PATENT DOCUMENT

Publication Number: US-9780474-B2
Application Number: US-201615069125-A
Country: US
Kind Code: B2

Title: Hidden electrical contacts

Abstract:
Electrical contacts are described. An electrical contact can be formed on an exterior surface of a housing of an electronic device and can be cosmetically similar to the exterior surface. For example, the electrical contact can include a conductive plug inserted through an opening in a wall of the housing. A metallic coating can be applied to an outward-facing end of the conductive plug and fill up an outer portion of the opening until the metallic coating is about flush with the exterior surface of the housing. Properties of the metallic coating can be selected to closely match a color and a texture of the housing.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a housing having a wall with an exterior surface, an interior surface, and an opening extending between the exterior surface and the interior surface in a contact region of the housing, the opening having an outer portion disposed at the exterior surface and an inner portion, wherein the exterior surface of the housing in the contact region has a color and a texture; and 
 an electrical contact formed in the contact region of the housing, the electrical contact comprising:
 a conductive plug disposed in the inner portion of the opening such that a first end of the conductive plug is recessed from the exterior surface of the housing to partially define the outer portion of the opening; and 
 a metallic coating that defines an exterior surface of the electrical contact and fills the outer portion of the opening covering the first end of the conductive plug, wherein a color and a texture of the metallic coating are selected to correspond to the color and the texture of the exterior surface of the housing. 
 
 
     
     
       2. The electronic device of  claim 1 , wherein the electrical contact further comprises an insulative sleeve that forms an insulative barrier between the housing and the electrical contact. 
     
     
       3. The electronic device of  claim 1 , further comprising an insulative layer disposed within at least a portion of the opening, the insulative layer forming an insulative barrier between the housing and the electrical contact. 
     
     
       4. The electronic device of  claim 1 , wherein a cross-section of the outer portion of the opening at the exterior surface of the housing is larger than a cross-section of the inner portion of the opening. 
     
     
       5. The electronic device of  claim 1 , wherein the opening has a circular cross-section, a rectangular cross-section, or a non-uniform cross-section. 
     
     
       6. The electronic device of  claim 1 , wherein the opening further comprises a transition region disposed between the outer region and the inner region, the transition region comprising a tapered transition from the inner region to the outer region, a curved contoured transition from the inner region to the outer region, or a stepped transition from the inner region to the outer region. 
     
     
       7. The electronic device of  claim 1 , wherein a diameter of the opening decreases from the outer portion to the inner portion. 
     
     
       8. An electronic device, comprising:
 a housing having a wall with an exterior surface, an interior surface, and a contact region; 
 one or more conductive elements disposed within the contact region and extending from the interior surface towards the exterior surface, the one or more conductive elements forming an electrical contact in the contact region; and 
 a continuous conductive surface corresponding to the electrical contact, the conductive surface being flush with or recessed less than 50 microns from a portion of the exterior surface surrounding the electrical contact at the exterior surface. 
 
     
     
       9. The electronic device of  claim 8 , wherein the one or more conductive elements comprise:
 a conductive plug disposed in an inner portion of an opening of the wall such that a first end of the conductive plug is recessed from the exterior surface of the housing to partially define an outer portion of the opening; and 
 a metallic coating that defines an exterior surface of the electrical contact and fills the outer portion of the opening covering the first end of the conductive plug, the continuous conductive surface corresponding to the metallic coating in the outer portion of the opening and the portion of the exterior surface surrounding the metallic coating. 
 
     
     
       10. The electronic device of  claim 8 , wherein the one or more conductive elements comprise one or more conductive pathways extending from the exterior surface to the interior surface. 
     
     
       11. The electronic device of  claim 10 , wherein the conductive plug is substantially wider near the exterior surface than at the interior surface. 
     
     
       12. The electronic device of  claim 10 , wherein the continuous cosmetic surfaces comprises:
 one or more conductive surfaces of the one or more conductive pathways that are adjacent to the exterior surface; and 
 one or more insulative surfaces of the plug that are adjacent to the exterior surface. 
 
     
     
       13. The electronic device of  claim 8 , wherein the one or more conductive elements comprise a hole cluster extending from the exterior surface to the interior surface, the hole cluster comprising:
 a plurality of miniature holes extending from the exterior surface to the interior surface; and 
 conductive material extending within at least a portion of the plurality of miniature holes. 
 
     
     
       14. The electronic device of  claim 13 , wherein the hole cluster is a first hole cluster, and wherein the one or more conductive elements comprise:
 a plurality of hole clusters extending from the exterior surface to the interior surface; and 
 a conductive plate disposed adjacent to the interior surface, the conductive plate electrically connecting the first hole cluster and at least one hole cluster of the plurality of hole clusters. 
 
     
     
       15. The electronic device of  claim 8 , wherein the one or more conductive elements comprise a conductive plug extending from the exterior surface to the interior surface, the conductive plug comprising a plurality of conductive fibers disposed within an insulative material. 
     
     
       16. The electronic device of  claim 15 , wherein the conductive plug comprises a first conductive plug, and wherein the one or more conductive elements comprise:
 a plurality of conductive plugs extending from the exterior surface to the interior surface; and 
 a conductive plate disposed adjacent to the interior surface, the conductive plate electrically connecting the first conductive plug and at least one conductive plug of the plurality of conductive plugs.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     The present application claims the benefit of priority of U.S. Provisional Application No. 62/235,513 entitled “Hidden Electrical Contacts,” filed on Sep. 30, 2015, the entire contents of which is hereby incorporated by reference. 
    
    
     FIELD 
     This disclosure relates to electrical contacts, in particular, electrical contacts that are used in connection with electronic devices. 
     BACKGROUND 
     Electronic devices (e.g., laptops, mobile devices, tablets) can interface with accessory devices, such as a keyboard, that can provide input to the electronic device or otherwise augment its functionality. While many different types of accessory devices can wirelessly connect to an electronic device, some accessory devices can consume less power and communicate more quickly and more accurately when physically connected to an electronic device using a connector that includes one or more electrical contacts. For such a physical connection to work, the electronic device can include one or more electrical contacts positioned at an exterior surface of the electronic device. Locating electrical contacts or a connector structure with electrical contacts at an exterior surface, however, represents a break in the housing of the electronic device and provides a contrast to the continuous housing in both color and texture. Such a break in color and texture can reduce aesthetic appeal. 
     SUMMARY 
     Examples of the present disclosure are directed to electrical contacts that can be exposed at but hidden along an exterior surface of a housing or other portion of an electronic device. In some examples, outward-facing portions of the contacts are designed to match color and texture of the housing. In this manner, the contacts can be cosmetically similar to the housing making the contacts difficult to discern, or when the color and texture of the housing is precisely matched, completely hidden to an unaided eye. The hidden contacts according to embodiments of the disclosure can be used to electrically connect an accessory to the electronic device. 
     In some examples, an electronic device can include a housing having one or more openings that extend through a wall of the housing. Each opening can represent a contact location and can have a circular or non-circular recessed portion along an exterior surface of the wall. Within each opening can be formed a conductive plug. Within the recessed portion can be placed a conductive material that electrically couples with the conductive plug. The conductive material can extend within the recessed portion of the wall and smoothly transition to the exterior surface. The conductive material can be selected to have a color and texture that correspond closely to the color and texture of the housing. In this manner, an outward-facing portion of the contact can be hidden in the housing. 
     In some examples, an electronic device can include a housing having one or more openings that extend through a wall of the housing. Each opening can represent a contact location and can include a plug of insulative material formed to correspond in size to the opening. The plug can include a plurality of pores that extend throughout the plug. The plurality of pores can be filled with conductive material to create conductive pathways from one end of the plug to the other. In some examples, each pore has a diameter less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. The plug, now conductive, can be placed in the opening. The insulative material and the conductive material can be selected to have colors and textures that correspond closely to the colors and textures of the housing. In this manner, an outward-facing portion of the contact can be hidden in the housing. 
     In some examples, an electronic device can include a housing having one or more contact locations each including an electrical contact that includes a plurality of hole clusters. Each hole cluster can be made up of a plurality of micro holes that each extend through a wall of the housing. In some examples, each micro hole has a diameter less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. After the micro holes are formed in the wall, the micro holes can be filled with conductive material to create conductive pathways from one side of the wall to the other side of the wall. The conductive pathways can be electrically coupled together using a contact plate on an interior side of the housing. The conductive material can be selected to have a color and texture that correspond closely to the color and texture of the housing. In this manner, an outward-facing portion of the contact can be hidden in the housing. 
     In some examples, an electronic device can include a housing having one or more pluralities of holes that extend through a wall of the housing. Each plurality of holes can represent a contact location along an exterior portion of the housing. Within each hole in each of the plurality of holes, can be inserted a conductive plug made up of a plurality of conductive fibers held by an insulative material. In some examples, each conductive fiber has a diameter less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. The conductive plugs for each contact location, i.e., each contact, can be electrically coupled using a contact plate on an interior portion of the housing. The insulative material and the conductive material can be selected to have colors and textures that correspond closely to the color and texture of the housing. In this manner, an outward-facing portion of the contact can be hidden in the housing. 
     To better understand the nature and advantages of the present disclosure, 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 disclosure. 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 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
         FIG. 1A  shows a profile view of an electrical contact in connection with a housing, in accordance with at least one example; 
         FIG. 1B  shows a frontal view of the electrical contact and the housing from  FIG. 1A , in accordance with at least one example; 
         FIG. 2A  shows a profile view of an electrical contact in connection with a housing, in accordance with at least one example; 
         FIG. 2B  shows a detailed view of the electrical contact from  FIG. 2A , in accordance with at least one example; 
         FIG. 2C  shows a frontal view of the electrical contact and the housing from  FIG. 2A , in accordance with at least one example; 
         FIG. 2D  shows a detailed view of the electrical contact from  FIG. 2A , in accordance with at least one example; 
         FIG. 2E  shows a frontal view of the electrical contact and the housing from  FIG. 2A , in accordance with at least one example; 
         FIG. 3A  shows a profile view of an electrical contact in connection with a housing, in accordance with at least one example; 
         FIG. 3B  shows a frontal view of the electrical contact and the housing from  FIG. 3A , in accordance with at least one example; 
         FIG. 4A  shows a profile view of an electrical contact in connection with a housing, in accordance with at least one example; 
         FIG. 4B  shows a detailed view of the electrical contact from  FIG. 4A , in accordance with at least one example; and 
         FIG. 4C  shows a frontal view of the electrical contact and the housing from  FIG. 4A , in accordance with at least one example. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
       FIG. 1A  illustrates a portion of an electronic device  100  that includes an electrical contact  102  held within a housing  104  of the electronic device  100 . The electronic device  100  (and any other electronic device described herein) can be any suitable electronic device including, for example, a mobile phone, a tablet, a laptop, a personal computer, a wearable device, a media player device, and any other suitable electronic device, each of which may also be considered a personal electronic device or user device. In some examples, the electrical contact  102  (and any other electrical contact described herein) can be included in other devices such as, for example, televisions, cable boxes, automobiles (e.g., for connecting diagnostic devices or connecting media players or mobile phones), modems, hard drives, routers, and any other suitable devices by which data signals and/or power signals can be transferred. In some examples, the electrical contact  102  can function to electrically connect an accessory or other equipment to the electronic device  100 . As described in more detail herein, the electrical contact  102  (or any other electrical contact described herein) can be designed and constructed to be cosmetically similar to the housing  104  (or any other housing described herein). In some examples, an electrical contact is cosmetically similar to a housing when the location of the electrical contact is difficult to discern, or when the color and texture of the housing is precisely matched, making the electrical contact completely hidden to an unaided eye. In some examples, an electrical contact is cosmetically similar to a housing when an average human is unable to perceive, whether by viewing or through touch, that an electrical contact is included within the housing. For example, with reference to  FIG. 1A , the colors of an outward portion of the electrical contact  102  and the housing  104  can be closely matched such that there is little to no color variation between the two. In some examples, the texture of the electrical contact  102  can also be closely matched to the texture of the housing  104 . In addition, the exterior surface of the electrical contact  102  can be slightly proud, slightly recessed, or flush with respect to the exterior surface of housing  104  that surrounds contact  102  such that the electrical contact  102  is seamlessly mounted in the housing  104 . For example, the contact  102  can extend beyond the exterior surface of the housing  104  by 1-25 microns, can be recessed below the exterior surface of the housing  104  by 1-25 microns, or can be positioned so as to have a height difference with respect the exterior surface of the housing  104  that is less than 1 micron. In some examples, the ranges for what constitutes slightly proud and slightly recessed can be greater than 25 microns (e.g., 50 microns) or less than 1 micron (e.g., 0.1 micron). 
     In order to achieve cosmetic similarity while also conducting electricity, the electrical contact  102  can include a conductive plug  106  in contact with a metallic coating  108 . The conductive plug  106  and the metallic coating  108  can each be considered a conductive element. The conductive plug  106  can be formed from any suitable conductive material including, for example, copper, or copper alloy. In some examples, the electrical contact  102  includes an insulative sleeve  110  that surrounds an exterior surface of the conductive plug  106  along the depth of the conductive plug. In other examples, the insulative sleeve  110  is not a part of the electrical contact  102 . The insulative sleeve  110  can be formed from any suitable insulative material, which, in some examples, can be pliable to help retain the conductive plug  106  within the housing  104 . The insulative sleeve  110  can function as an insulative barrier between the electrical contact  102  and the housing  104 . 
     The electrical contact  102  is shown inserted into an opening  112  in a wall  114  of the housing  104 . In some examples, the opening  112  can be included in an array of openings, with each opening including its own electrical contact. The opening  112  can be a circular opening, which can correspond to a circular cross-section of the conductive plug  106 . In some examples, the opening  112  has a non-circular cross-section, which can correspond to a non-circular cross-section of the conductive plug  106 . The opening  112  extends between an interior surface  116  of the housing  104  and an exterior surface  118  of the housing  104 . The interior surface  116  can face the inside of the housing  104  and the exterior surface  118  can face outside of the housing  104 . While the wall  114  is illustrated as being in a straight portion of the housing  104 , it is understood that the electrical contact  102  can also be formed in an opening that is placed in the wall  114  along a curved section of the housing  104 . 
     The opening  112  can be formed in a contact region of the housing  104 . The contact region can be a region on the housing  104  in which forming the electrical contact  102  can be achieved. In some examples, the exterior surface  118  that corresponds to the contact region can have a color and a texture. A color and a texture of the metallic coating  108  can be selected to match the color and the texture of the contact region and/or the housing  104  generally. In some examples, the housing  104  can have more than one contact region. 
     The opening  112  can extend from the exterior surface  118  within the contact region to the interior surface  116 . In some examples, the opening  112  can include an outer portion  120 , an inner portion  126 , and a transition portion  128  disposed between the outer portion  120  and the inner portion  126 . The outer portion  120  can extend from a first end of the conductive plug  106  that is recessed from the exterior surface  118  to the exterior surface  118 . The inner portion  126  can extend from the outer portion  120  towards the interior surface  116 . 
     In some examples, a cross-section of the inner portion  126  can be uniform such that the inner portion  126  resembles a shaft. In some examples, the cross-section of the outer portion  120  can have a similar cross-section that also resembles a shaft, which can be of the same size as the inner portion  126  or larger. In some examples, the outer portion  120  and the inner portion  126  each have circular cross-sections, with the outer portion  120  having a circular cross-section at the exterior surface  118  that is larger than a circular cross-section of the inner portion  126  of the opening  112 . In some examples, the transition portion  128  can have a circular cross-section that gradually increases as it moves axially from the inner portion  126  to the outer portion  120 . In other examples, the cross-sections of the inner portion  126 , the outer portion  120 , and/or the transition portion  128  are non-circular. For example, a square cross-section of the outer portion  120  of the opening  112  at the exterior surface  118  can be larger than a square cross-section of the inner portion  126  of the opening  112 . 
     In some examples, the transition portion  128  can overlap with the outer portion  120  and/or the inner portion  126 . In some examples, the transition portion  128  can include any suitable transition in shape or cross-section between the outer portion  120  and the inner portion  126 . For example, the transition portion  128  can form a tapered transition that extends from the inner portion  126  to the outer portion  120 . In this example, a cross-section of the transition portion  128  can uniformly increase as it moves away from the conductive plug  106  towards the exterior surface  118  until it intersects with the exterior surface  118 . The transition portion  128  can also form a curved contoured transition that extends from the inner portion  126  to the outer portion  120 . In this example, a cross-section of the transition portion  128  can increase at a variable rate as it moves away from the conductive plug  106  towards the exterior surface  118 . For example, interior walls of the opening  112  in the curved contoured example can decrease in slope as they move from the conductive plug  106  towards the exterior surface  118 . In this manner, the opening  112  gradually opens larger moving from the inner portion  126  to the exterior surface  118 . The transition portion  128  can also form a stepped transition that extends from the inner portion  126  to the outer portion  120 . In this example, a change between a cross-section of the inner portion  126  and a cross-section of the outer portion  120  can correspond to a step. In some examples, the transition portion  128  can include more than one steps. The transition portion  128  can also include any suitable combination of the examples described herein. In some examples, a cross-section of the opening  112  (e.g., a diameter of the opening when the opening  112  is round) can decrease between the outer portion  120  and the inner portion  126 . This decrease of the cross-section of the opening  112  can take place in the transition portion  128 . 
     In some examples, after the opening  112  has been formed in the wall  114 , the housing  104  can be anodized to create anodization layer  122 . As the housing  104  can be formed from aluminum, in some examples, the anodization layer  122  can extend across the entirety of the housing  104 , including within the opening  112 . In some examples, the anodization layer  122  can function as an insulative layer between the conductive plug  106  and the wall  114 , and between the metallic coating  108  and the wall  114 . The conductive plug  106  can be held in the wall  114  via threads, an anti-rotation pin (not shown) embedded in the wall  114 , or in any other suitable manner. 
     The outer portion  120  can be included in the wall  114  to provide an area where the metallic coating  108  can be applied. As illustrated in  FIG. 1A , a portion of the metallic coating  108  can be in physical contact with the conductive plug  106  to form the electrical contact  102 . A portion of the metallic coating  108  can also be in physical contact with the exterior surface  118  of the wall  114 . Because of the anodization layer  122 , however, the metallic coating  108  can be insulated from the exterior surface  118 . In some examples, the electrical conductivity of the electrical contact  102  can be greater than the electrical conductivity of at least a portion of the housing  104  surrounding the electrical contact  102 . For example, in the absence of the anodization layer  122  or at least a strong anodization layer  122 , the electrical contact  102  may nevertheless conduct electricity at least in part because it has a higher electrical conductivity value as compared to a portion of the wall  114  surrounding the electrical contact  102 . In some examples, when the housing  104  is formed from a non-metallic material (e.g., a ceramic material), the electrical conductivity of the electrical contact  102  can be greater than the portion of the housing  104  surrounding the electrical contact  102 . 
     The metallic coating  108  can define an exterior surface of the electrical contact  102 . The metallic coating  108  can therefore be disposed within the outer portion  120  and fill the outer portion  120  covering the first end of the conductive plug  106 . The metallic coating  108  can be any suitable conductive material that can be sprayed, deposited, or otherwise applied within the outer portion  120 . Such materials can include, for example, gold, titanium nitride, titanium carbon nitride, and other such materials. In some examples, the type of material can be selected that has conductive properties and also has similar color and texture properties as the exterior surface  118 . For example, when the exterior surface  118  is gold colored, gold or a gold alloy can be selected as the metallic coating  108 . In this manner, the colors between the metallic coating  108  and the exterior surface  118  can be cosmetically similar. 
       FIG. 1B  illustrates a frontal view of the exterior surface  118  of the wall  114 . In the view illustrated in  FIG. 1B , the conductive plug  106  is shown behind the metallic coating  108 . The metallic coating  108  can extend radially in the direction of arrows  124  from within the outer portion  120  towards a flat portion  130  of the exterior surface  118  that surrounds the opening  112 . The thickness of the metallic coating  108  can decrease as it extends in the direction of the arrows  124  towards the flat portion  130  of the exterior surface  118 . In this manner, the metallic coating  108  can be “feathered out” (i.e., become thinner and thinner) within the flat portion  130  and beyond in order to make a smooth and cosmetically imperceptible transition to the exterior surface  118 . In this manner, the metallic coating  108  and a portion of the exterior surface  118  surrounding the metallic coating  108  can together form a continuous cosmetic surface. Texture, color, and/or other cosmetic characteristics (e.g., reflectivity, hue, shade, tint, value, iridescence, etc.) can be cosmetically similar within the continuous cosmetic surface; and, thus, cosmetically imperceptible. In some examples, some degree of perceptibility is tolerated other than total imperceptibility. In some examples, a masking is used to control the extents of the metallic coating  108  with respect to the exterior surface  118 . In some examples, the metallic coating  108  can be slightly proud (e.g., extending beyond the exterior surface  118  by 1-25 microns), slightly recessed (e.g., recessed below the exterior surface  118  by 1-25 microns), or flush with the exterior surface  118  (e.g., difference between the metallic coating  108  and the exterior surface of less than 1 micron). 
       FIG. 2A  illustrates a portion of an electronic device  200  that includes an electrical contact  202  according to some embodiments of the disclosure. As shown in  FIG. 2A , electrical contact  202  is held within a housing  204  of the electronic device  200 . Like the electrical contact  102 , the electrical contact  202  can function as an electrical contact when an accessory or other equipment is connected to the electronic device  200 . 
     To this end, the electrical contact  202  can include a plug  206  that extends through an opening  208  within a wall  210  of the housing  204 . In some examples, the opening  208  can be included in an array of openings, with each opening including its own electrical contact. The opening  208  extends from an interior surface  214  of the housing  204  to an exterior surface  212  of the housing  204 . The plug  206  can be formed as a puck having a shape that corresponds to the shape of the exterior surface  212  and the interior surface  214 . In some examples, the plug  206  has a columnar shape that corresponds to the opening  208 . The plug  206  can be formed from any suitable insulative material having an open-cell porous composition or capable of having a plurality of pores placed therein. For example, the insulative material can be ceramic. As discussed with reference to  FIGS. 2B-2D , the plug  206  can be processed in order to fill the pores, whether naturally occurring or created, of the plug  206  with conductive material. The plug  206  can then be placed within the opening  208  to create the electrical contact  202 . In some examples, the electrical contact  202  also includes an insulator  216 . The insulator  216  can function to insulate the plug  206  from the wall  210  which may be conductive. In some examples, the plug  206  can be placed in the opening  208  after the housing  204  has been anodized. The opening  208  can have a circular cross-section or any other non-circular cross-section. 
       FIG. 2B  illustrates the plug  206  having an example porous composition. The porous composition can include a plurality of pores  218  disposed within an insulative material  220 . At least a portion of the plurality of pores  218  may be connected to each other in order to form a continuum of cavity space. While the pores  218  are drawn for illustrative purposes as being visible, it is understood that the pores  218  can be much smaller in size and shape. For example, the diameter of the pores  218  can be less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. The pores  218  can be considered amorphous because their structure and size are varied with respect to each other. In some examples, the pores  218  can be considered uniform because their structure and size correspond to a pattern of pores. In some examples, the pores  218  naturally occur within the insulative material  220 . In other words, the pores  218  can be present based on properties of the insulative material  220  selected to create the plug  206  illustrated in  FIG. 2B . In some examples, the insulative material  220  is processed in some manner to cause the pores  218  to appear. For example, the insulative material  220  can be heated and cooled in a manner that causes the pores  218  to appear. In some examples, the pores  218  pass through the insulative material  220  in all directions. In this manner the insulative material  220  can be compared to an open-cell sponge, with the pores  218  being the openings in the sponge or the cell-like structure within the sponge. 
     For the plug  206  to become conductive, the pores  218  can be filled with conductive material. For example, a conductive metal can be heated and forced into the pores  218 . Depending on the properties of the conductive material and the size of the pores  218 , filling the pores  218  can include filling the pores  218  using vacuum suction, high pressure, and/or high heat. In this manner, the conductive material can extend throughout the pores  218  from end to end and side to side of the plug  206 . In some examples, filling the pores  218  with the conductive material can create conductive pathways through the plug  206  that extend from the exterior surface  212  to the interior surface  214 . The conductive pathways can be considered conductive elements. 
     In some examples, the plug  206  is formed such that an amount of visible conductive material within the pores  218  compared to visible insulative material  220  falls within some threshold. Values that fall below the threshold can be said to be visually imperceptible, while values that exceed the threshold can be said to be more visually perceptible. In this manner, the plug  206  can be formed such that when inserted into the opening  208  becomes visually imperceptible. 
     The conductive material and the insulative material  220  can be selected to have colors and textures that can be matched to a color and a texture of the exterior surface  212 . In some examples, when the size of the pores  218  when filled with the conductive material are imperceptible by the naked eye, just the insulative material  220  can be matched to the exterior surface  212 . 
       FIG. 2C  illustrates a frontal view of the exterior surface  212  of the wall  210  after the plug  206  has been installed in the opening  208 . In the view illustrated in  FIG. 2C , a frontal face of the electrical contact  202  is shown along with the insulator  216 . Additionally, in  FIG. 2C , the pores  218  are illustrated within the insulative material  220 . In some examples, after the plug  206  has been placed in the opening  208  of the wall  210 , the frontal face of the electrical contact  202  can be processed to create a smooth transition between the electrical contact  202  and the exterior surface  212 . Such processing can include machining, sand blasting, or any other suitable process. In some examples, before or after processing, the plug  206  and a portion of the wall  210  surrounding the plug  206  can together form a continuous cosmetic surface. Texture, color, and/or other cosmetic characteristics (e.g., reflectivity, hue, shade, tint, value, iridescence, etc.) can be cosmetically similar within the continuous cosmetic surface; and, thus, cosmetically imperceptible. In some examples, some degree of perceptibility is tolerated other than total imperceptibility. 
       FIG. 2D  illustrates the plug  206  having an example porous composition. The porous composition in  FIG. 2D  can include a plurality of columnar pores  222  disposed within an insulative material  224 . While the columnar pores  222  are drawn for illustrative purposes as being visible, it is understood that the columnar pores  222  can be much smaller in diameter. For example, the diameter of the columnar pores  222  can be less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. The columnar pores  222  can be considered columnar because their structure can be column-shaped. In some examples, the columnar pores  222  constitute a uniform pattern of pores. In some examples, the columnar pores  222  are aligned to extend from a first end of the plug  206  to a second end of the plug  206 . 
     In some examples, the columnar pores  222  can be placed in the insulative material  224  using any suitable processing technique. For example, the columnar pores  222  can be laser drilled or micro drilled in the insulative material  224 . In some examples, the plug  206  can be cast or extruded from the insulative material  224 . In this manner, the columnar pores  222  can be formed in the insulative material  224  selected as part of the casting or extruding the plug  206 . In some examples, the insulative material  224  is processed in some manner to cause the columnar pores  222  to appear. For example, the insulative material  224  can be heated and cooled in a manner that causes the columnar pores  222  to appear. 
     For the plug  206  to become conductive, the columnar pores  222  can be filled within conductive material. For example, a conductive metal can be heated and forced into the columnar pores  222  similarly as discussed with reference to the pores  218 . In this manner, the columnar pores  222  can act as conductive pathways through the plug  206  that extend from the first end of the plug  206  to the second end. 
     In some examples, the plug  206  is formed such that an amount of visible conductive material within the columnar pores  222  compared to visible insulative material  220  falls within some threshold. Values that fall below the threshold can be said to be visually imperceptible, while values that exceed the threshold can be said to be more visually perceptible. In this manner, the plug  206  can be formed such that when inserted into the opening  208  it becomes visually imperceptible. 
     The conductive material and the insulative material  224  can be selected to have colors and textures that can be matched to a color and texture of the exterior surface  212 . In some examples, when the size of the columnar pores  222  when filled with the conductive material are imperceptible by the naked eye, just the insulative material  224  can be matched to the exterior surface  212 . 
       FIG. 2E  illustrates a frontal view of the exterior surface  212  of the wall  210  after the plug  206  from  FIG. 2D  has been installed in the opening  208 . In the view illustrated in  FIG. 2E , a frontal face of the electrical contact  202  is shown along with the insulator  216 . Additionally, in  FIG. 2E , the columnar pores  222  are illustrated within the insulative material  224 . The columnar pores  222  are shown within the plug  206  having a uniform pattern in all three directions (length, width, and height). 
     In some examples, after the plug  206  has been placed in the opening  208  of the wall  210 , the frontal face of the electrical contact  202  can be processed to create a smooth transition between the electrical contact  202  and the exterior surface  212 . Such processing can include machining, sand blasting, or any other suitable process. In some examples, before or after processing, the plug  206  and a portion of the wall  210  surrounding the plug  206  can together form a continuous cosmetic surface. Texture, color, and/or other cosmetic characteristics (e.g., reflectivity, hue, shade, tint, value, iridescence, etc.) can be cosmetically similar within the continuous cosmetic surface; and, thus, cosmetically imperceptible. In some examples, some degree of perceptibility is tolerated other than total imperceptibility. 
       FIG. 3A  illustrates a portion of an electronic device  300  that includes an electrical contact  302  according to some embodiments of the disclosure. As shown in  FIG. 3A , electrical contact  302  is held within a housing  304  of the electronic device  300 . Like the electrical contact  102 , the electrical contact  302  can function as an electrical contact when an accessory or other equipment is connected to the electronic device  300 . 
     To this end, the electrical contact  302  can include a plurality of hole clusters  306  that extends through a wall  308  of the housing  304 . The plurality of hole clusters  306  can extend from an exterior surface  310  to an interior surface  312  of the housing  304 . Each hole cluster  306  can include a plurality of micro holes formed within the respective hole cluster  306 . The plurality of micro holes can be formed using micro-forming techniques such as micro-drilling, laser drilling, etc. In some examples, each micro hole has a diameter less than 0.5 millimeter and in some examples, the diameters are less than 50 microns. In some examples, each hole cluster  306  can include hundreds, thousands, or more micro holes. The pluralities of micro holes that make up the plurality of hole clusters  306  can be filled with a conductive material to create a plurality of conductive pathways via the wall  308 . For example, the pluralities of micro holes can be backfilled with copper, a conductive precious metal, nickel, tin, conductive polymers, and any other suitable conductive material. In some examples, the pluralities of micro holes are filled by magnetically drawing the conductive material through the micro holes. In some examples, the pluralities of micro holes are filled using a pressure vessel to force the conductive material into the micro holes at high pressure. In some examples, the pluralities of micro holes are filled using a plating process. In some examples, the plurality of conductive pathways, i.e., the plurality of hole clusters  306  with conductive material disposed within the micro holes, can be electrically coupled to a conductive plate  314 . The conductive plate  314  can function to electrically couple the plurality of conductive pathways with other items within housing  304 . In some examples, each hole cluster  306  functions as its own conductive pathway electrically insulated from the other hole clusters  306 . The conductive pathways and the conductive plate  314  can be considered conductive elements. The conductive material can be selected to have color and texture properties that can be matched to the color and texture properties of the exterior surface  310  of the housing  304 . 
     In some examples, the plurality of hole clusters  306  is disposed within the wall  308  of the housing  304  in accordance with some predetermined pattern. For example, as illustrated in the frontal view shown in  FIG. 3B , the plurality of hole clusters  306  can correspond to an array of clusters disposed within an exterior boundary of the electrical contact  302 . Similarly, the plurality of micro holes can be disposed within each of the plurality of hole clusters  306  in accordance with some predetermined pattern. Both predetermined patterns can be selected to maximize conductivity of the electrical contact  302 , while also seeking to minimize the cosmetic perceptibility of the plurality of hole clusters  306  in the exterior surface  310 . In some examples, the plurality of hole clusters  306  can be randomly disposed within the wall  308 . In this manner, the plurality of hole clusters  306  may not correspond to a predetermined pattern. Similarly, the plurality of micro holes can be randomly disposed within each of the plurality of hole clusters  306 . In some examples, an optimal ratio of micro holes per hole cluster  306  can be computed and maintained as the electrical contact  302  is being formed in the housing  304 . In some examples, a similar ratio can be computed that considers the number of hole clusters  306  per surface area of the electrical contact  302 . In any event, each ratio may depend also on the diameter of the micro holes, the diameter of the hole clusters  306 , the color of the conductive material in the micro holes, and the color of the housing  304 . 
     In some examples, the electrical contact  302  is formed such that an amount of visible conductive material within the micro holes compared to visible exterior surface  310  within the extents of the electrical contact  302  falls within some threshold. Values that fall below the threshold can be said to be visually imperceptible, while values that exceed the threshold can be said to be more visually perceptible. In this manner, the electrical contact  302  can be formed to be visually imperceptible. 
     In some examples, the pluralities of micro holes of the plurality of hole clusters  306  are formed in the housing  304  after the housing  304  has been anodized. In some examples, after the micro holes have been filled with conductive material, the frontal face of the electrical contact  302  can be processed to create a smooth transition between the electrical contact  302  and the exterior surface  310 . Such processing can include machining, sand blasting, or any other suitable process. In some examples, before or after processing, the electrical contact  302  and a portion of the wall  308  surrounding the electrical contact  302  can together form a continuous cosmetic surface. Texture, color, and/or other cosmetic characteristics (e.g., reflectivity, hue, shade, tint, value, iridescence, etc.) can be cosmetically similar within the continuous cosmetic surface; and, thus, cosmetically imperceptible. In some examples, some degree of perceptibility is tolerated other than total imperceptibility. 
       FIG. 4A  illustrates a portion of an electronic device  400  that includes an electrical contact  402  according to some embodiments of the disclosure. As shown in  FIG. 4A , electrical contact  402  is held within a housing  404  of the electronic device  400 . Like the electrical contact  102 , the electrical contact  402  can function as an electrical contact when an accessory or other equipment is connected to the electronic device  400 . 
     To this end, the electrical contact  402  can include a plurality of openings  406  that extends through a wall  408  of the housing  404 . The plurality of openings  406  can extend from an exterior surface  410  to an interior surface  412  of the wall  408 . Each opening  406  can include a conductive plug  414  formed within the respective opening  406 .  FIG. 4B  illustrates an example conductive plug  414 . The conductive plug  414  can include a plurality of conductive fibers  416  disposed within an insulative material  418 . For example, the conductive fibers  416  can be arranged into the shape of the conductive plug  414  and the insulative material  418  can be a type of aluminum that is cast around the conductive fibers  416  to form the conductive plug  414 . In some examples, the insulative material  418  can be a ceramic material. 
     In some examples, the plurality of openings  406 , when filled with the conductive plugs  414 , can create a plurality of conductive pathways. The plurality of conductive pathways can be electrically coupled via a conductive plate  420 . In some examples, each conductive plug  414  can function as its own conductive pathway electrically insulated from the other conductive plugs  414 . The conductive plugs  414  and the conductive plate  420  can be considered conductive elements. 
     The conductive material of the conductive fibers  416  and the insulative material  418  can be selected to have color and texture properties that can be matched to the color and texture properties of the exterior surface  410  of the housing  404 . 
     In some examples, the plurality of openings  406  (and the plurality of conductive plugs  414 ) can be disposed within the wall  408  in accordance with some predetermined pattern. For example, as illustrated in the frontal view shown in  FIG. 4C , the plurality of conductive plugs  414  can correspond to an array disposed within an exterior boundary of the electrical contact  402 . The predetermined patterns can be selected to maximize conductivity of the electrical contact  402 , while also seeking to minimize the cosmetic perceptibility of the conductive plugs  414  in the exterior surface  410 . In some examples, an optimal ratio of visible surface area of conductive fibers  416  to visible surface area of insulative material  418  can be computed and maintained as the conductive plug  414  is being formed. In some examples, a similar ratio can be computed that considers the number and surface area of the openings  406  per exterior surface area of the electrical contact  402 . In any event, each ratio may depend also on the diameter of the conductive fibers  416 , the diameter of the openings  406 , the color of the conductive material used in the conductive fibers  416 , the color of the insulative material  418 , and the color of the housing  404 . 
     In some examples, the electrical contact  402  is formed such that an amount of visible conductive material within the conductive plugs  414  compared to an amount of visible insulative material  418  falls within some threshold. Values that fall below the threshold can be said to be visually imperceptible, while values that exceed the threshold can be said to be more visually perceptible. In this manner, the electrical contact  402  can be formed such to be visually imperceptible. 
     In some examples, the plurality of openings  406  is formed in the housing  404  after the housing  404  has been anodized. In some examples, the housing  404  can be anodized after the conductive plugs  414  have been inserted into the openings  406 . In some examples, after conductive plugs  414  have been placed in the openings  406 , the frontal face of the electrical contact  402  can be processed to create a smooth transition between the electrical contact  402  and the exterior surface  410 . Such processing can include machining, sand blasting, or any other suitable process. In some examples, before or after processing, the electrical contact  402  and a portion of the wall  408  surrounding the electrical contact  402  can together form a continuous cosmetic surface. Texture, color, and/or other cosmetic characteristics (e.g., reflectivity, hue, shade, tint, value, iridescence, etc.) can be cosmetically similar within the continuous cosmetic surface; and, thus, cosmetically imperceptible. In some examples, some degree of perceptibility is tolerated other than total imperceptibility. 
     It is understood that any of the electrical contacts described herein can be included in an array or in any other suitable pattern. Any of the electrical contacts can transfer power, ground, control signals, or data. In some examples, multiple arrays of electrical contacts can be included in a single electronic device. Also, since in many embodiments the contacts are mostly or even completely hidden from sight and/or touch, in some embodiments of the disclosure an alignment mechanism can be positioned within the housing of the electronic device proximate to the contact region of the housing. In some examples, the alignment mechanism can include one or more magnets (e.g., an array of magnets) aligned in a manner that attract appropriately aligned magnets in an accessory device having a connector that can be operatively coupled to the contact in the contact region of the electronic device. The alignment mechanism can serve to align the accessory connector with the contact region to ensure proper electrical contact between the hidden contacts in the electronic device and electrical contacts in the accessory connector. 
     Spatially relative terms, such as “below”, “above”, “lower”, “upper” and the like may be used above to describe an element and/or feature&#39;s relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” and/or “beneath” other elements or features would then be oriented “above” the other elements or features. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     The above description of embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form described, and many modifications and variations are possible in light of the teaching above. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. Thus, it will be appreciated that the invention is intended to cover all modifications and equivalents within the scope of the following claims.

Metadata:
Filing Date: 20160314
Publication Date: 20171003
Grant Date: 20171003
Priority Date: 20150930
Inventors: TRYON BRIAN S.
WILLIAMS ALEXANDER W.
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H1/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H1/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/181", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/182", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 58409948