to a dielectric ring  604 ). As another example, a mechanical connector, clip, or other connector can be used to secure conductive region  606 . 
       FIG. 7  is a flowchart of an illustrative process for constructing a plug assembly in accordance with some embodiments of the invention. Process  700  can begin at step  702 . At step  704 , a plug portion can be provided. In some cases, the plug portion can include several conductive regions, each associated with a plug extension member. At step  706 , conductors can be coupled to the plug extension members. In some cases, the conductors can form part of a cable portion. At step  708 , a ring can be slide axially over the cable portion towards the plug portion. The ring can abut at least one of the plug extension members. In some cases, the ring can a spring arm extending from the ring towards the cable portion. At step  710 , a conductor of the cable bundle can be coupled to the spring arm. For example, the spring arm can include a contact pad to which the conductor can be soldered. At step  712 , a final conductive region can be slid over the cable portion towards the plug portion. In some cases, an inner surface of the final conductive region can be placed in contact with the spring arm. Process  700  can end at step  714 . 
     In some cases, a plug assembly as described in embodiments above can be used in a cable structure. For example, the 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 multiple 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 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. It may be particularly pleasing aesthetically for the plug assembly to have a diameter that is substantially the same as the plug portion in such a cable having 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 super-elastic material. The super-elastic rods can resist deformation to reduce or prevent tangling of the legs. 
       FIG. 8  shows an illustrative headset  800  having cable structure  820  that seamlessly integrates with non-cable components  840 ,  842 , and  844 . For example, non-cable components  840 ,  842 , and  844  can be a male plug, left headphones, and right headphones, respectively. Cable structure  820  has three legs  822 ,  824 , and  826  joined together at bifurcation region  830 . Leg  822  may be referred to herein as main leg  822 , and includes the portion of cable structure  820  existing between non-cable component  840  and bifurcation region  830 . In particular, main leg  822  includes interface region  831 , bump region  832 , and non-interface region  833 . Leg  824  may be referred to herein as left leg  824 , and includes the portion of cable structure  820  existing between non-cable component  842  and bifurcation region  830 . Leg  826  may be referred to herein as right leg  826 , and includes the portion of cable structure  820  existing between non-cable component  844  and bifurcation region  830 . Both left and right legs  824  and  826  include respective interface regions  834  and  837 , bump regions  835  and  838 , and non-interface regions  836  and  839 . 
     Legs  822 ,  824 , and  826  generally exhibit a smooth surface throughout the entirety of their respective lengths. Each of legs  822 ,  824 , and  826  can vary in diameter, yet still retain the smooth surface. 
     Non-interface regions  833 ,  836 , and  839  can each have a predetermined diameter and length. The diameter of non-interface region  833  (of main leg  822 ) may be larger than or the same as the diameters of non-interface regions  836  and  839  (of left leg  824  and right leg  826 , respectively). For example, leg  822  may contain a conductor bundle for both left and right legs  824  and  826  and may therefore require a greater diameter to accommodate all conductors. In some embodiments, it is desirable to manufacture non-interface regions  833 ,  836 , and  839  to have the smallest diameter possible, for aesthetic reasons. As a result, the diameter of non-interface regions  833 ,  836 , and  839  can be smaller than the diameter of any non-cable component (e.g., non-cable components  840 ,  842 , and  844 ) physically connected to the interfacing region. Since it is desirable for cable structure  820  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  832 ,  835 , and  838  provide a diameter changing transition between interfacing regions  831 ,  834 , and  837  and respective non-interfacing regions  833 ,  836 , and  839 . 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  832 ,  835 , and  838  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). 
     Interface regions  821 ,  834 , and  837  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  821  can be substantially the same as the diameter of non-cable component  840 . In some embodiments, the diameter of a non-cable component (e.g., component  840 ) and its associated interfacing region (e.g., region  831 ) are greater than the diameter of the non-interface region (e.g., region  833 ) they are connected to via the bump region (e.g., region  832 ). 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  840 ) and its associated interfacing region (e.g., region  831 ) are less than the diameter of the non-interface region (e.g., region  833 ) they are connected to via the bump region (e.g., region  832 ). 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  810 . 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  820 . Moreover, the extra girth better enables the interface and bump regions to withstand bend stresses. 
     The interconnection of legs  822 ,  824 , and  826  at bifurcation region  830  can vary depending on how cable structure  820  is manufactured. In one approach, cable structure  820  can be a jointly formed multi-leg or 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  830 , nor are the legs manufactured separately and then later joined together. Some jointly formed multi-leg cable structures may have a top half and a bottom half, which are molded together and extend throughout the entire cable structure. Thus, although a mold-derived jointly formed multi-leg cable structure has two components (i.e., the top and bottom halves), it is considered a jointly formed multi-leg cable structure for the purposes of this disclosure. Other jointly formed multi-leg cable structures may exhibit a contiguous ring of material that extends throughout the entire cable structure. 
     In another approach, cable structure  820  can be a multi-segment unibody cable structure in which three discrete or independently formed legs are connected at a bifurcation region. A multi-segment unibody cable structure may have the same appearance of the jointly formed multi-leg cable structure, but the legs are manufactured as discrete components. The legs and any conductors contained therein are interconnected at bifurcation region  830 . The legs can be manufactured, for example, using any of the processes used to manufacture the jointly formed multi-leg cable structure. 
     The cosmetics of bifurcation region  830  can be any suitable shape. In one embodiment, bifurcation region  830  can be an overmold structure that encapsulates a portion of each leg  822 ,  824 , and  826 . The overmold structure can be visually and tactically distinct from legs  822 ,  824 , and  826 . The overmold structure can be applied to the single or multi-segment unibody cable structure. In another embodiment, bifurcation region  830  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  820  maintains its unibody aesthetics. That is, a multi-segment cable structure has the look and feel of jointly formed multi-leg cable structure even though it has three discretely manufactured legs joined together at bifurcation region  830 . 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  820  can include a conductor bundle that extends through some or all of legs  822 ,  824 , and  826 . Cable structure  820  can include conductors for carrying signals from non-cable component  840  to non-cable components  842  and  844 . Cable structure  820  can include one or more rods constructed from a super-elastic 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  840  to non-cable components  842  and  844 , but share the same space within cable structure  820 . Several different rod arrangements may be included in cable structure  820 . 
     In yet another embodiment, one or more of legs  822 ,  824 , and  826  can vary in diameter in two or more bump regions. For example, the leg  822  can include bump region  832  and another bump region (not shown) that exists at leg/bifurcation region  830 . This other bump region may vary the diameter of leg  822  so that it changes in size to match the diameter of cable structure at bifurcation region  830 . This other bump region can provide additional strain relief. Each leg can have any suitable diameter including, for example, a diameter in the range of 0.4 mm to 1 mm (e.g., 0.8 mm for leg  820 , and 0.6 mm for legs  822  and  824 ). 
     The previously described embodiments are presented for purposes of illustration and not of limitation. It is understood that one or more features of an embodiment can be combined with one or more features of another embodiment to provide systems and/or methods without deviating from the spirit and scope of the invention.

Metadata:
Filing Date: 20110331
Publication Date: 20130507
Grant Date: 20130507
Priority Date: 20100331
Inventors: AASE JONATHAN
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49194", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01B7/223", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01B7/223", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/1033", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01B7/0045", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1033", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01B7/0045", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49194", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49204", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 44709709