PATENT DOCUMENT

Publication Number: US-7927151-B2
Application Number: US-47940409-A
Country: US
Kind Code: B2

Title: Audio plug with core structural member

Abstract:
Plugs with core structural members and methods for manufacturing plugs with core structural members are provided. A plug can include a core structural member that may increase the structural integrity of the plug. The plug can further include contact pads and traces, and each trace can electrically couple with one of the contact pads and extend along a plug axis towards the proximal end (e.g., base section) of the plug. In orientation-specific embodiments, the traces may be disposed on the surface of the plug. However, in other embodiments, the traces may be disposed below but near the surface of the plug. The plug may also include one or more insulating layers to prevent contact pads and traces from shorting.

Claims:
1. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 contact pads positioned over an outer surface of the structural member; 
 traces positioned over the outer surface of the structural member, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end; and 
 an insulating layer disposed between the structural member and the contact pads and traces. 
 
     
     
       2. The plug of  claim 1 , wherein:
 the traces include a first trace located at a radial distance from the plug axis; and 
 all other traces are located at the same radial distance from the plug axis. 
 
     
     
       3. The plug of  claim 1 , wherein the contact pads are arranged on the outer surface of the plug in a straight line parallel with the plug axis. 
     
     
       4. The plug of  claim 1 , further comprising:
 a housing positioned over the proximal end of the plug, wherein the structural member extends into the housing. 
 
     
     
       5. The plug of  claim 1 , wherein the insulating layer encapsulates the structural member. 
     
     
       6. The plug of  claim 1 , wherein the contact pads protrude from the insulating layer. 
     
     
       7. The plug of  claim 1 , wherein the contact pads have a thickness that is greater than a thickness of the traces. 
     
     
       8. The plug of  claim 1 , wherein each of the contact pads has an outer surface that is flush with an outer surface of the insulating layer. 
     
     
       9. The plug of  claim 8 , wherein:
 the insulating layer comprises indentations; and 
 the contact pads include conductive material deposited in the indentations. 
 
     
     
       10. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis, the structural member being conductive: 
 contact pads positioned over an outer surface of the structural member, one of the contact pads being electrically coupled with the structural member; and 
 traces positioned over the outer surface of the structural member, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end. 
 
     
     
       11. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 contact pads positioned over an outer surface of the structural member; and 
 traces positioned over the outer surface of the structural member, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end, wherein at least one of the traces extends at least partially around the plug axis before extending along the plug axis. 
 
     
     
       12. The plug of  claim 11 , wherein:
 the structural member has insulating properties; and 
 the contact pads and traces are disposed on an outer surface of the structural member. 
 
     
     
       13. A connector comprising:
 elongated plug extending from a proximal end to a distal end and comprising:
 a structural member extending along a plug axis; 
 contact pads positioned over an outer surface of the structural member; and 
 traces positioned over the outer surface of the structural member, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end; and 
 
 a protuberance adjacent to the proximal end of the plug, the protuberance being shaped to interface with a female connector so that the plug inserts into the female connector in a proper orientation. 
 
     
     
       14. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 a first insulating layer disposed over an outer surface of the structural member; 
 traces disposed on the first insulating layer, at least one of the traces extending along the plug axis; 
 a second insulating layer disposed over the first insulating layer and the traces; and 
 contact pads disposed on the second insulating layer, at least one of the contact pads electrically coupling with one of the traces through the second insulating layer. 
 
     
     
       15. The plug of  claim 14 , wherein:
 the structural member is conductive; and 
 one of the contact pads is electrically coupled with the structural member. 
 
     
     
       16. The plug of  claim 14 , wherein each of the traces extends directly towards the proximal end in a direction parallel to the plug axis. 
     
     
       17. The plug of  claim 14 , wherein:
 the traces include a first trace located at a radial distance from the plug axis; and 
 all other traces are located at the same radial distance from the plug axis. 
 
     
     
       18. The plug of  claim 14 , wherein the first insulating layer and the second insulating layer are formed from a different material. 
     
     
       19. The plug of  claim 14 , wherein each of the contact pads is in a ring shape that extends completely around the plug axis. 
     
     
       20. The plug of  claim 14 , wherein the at least one of the contact pads electrically couples with one of the traces through a conductive path extending radially from the plug axis through the second insulating layer. 
     
     
       21. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 contact pads positioned on an outer surface of the plug; 
 traces positioned a uniform radial distance from the plug axis, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end; and 
 an insulating layer disposed between the structural member and the contact pads and traces. 
 
     
     
       22. The plug of  claim 21 , further comprising:
 a housing positioned over the proximal end of the plug, wherein the structural member extends into the housing. 
 
     
     
       23. The plug of  claim 21 , wherein the insulating layer encapsulates the structural member. 
     
     
       24. The plug of  claim 21 , wherein the contact pads protrude from the outer surface of the plug. 
     
     
       25. The plug of  claim 21 , wherein the contact pads have a thickness that is greater than a thickness of the traces. 
     
     
       26. The plug of  claim 21 , wherein each of the contact pads has an outer surface that is flush with a portion of the plug&#39;s outer surface. 
     
     
       27. The plug of  claim 26 , wherein:
 the insulating layer comprises indentations; and 
 the contact pads include conductive material deposited in the indentations. 
 
     
     
       28. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 contact pads positioned on an outer surface of the plug; and 
 traces positioned a uniform radial distance from the plug axis, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end, wherein the traces are disposed under the outer surface of the plug. 
 
     
     
       29. An elongated plug extending from a proximal end to a distal end, the plug comprising:
 a structural member extending along a plug axis; 
 contact pads positioned on an outer surface of the plug; 
 traces positioned a uniform radial distance from the plug axis, at least one of the traces electrically coupling with one of the contact pads and extending along the plug axis towards the proximal end; and 
 an insulating layer disposed between the traces and the contact pads.

Description:
BACKGROUND OF THE INVENTION 
     Traditional audio plugs (i.e., male connectors) can have structural limitations. Each contact of an audio plug is typically a ring of metal with a thin lead. During manufacture, the rings are assembled so that each ring&#39;s lead extends through the center of other rings towards the plug&#39;s base and plastic is then injection-molded into the center of the rings. This manufacturing technique creates a plug core consisting of several thin leads separated by injection-molded plastic. While such a core insulates the leads from each other and the other contacts, this structure may have a limited resistance to bending or other forces applied to the plug. 
     SUMMARY OF THE INVENTION 
     Improved plugs and methods for manufacturing improved plugs are provided. A plug can include a structural member that may increase the structural integrity of the plug. The plug can further include contact pads and traces, and each trace can electrically couple with one of the contact pads and extend along a plug axis towards the proximal end (e.g., base section) of the plug. In orientation-specific embodiments, the traces may be disposed on the surface of the plug. However, in other embodiments, the traces may be disposed below but near the surface of the plug. The plug may also include one or more insulating layers to prevent contact pads and traces from shorting. 
    
    
     
       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. 1A  is a perspective view of an illustrative male connector in accordance with one embodiment of the invention; 
         FIG. 1B  is a perspective view of an illustrative male connector inserted into a cross-section of a female connector in accordance with one embodiment of the invention; 
         FIG. 2A  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 2B  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 3  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 4  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 5  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 6A  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 6B  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 7  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 8  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 9  is a perspective view of an illustrative connector incorporating a plug in accordance with one embodiment of the invention; 
         FIG. 10  is a perspective view of an illustrative connector incorporating a plug in accordance with one embodiment of the invention; 
         FIG. 11A  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 11B  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 11C  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 11D  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 12  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 13  is a cross-sectional view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 14  is a perspective view of an illustrative plug in accordance with one embodiment of the invention; 
         FIG. 15  is a flowchart of an illustrative process for forming a plug in accordance with one embodiment of the invention; and 
         FIG. 16  is a flowchart of an illustrative process for forming a plug in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  includes male connector  100  in accordance with one embodiment. Male connector  100  may, for example, include functionality related to audio signals, visual signals, data signals, or other electrical signals. Male connector  100  may include an elongated plug  101  that extends axially from a proximal to distal end along axis  105 . Plug  101  may include one or more contacts  150  that are spaced apart axially between the proximal and distal ends. While the embodiment shown in  FIG. 1  includes four contacts, any number of contacts may be used depending on the needs of the male connector. For example, the number of contacts included in a plug may be based on how many electrical signals will be transmitted through the plug. In an embodiment for coupling with audio headsets with integrated microphones, four contacts may be used to provide outgoing audio signals in stereo, receive an incoming microphone signal, and form a ground circuit. In an audio/video connector embodiment, the four contacts may be used to form a group circuit and provide or receive audio signals in stereo as well as composite video. In a Universal Serial Bus (USB) embodiment, four contacts may be used to form a ground and power circuit and provide and receive a differential data signal. In a Firewire embodiment, six contacts may be used to form a group and power circuit and provide and receive two differential data signals. 
     In some embodiments, a connector can include a housing with a mating surface. For example, connector  100  can include housing  190  with mating surface  192  for abutting a corresponding mating surface in a female connector when the two connectors are coupled together. Referring to  FIG. 1B , male connector  100  can couple with female connector  102  by inserting plug  101  into jack  103  (e.g., an aperture) in the female connector. When the two connectors are coupled together, mating surface  192  on male connector  100  abuts mating surface  194  on female connector  102 . Moreover, when the two connectors are coupled together, contacts  151  disposed within jack  103  may couple with contacts  150  on plug  101 . Contacts  151  may, for example, be electrical contacts configured to extend into jack  103  (e.g., coupled with a spring) so that contacts  151  engage contacts  150  on plug  101 . Contacts  151  may be spaced apart so that each contact will only couple with a single contact on plug  101 . Contacts in a female connector may be coupled with a cable, printed circuit board, or any other similar device. For example, contacts  151  may be coupled with printed circuit board  159 , and an electronic device that includes female connector  102  can receive electrical signals from another device that includes male connector  100 . 
     Referring back to  FIG. 1A , male connector  100  may include termination point  180  where plug  101  may be operatively and structurally coupled to a cable, printed circuit board, or any other similar device. For example, plug  101  may couple with cable  189  at termination point  180 . In some embodiments, a connector may include a strain relief to make a structurally robust connection between a plug and a cable, printed circuit board, or other similar device. For example, termination point  180  may include a strain relief to strengthen the connection between plug  101  and cable  189 . In some embodiments, a termination point may be covered by a housing, body, or enclosure. For example, termination point  180  may be covered by housing  190 . In embodiments including a cable (e.g., connector  100 ), a housing may form a portion of the strain relief. A more detailed description of suitable connector housings and strain reliefs can be found in U.S. patent application Ser. No. 12/218,450, entitled “Audio Plug with Cosmetic Hard Shell” and filed on Jul. 14, 2008, which is incorporated by reference herein in its entirety. 
     In some embodiments, plug  101  can be configured with core structural member  110  (shown in dotted lines) to provide an extremely robust male connector  100 . For example, core structural member  110  may prevent plug  101  from bending. Structural member  110  may be disposed entirely or partially along the length of elongated plug  101 . For example, a structural member can be a cylindrical component extending through the center of the plug. In some embodiments, structural member  110  may extend proximally past at least the distal end of housing  190  (e.g., mating surface  192 ) and further proximate towards, and possibly abutting, terminal point  180 . In one particular embodiment, structural member  110  may substantially extend from the distal end of plug  101  to at least termination point  180 . 
     In order to provide connections between contacts and the termination point, a plug may include one or more conductive paths (e.g., traces) that extend between the contacts and the termination point. In order to accomplish this, the outer surface of the plug may be configured with a dielectric material so that the conductive paths can run through or on the plug while being electrically separated from the contacts and, potentially, the core structural member. 
     In one embodiment, a core structural member may be formed from a metal such as steel, and the metal structural member may be substantially encapsulated by an insulating dielectric layer. In such an embodiment, the contacts may be disposed on the outer surface of the insulating layer. Accordingly, the plug may be a composite plug that includes multiple materials. For example, a conductive material may be deposited onto the surface of the insulating dielectric layer to form one or more contacts. Moreover, traces may be disposed on the insulating layer, within the insulating layer, underneath the insulating layer, or any combination thereof. The contacts and/or the traces may be insulated from the core structural member and each other by the insulating dielectric layer. 
       FIGS. 2A and 2B  include plug  200  with traces on the outer surface of the plug in accordance with one embodiment. Plug  200  can be provided on any male connector (e.g., connector  100  of  FIG. 1A ) for coupling with a female connector (e.g., connector  102  of  FIG. 1B ). For example, plug  200  can be provided on a connector for a pair of headphones, a pair of earbuds, an external speaker, a charging device, a cable that couples a personal computer with an electronic device (e.g., a Universal Serial Bus cable), a cable that couples a video display with an electronic device, or any other suitable male connector that couples with a female connector. Moreover, plug  200  can be provided for transmitting audio signals, video signals, data signals, or any other suitable types of electrical signal. Plug  200  can be used to couple with a female connector on any suitable electronic device, including, for example, a digital music player or a communications device (e.g., a cellular telephone). 
     Plug  200  can be sized and shaped to mate with a jack in an electronic device. Plug  200  can have an elongated shape extending along plug axis  205 . Along plug axis  205 , plug  200  can include proximal end  202  (e.g., a base section) and distal end  204  (e.g., a tip section). While the plug embodiment shown in  FIG. 2  may have an elongated shape, it is understood that a plug can have any suitable shape for mating with a jack in an electronic device. For example, a plug (e.g., plug  200 ) can have a shape similar to plug  101  of  FIGS. 1A and 1B . Moreover, while the distal end of the plug embodiment shown in  FIG. 2  may have a relatively smooth surface, it is understood that the distal end of a plug can have any suitable shape. For example, the distal end of a plug (e.g., distal end  204 ) can have a shape similar to the distal end of plug  101  of  FIGS. 1A and 1B . 
     As seen in the cross-section view of  FIG. 2B , plug  200  includes core structural member  210  extending along plug axis  205 . Structural member  210  can be formed from a rigid material. In some embodiments, structural member  210  can be formed from a metal. For example, structural member  210  can be formed from steel, aluminum, titanium, or any other suitable metal or alloy. In some embodiments, structural member  210  may be a solid piece of rigid material that is formed by turning, machining, forging, casting, any other suitable manufacturing technique, or any combination thereof. In some embodiments, structural member  210  may be shaped to increase its structural integrity. For example, structural member  210  may have a length, width, length-to-width ratio, or any other dimension or characteristic that provides structural integrity. Structural member  210  can add structural integrity to plug  200 . 
     Plug  200  can include insulating layer  220  that may be formed from a dielectric material. Insulating layer  220  may surround, encapsulate or cover core structural member  210 . In some embodiments, insulating layer  220  may be formed by coating structural member  210  with a dielectric material. Insulating layer  220  may be formed from ceramic, polycarbonate, polyethylene, polystyrene, or any other suitable dielectric material. Insulating layer  220  can, for example, insulate any contact pads or traces on the outer surface of the plug from each other. In some embodiments, the insulating layer  220  can be a relatively large portion of the outer surface of plug  200 . 
     Plug  200  can include one or more contact pads (e.g., contact pads  251 ,  252 ,  253 , and  254 ). Contacts pads  251 - 254  can be located on or disposed over the outer surface of insulating layer  220 . Contact pads  251 - 254  can be spaced along axis  205  so that each contact pad is located at a different point along the axis. Contact pads  251 - 254  can extend circumferentially around axis  205  to cover a portion of the circumference of plug  200 . For example, contact pads  251 - 254  may extend 20% around the circumference of plug  200 . In another example, contact pads  251 - 254  may extend up to 50% around the circumference of plug  200 . In yet another example, contact pads  251 - 254  may extend up to 75% around the circumference of plug  200 . In yet a further example, contact pads  251 - 254  may extend up to 90% around the circumference of plug  200 . 
     Contact pads  251 - 254  can be formed from a conductive material. For example, contact pads  251 - 254  may be formed by depositing a conductive material onto insulating layer  220 . Contact pads  251 - 254  may be sufficiently thick enough to withstand forces from mating with a female connector (e.g., frictional forces from inserting plug  200  in a jack and withdrawing plug  200  from a jack). In some embodiments, contact pads  251 - 254  may protrude from the outer surface of insulating layer  220 . 
     Each of contact pads  251 - 254  can be sized and shaped to mate with a corresponding contact in a female connector. Moreover, the array of contact pads  251 - 254  may be arranged to mate with an array of contacts in a female connector (e.g., contacts  151  in connector  102  of  FIG. 1B ). In some embodiments, contact pads  251 - 254  may be arranged in a straight line along one side of plug  200  that corresponds to an array of contacts along one side of a female connector. In another example, contact pads may be arranged on different sides of plug  200  so that the contact pads correspond to an array of contacts on different sides of a female connector. 
     Plug  200  can include traces  261 ,  262 ,  263 , and  264  formed from a conductive material. Traces  261 - 264  can be located on or disposed over the outer surface of insulating layer  220 . Insulating layer  220  may insulate each of traces  261 - 264  from the other traces and structural member  210 . Each of traces  261 - 264  may electrically couple with one of contact pads  251 - 254 . For example, trace  261  may electrically couple with contact pad  251 , trace  262  may electrically couple with contact pad  252 , and so forth. Each of traces  261 - 264  may be directly coupled with one of contact pads  251 - 254  by overlapping the contact pad, either above or below the contact pad, or abutting against the edge of the contact pad. In some embodiments, traces  261 - 264  and contact pads  251 - 254  may be integral parts of a single layer and, therefore, inherently coupled. 
     In some embodiments, traces  261 - 264  may be formed in the same manner as contact pads  251 - 254 . For example, traces  261 - 264  and contact pads  251 - 254  may be formed in a single manufacturing step (e.g., depositing conductive material on the outer surface of insulating layer  220 ). In such embodiments, traces  261 - 264  may be formed from the same material as contact pads  251 - 254 . In other embodiments, traces  261 - 264  may be formed in a different manner and/or at a different time than contact pads  251 - 254 . For example, traces  261 - 264  may be formed from a different material than contact pads  251 - 254 . Moreover, traces  261 - 264  may be formed before or after contact pads  251 - 254  are formed. 
     In some embodiments, traces  261 - 264  may be the same thickness as contact pads  251 - 254 . For example, traces  261 - 264  may be formed using the same process used to form contact pads  251 - 254  and both the traces and contact pads may have the same thickness. In other embodiments, traces  261 - 264  may be thinner than contact pads  251 - 254 . For example, traces  261 - 264  may not necessarily be as thick as contact pads  251 - 254  because traces  261 - 264  do not undergo the same forces when mating with a female connector (e.g., frictional forces) as contact pads  251 - 254 . 
     In some embodiments, each of traces  261 - 264  can be located the same distance from axis  205  (e.g., at the same radius or radial layer) as the other traces. For example, insulating layer  220  may be centered around plug axis  205  so that traces  261 - 264  are the same radial distance from plug axis  205  when deposited on insulating layer  220 . In other words, traces  261 - 264  may all be on the same radial layer. In some embodiments, each of traces  261 - 264  can be located the same distance from axis  205  (e.g., at the same radius or radial layer) as contact pads  251 - 254  as well as the other traces. 
     While an array of contact pads may be arranged to mate with an array of contacts in a female connector, the corresponding traces may be arranged so that they will not couple with any of the contacts in the female connector. For example, contact pads  251 - 254  and traces  261 - 264  may be arranged on the surface of plug  200  so that each of contact pads  251 - 254  mates with a different contact in a female connector while none of traces  261 - 264  couple with the contacts. In some embodiments, the traces on a plug may be less thick than the contact pads on the plug so that, when the plug is inserted into a female connector, the traces will not touch the connector. 
     In some embodiments, contact pads and traces may be substantially flush with the outer surface of a plug.  FIGS. 3A and 3B  include plug  300  with contact pads and traces substantially flush with the outer surface of the plug in accordance with one embodiment. Plug  300  can be substantially similar to plug  200  of  FIGS. 2A and 2B . For example plug  300  can include core structural member  310  extending along plug axis  305 , and structural member  310  may be substantially similar to structural member  210  of plug  200 . Plug  300  may also include insulating layer  320  that is similar to insulating layer  220  of plug  200  but, unlike insulating layer  220  and the contact pads and traces disposed thereon, the outer surface of insulating layer  320  may be substantially flush with contact pads  351 - 354  and traces  361 - 364 . 
     In some embodiments, one or more indentations can be provided in insulating layer  320  (e.g., by chemical or laser etching), and conductive material can be deposited in the indentations to create contact pads  351 - 354  and traces  361 - 364  that are substantially flush with the outer surface of insulating layer  320 . In other embodiments, contact pads  351 - 354  and traces  361 - 364  may be deposited onto insulating layer  320 , and then additional dielectric material may be deposited over insulating layer  320  to make it substantially flush with the contact pads and traces. 
     In some embodiments, a plug may include a structural member with insulating properties rather than a structural member and an insulating layer covering the structural member.  FIG. 4  includes plug  400  with structural member  410  in accordance with one embodiment. Plug  400  can be provided on any male connector for coupling with a female connector. Plug  400  can be similar to plug  200  of  FIGS. 2A and 2B , and plug  400  may include many of the same elements as plug  200 . For example, plug  400  can include contact pads  451 - 254  (see, e.g., contact pads  251 - 254  of plug  200 ) and traces (see, e.g., traces  261 - 264  of plug  200 ). While only trace  464  is shown in  FIG. 4 , it is understood that plug  400  can include other traces on the outer surface of plug  400 . For example, plug  400  may include three other traces and each of the traces may electrically couple with one of contact pads  451 - 453  (see, e.g., traces  261 - 263  provided on plug  200 ). 
     Unlike plug  200 , plug  400  may not include a separate core structural member and insulating layer covering the structural member. For example, plug  400  may include core structural member  410  that can provide structural integrity while also forming the outer surface of plug  400 . A separate insulating layer may not be necessary if structural member  410  is formed from a dielectric material. For example, structural member  410  may be formed from ceramic, polycarbonate, polyethylene, polystyrene, or any other suitable dielectric material. In some embodiments, structural member  410  may be formed from a rigid dielectric material that will increase the structural integrity of plug  400 . In some embodiments, structural member  410  may be a solid piece of rigid dielectric material that is formed by any suitable manufacturing technique. In some embodiments, structural member  410  may be shaped to increase its structural integrity. For example, structural member  410  may have a length, width, length-to-width ratio, or any other dimension or characteristic that provides structural integrity. Structural member  410  may also provide structural integrity by acting as the core or inner member of plug  400 . 
     While the embodiment shown in  FIG. 4  includes a core structural member formed from a single dielectric material, it is understood that an structural member can be formed from multiple dielectric materials depending on the needs of the system. For example, a structural member can include an inner core with dielectric and structural characteristics and an outer layer with a texture that is advantageous for receiving conductive material to form contact pads and traces. 
     To couple plug contacts pads with a cable, printed circuit board, or other suitable device, conductive paths (e.g., traces) may extend at least partially along a plug&#39;s axis towards the proximal end of the plug. In some embodiments, traces can be spaced around the plug&#39;s axis so that each trace is located at a different position around the axis. For example, one or more of the traces can extend circumferentially around a plug&#39;s axis to avoid contact pads and the other traces. Referring to plug  200  in  FIG. 2A , trace  264  may couple with contact pad  254  and extend directly along plug axis  205  towards proximal end  202 , while trace  263  may couple with contact pad  253 , extend at least partially around plug axis  205  to avoid contact pad  254 , and then extend along plug axis  205  towards proximal end  202 . 
     A plug&#39;s traces can extend beyond the plug&#39;s proximal end for coupling with a cable, printed circuit board, or other suitable device (e.g., cable  189  of  FIG. 1A ). For example, referring to  FIG. 2A , each of traces  261 - 264  may extend beyond proximal end  202  and end in a terminating contact pad (e.g., a solder pad) for electrically coupling with a line in a cable or a circuit board in an accessory.  FIG. 5  includes plug  500  with termination point  580  in accordance with one embodiment. Plug  500  can be provided on any male connector for coupling with a female connector. Plug  500  can be similar to plug  200  of  FIGS. 2A and 2B , plug  300  of  FIG. 3  and plug  400  of  FIG. 4 . Plug  500  may include many of the same elements as plugs  200 ,  300 , and  400 . For example, plug  500  can include contact pads  551 - 554  (see, e.g., contact pads  251 - 254  of plug  200 ) and traces  561 - 564  (see, e.g., traces  261 - 264  of plug  200 ). Each of traces  561 - 564  can extend along plug axis  505  towards proximal end  502  of plug  500 . Plug  500  may include termination point  580  at proximal end  502  of the plug, and each of traces  561 - 564  may end at the termination point. At termination point  580 , each of traces  561 - 564  can couple with a line in a cable, a trace on a printed circuit board, or any other suitable electrical line. For example, termination point  580  can include multiple solder pads  581 - 584  for coupling with various lines in cable  589 . While the embodiment shown in  FIG. 5  include solder pads for coupling with lines in a cable, it is understood that any other suitable connection technique can be used to couple a termination point with a cable, printed circuit board, or other suitable device. 
     In some embodiments, a plug may include a structural member that functions as a conductive path for a contact pad.  FIGS. 6A and 6B  include plug  600  with structural member  610  in accordance with one embodiment. Plug  600  can be provided on any male connector for coupling with a female connector. Plug  600  can be similar to plug  200  of  FIGS. 2A and 2B , and plug  600  may include many of the same elements as plug  200 . For example, plug  600  can include contact pads  652 - 654  (see, e.g., contact pads  252 - 254  of plug  200 ) and traces  662 - 664  (see, e.g., traces  262 - 264  of plug  200 ). 
     Unlike plug  200 , plug  600  may include structural member  610  that functions as a conductive path for contact pad  651 . Structural member  610  may be formed from a rigid material with conductive properties. For example, structural member  610  may be formed from steel or any other suitable metal or alloy with conductive properties. Beyond proximal end  602 , structural member  610  may electrically couple with a cable or an accessory (not shown). For example, the proximal end of structural member  610  may include a terminating contact pad (e.g., a solder pad) for electrically coupling with a line in a cable or a circuit board in an accessory. Moreover, structural member  610  may include protrusion  612  extending radially away from plug axis  605 . 
     In the embodiment shown in the cross-section view of  FIG. 6B , the tip of protrusion  612  may form contact pad  651 . In such an embodiment, insulating layer  620  may cover structural member  610  except for the end of protrusion  612 , which may extend past the outer surface of insulating layer  620 . Accordingly, the end of protrusion  612  may form contact pad  651  that may be flush with contact pads  652 - 654 . 
     In other embodiments, contact pad  651  may be formed on top of the tip of protrusion  612 . For example, the tip of protrusion  612  may be substantially flush with the outer surface of insulating layer  620  and a conductive material can be applied over the tip of protrusion  612  and a surrounding section of insulating layer  620  to form contact pad  651 . In such embodiments, once the tip of protrusion  612  is substantially flush with the outer surface of insulating layer  620 , contact pads  651 - 654  may be formed using the same process (see, e.g., discussion of contact pads  251 - 254 ). 
     In the embodiment shown in  FIGS. 6A and 6B , structural member  610  may be a conductive path for contact pad  651  near distal end  604  of plug  600  but, in other embodiments, it is understood that a structural member may be a conductive path for any other contact pad on plug  600 , including contact pads closer to proximal end  602 . Moreover, in other embodiments, a structural member may not include a protrusion, and a plug may include one or more conductive vias extending through an insulating layer and electrically coupling a contact pad with a structural element. 
       FIG. 7  includes plug  700  with conductive path  771  coupling structural member  710  and contact pad  751  in accordance with one embodiment. Plug  700  can be provided on any male connector for coupling with a female connector. Plug  700  can be similar to plug  600  of  FIGS. 6A and 6B , and plug  700  may include many of the same elements as plug  600 . For example, plug  700  can include contact pads  752 - 754  (see, e.g., contact pads  652 - 654  of plug  600 ) and trace  764  (see, e.g., traces  664  of plug  600 ). 
     Unlike plug  600 , plug  700  may include contact pad  751  that is a separate element from core structural member  710  (see, e.g., contact pad  651  which is a protrusion of structural member  650 ). However, even though contact pad  751  is a separate element from core structural member  710 , contact pad  751  is coupled with structural member  710  through conductive path  771 . Conductive path  771  can, for example, be a conductive via through insulating layer  720 . Conductive path  771  can be formed from conductive material. In some embodiments, conductive path  771  can be formed from the same conductive material as contact pads and traces. For example, after insulating layer  720  is applied, through-holes can be created at specific points in layer  720  (e.g., by chemical or laser etching) and conductive material can be applied to fill the through-holes and create conductive path  771 . Conductive path  771  can be any suitable structure for conducting electrical current through specific points in layer  720 , and conductive path  771  can be formed using any suitable process. 
     In embodiments where a plug&#39;s core structural member serves as a conductive path, the plug&#39;s terminating point may include one or more conductive paths for coupling a cable, printed circuit board, or other suitable device (e.g., cable  189  of  FIG. 1A ) with the structural member.  FIG. 8  includes plug  800  with termination point  880  in accordance with one embodiment. Plug  800  can be provided on any male connector for coupling with a female connector. Plug  800  can be similar to plug  600  of  FIGS. 6A and 6B  and plug  700  of  FIG. 7 . Plug  800  may include many of the same elements as plugs  600  and  700 . For example, plug  800  can include contact pads  851 - 854  (see, e.g., contact pads  651 - 654  of plug  600 ) and traces  862 - 864  (see, e.g., traces  661 - 664  of plug  600 ). Each of traces  862 - 864  can extend along plug axis  805  towards proximal end  802  of plug  800 . Plug  800  may include termination point  880  at proximal end  802  of the plug, and each of traces  862 - 864  may end at the termination point. Plug  800  may also include a core structural member that serves as a conductive path for contact pad  851  (see, e.g., conductive structural member  610  of  FIG. 6B  and conductive structural member  710  of  FIG. 7 ). Termination point  880  may include a conductive path through insulating layer  820  to electrically couple the structural member of plug  800 , and therefore contact pad  851 , with a cable, printed circuit board, or other suitable device. The conductive path through insulating layer  820  may be substantially similar to conductive path  771  of plug  700 , and the description of the latter can be applied to the former. In some embodiments, termination point  880  may include a conductive via and solder pad  881  to couple the conductive structural member of plug  800  with a line in cable  889 . In some embodiments, rather than providing a conductive path through an insulating layer, a conductive structural member may simply extend beyond an insulating layer, and a line in a cable, printed circuit board, or other suitable device can be directly coupled with the exposed structural element. Similar to termination point  580  and traces  581 - 584  of plug  500 , each of traces  862 - 864  on the surface of plug  800  can couple with a line in a cable, a trace on a printed circuit board, or any other suitable electrical line at termination point  880 . For example, termination point  880  can include multiple solder pads  882 - 884  for coupling with various lines in cable  889 . While the embodiment shown in  FIG. 8  includes solder pads for coupling with lines in a cable, it is understood that any other suitable connection technique can be used to couple a termination point with a cable, printed circuit board, or other suitable device. 
     In some embodiments, a plug may electrically couple with a female connector when the plug is inserted into the female connector in the proper orientation. For example, contact pads  251 - 254  of plug  200  may be arranged in a straight line along one side of plug  200  and, for plug  200  to properly couple with a female connector, plug  200  may need to be inserted into the female connector so that the side of the plug with contact pads  251 - 254  is adjacent to an array of contacts in the female connector. Continuing the example, if plug  200  is inserted into the female connector in the wrong orientation, the plug may be unable to properly couple with the female connector because a contact in the female connector may overlap both a contact pad and a nearby trace on the plug (e.g., contact pad  254  and trace  263 ). Such embodiments are referred to herein as “orientation-specific” embodiments because the plug may need to be in a specific orientation to properly couple with a female connector. Plug  200 , plug  400 , and plug  600  may each be considered orientation-specific embodiments. 
     In some orientation-specific embodiments, a plug may be provided on a male connector with a mating surface having a feature (e.g., a key) to ensure that the plug inserts into a female connector in the proper orientation. For example, female connectors on electronic devices or the electronic devices themselves may have a particular geometry and a male connector may include a mating surface with a feature that correspondence to the particular geometry. 
       FIG. 9  includes plug  900  provided on a male connector with a key in accordance with one embodiment. Plug  900  may include protuberance  994  that can serve as a key to prevent plug  900  from coupling with a female connector in an improper orientation. Plug  900  may be any orientation-specific plug. For example, plug  900  may be substantially similar to plug  200  and may include contact pads  951 - 954  (see, e.g., contact pads  251 - 254 ). 
     Plug  900  may be provided on connector  990  for coupling connector  990  with a female connector. Connector  990  can include mating surface  992  adjacent to proximal end  902  of plug  900 . When connector  990  couples with a female connector, mating surface  992  may abut a corresponding mating surface on the female connector. Accordingly, mating surface  992  may include protuberance  994  that may be any shape or size suitable for interfacing with a corresponding feature on a mating surface of a female connector. For example, protuberance  994  may be a raised ridge extending radially from plug axis  905  and a mating surface on a female connector may include a corresponding indentation extending radially from an aperture for receiving plug  900 . With respect to the location of contact pads  951 - 954 , protuberance  994  may be located in a specific location on mating surface  992  so that, when protuberance  994  interfaces with an indentation in a female connector, contact pads  951 - 954  may couple with an array of contacts in the female connector. Accordingly, plug  900  may only couple with a female connector in the proper orientation. 
       FIG. 10  includes plug  1000  provided on a male connector with a key in accordance with one embodiment. Plug  1000  may include protuberance  1094  and rim  1096  that can serve as a key to prevent plug  1000  from coupling with a female connector in an improper orientation. Plug  1000  may be any orientation-specific plug. For example, plug  1000  may be substantially similar to plug  200  and may include contact pads  1051 - 1054  (see, e.g., contact pads  251 - 254 ). 
     Plug  1000  may be provided on connector  1090  for coupling connector  1090  with a female connector. Connector  1090  may be substantially similar to connector  990  of  FIG. 9 . For example, connector  1090  may include mating surface  1092  adjacent to proximal end  1002  of plug  1000 . However, connector  1090  may include protuberance  1094  and rim  1096  for preventing plug  1000  from coupling with a female connector in an improper orientation. When connector  1090  couples with a female connector included in an electronic device, mating surface  1092  may abut a surface of the electronic device that includes the female connector. Accordingly, mating surface  1092  may include protuberance  1094  and rim  1096  that may be any shape or size suitable for interfacing with a surface of the electronic device that includes a female connector. For example, protuberance  1094  may interface with an indentation in the surface of an electronic device that includes a female connector and the edge of the surface may fit within rim  1096 . 
     In some situations, it may be desirable to have a plug that is not orientation specific. For example, an embodiment that is not orientation specific may be easier and quicker to couple because the connectors may not need to be aligned in order to couple together. In some embodiments, a connector that is not orientation specific may include circumferential contacts. For example, a contact could be a ring of conductive material around a circumference of a connector. In such embodiments, each contact can be coupled to a conductive path located below the outer surface of the plug so that it does not couple with any other contacts. For example, traces can be located below the outer surface of the plug and each trace can electrically couple with a single contact pad on the outer surface of the plug. In some embodiments, even though such conductive paths are below the outer surface, the paths may be near the outer surface to allow for a large core structural member. 
       FIGS. 11A-11D  include plug  1100  with traces below but near the outer surface of the plug in accordance with one embodiment. Plug  1100  can be provided on any male connector for coupling with a female connector. Compared to plug  200  of  FIGS. 2A and 2B , plug  1100  can have a similar shape and size and can perform similar functions (e.g., coupling with a female connector). Plug  1100  can include structural member  1110  that may be substantially similar to structural member  210  of plug  200 , although structural member  1110  may be smaller than structural member  210 . However, plug  1100  can include different insulating layers, contact pads and traces. For example, plug  1100  can include, in order from inner core to outer surface, a core structural member, an inner insulating layer, one or more conductive paths, an outer insulating layer, and contact pads. 
     Plug  1100  can include outer insulating layer  1130  that can be formed from a dielectric material. Outer insulating layer  1130  may be formed from ceramic, polycarbonate, polyethylene, polystyrene, or any other suitable dielectric material. Outer insulating layer  1130  can, for example, insulate any contact pads on the outer surface of plug  1100  from each other as well as any conductive paths below the surface of plug  1100 . 
     Plug  1100  can include contact pads  1151 ,  1152 ,  1153 , and  1154  on the outer surface of plug  1100 . Each of contact pads  1151 - 1154  may have a ring or cylindrical shape that extends completely around the circumference of plug  1100 . Contact pads  1151 - 1154  can be formed from a conductive material. For example, contact pads  1151 - 1154  may be formed by depositing a conductive material onto outer insulating layer  1130 . Contact pads  1151 - 1154  may be sufficiently thick enough to withstand forces from mating with a female connector (e.g., frictional forces from inserting plug  1100  in a jack and withdrawing plug  1100  from a jack). In some embodiments, contact pads  1151 - 1154  may protrude from the outer surface of outer insulating layer  1130 . In other embodiments, contact pads  1151 - 1154  may be substantially flush with the outer surface of outer insulating layer  1130 . For example, one or more indentations can be provided in outer insulating layer  1130  (e.g., by chemical or laser etching), and conductive material can be deposited in the indentations to create contact pads  1151 - 1154  substantially flush with the outer surface of outer insulating layer  1130 . Each of contact pads  1151 - 1154  can be sized and shaped to mate with a corresponding contact in a female connector (e.g., a jack). Moreover, the array of contact pads  1151 - 1154  may be arranged to mate with an array of contacts in a female connector. For example, contact pads  1151 - 1154  may be arranged in an order along plug axis  1105  that corresponds to an array of contacts in a female connector. 
     Plug  1100  may not be an orientation-specific embodiment. All of contacts pads  1151 - 1154  extend completely around the circumference of plug  1100  at a particular location on plug axis  1105 . Therefore, each of contact pads  1151 - 1154  will electrically couple with a particular contact in a female connector regardless of the orientation of plug  1100  when it is inserted into the female connector. Because plug  1100  may not be an orientation-specific embodiment, plug  1100  may be provided on a connector without any special features to ensure that plug  1100  is inserted into a female connector in a particular orientation (see, e.g., connector  990  with protuberance  994  and connector  1090  with protuberance  1094  and rim  1096 ). 
     As seen in the cross-section views of  FIGS. 11B-11D , plug  1100  may include an inner insulating layer  1120  between structural member  1110  and outer insulating layer  1130 . Inner insulating layer  1120  may be formed from dielectric material. For example, inner insulating layer  1120  may be formed from ceramic, polycarbonate, polyethylene, polystyrene, or any other suitable dielectric material. In some embodiments, inner insulating layer  1120  may be formed from the same material as outer insulating layer  1130 . Inner insulating layer  1120  can, for example, provide a platform for one or more conductive paths below the surface of plug  1100  (e.g., below outer insulating layer  1130 ) but above structural member  1110 . 
     Plug  1100  may include traces below the outer surface of plug  1100 . For example, as seen in  FIG. 11D , plug  1100  may include traces  1161 - 1164  between inner insulating layer  1120  and outer insulating layer  1130 . Inner insulating layer  1120  may insulate each of traces  1161 - 1164  from other traces and structural member  1110 . Traces  1161 - 1164  can be formed from a conductive material. For example, traces  1161 - 1164  can be formed by depositing a conductive material onto inner insulating layer  1120  before outer insulating layer  1130  is applied. After outer insulating layer  1130  is in place, traces  1161 - 1164  may electrically couple with contact pads above layer  1130  through one or more conductive paths extending through layer  1130 . For example, as seen in  FIG. 11B , trace  1161  may electrically couple with contact pad  1151  through conductive path  1171 , and trace  1163  may electrically couple with contact pad  1153  through conductive path  1173 . Continuing the example, as seen in  FIG. 11C , trace  1162  may electrically couple with contact pad  1152  through conductive path  1172  and, as seen in  FIG. 11D , trace  1164  may electrically couple with contact pad  1154  through conductive path  1174 . Like contact pads  1151 - 1154  and traces  1161 - 1164 , conductive paths  1171 - 1174  can be formed from conductive material. For example, after outer insulating layer  1130  is applied, through-holes can be created at specific points in layer  1130  (e.g., by chemical or laser etching) and conductive material can be applied to fill the through-holes and create conductive paths  1171 - 1174 . Conductive paths  1171 - 1174  can be any suitable structures for conducting electrical current through specific points in layer  1130 , and conductive paths  1171 - 1174  can be formed using any suitable process. Outer insulating layer  1130  may insulate each of traces  1161 - 1164  from other traces and any of conductive paths  1171 - 1174  or any of contact pads  1151 - 1154  to which the traces are not intentionally coupled. 
     In some embodiments, each of traces  1161 - 1164  can be located the same distance from axis  1105  (e.g., at the same radius or radial layer) as the other traces. For example, insulating layer  1120  may be centered around plug axis  1105  so that traces  1161 - 1164  are the same radial distance from plug axis  1105  when deposited on insulating layer  1120 . In other words, traces  1161 - 1164  may all be on the same radial layer. 
     In some embodiments, a plug with conductive paths below but near the surface of the plug may include a structural member with insulating properties (see, e.g., dielectric structural member  410  of plug  400 ) rather than a structural member and an inner insulating layer covering the structural member (see, e.g., structural member  1110  and insulating layer  1120  of plug  1100 ).  FIG. 12  includes plug  1200  with dielectric structural member  1210  in accordance with one embodiment. Plug  1200  can be provided on any male connector for coupling with a female connector. Plug  1200  can be similar to plug  1100  of  FIGS. 11A-D , and plug  1200  may include many of the same elements as plug  1100 . For example, plug  1200  can include contact pads  1251 - 1254  (see, e.g., contact pads  1151 - 1154  of plug  1100 ), traces  1261  and  1263  (see, e.g., traces  1161  and  1163  of plug  1100 ), and conductive paths  1271  and  1273  (see, e.g., conductive paths  1171  and  1173  of plug  1100 ). 
     Unlike plug  1100 , plug  1200  may not include a separate core structural member and inner insulating layer covering the structural member. For example, plug  1200  may include core structural member  1210  that can provide structural integrity while also forming an insulating surface for receiving conductive material. A separate insulating layer may not be necessary if structural member  1210  is formed from a dielectric material. For example, structural member  1210  may be formed from ceramic, polycarbonate, polyethylene, polystyrene, or any other suitable dielectric material. In some embodiments, structural member  1210  may be formed from a rigid dielectric material that will increase the structural integrity of plug  1200 . In some embodiments, structural member  1210  may be a solid piece of rigid dielectric material that is formed by any suitable manufacturing technique. In some embodiments, structural member  1210  may be shaped to increase its structural integrity. For example, structural member  1210  may have a length, width, length-to-width ratio, or any other dimension or characteristic that provides structural integrity. Structural member  1210  may also provide structural integrity by acting as the core or inner member of plug  1200 . 
     In some embodiments, a plug with conductive paths below but near the surface of the plug may include a structural member that functions as a conductive path for a contact pad. For example, a conductive path through multiple insulating layers can electrically couple a contact pad with a structural element (see, e.g., protrusion  612  of plug  600  and conductive path  771  of plug  700 ), and conductive paths through the outermost insulating layer (see, e.g., conductive paths  1172 - 1174  of plug  1100 ) can electrically couple each of the more proximal contact pads with a different trace below the outer surface of the plug that extends towards the proximal end of the plug.  FIG. 13  includes plug  1300  with structural member  1310  functioning as a conductive path in accordance with one embodiment. Plug  1300  can be provided on any male connector for coupling with a female connector. Plug  1300  can be similar to plug  1100  of  FIGS. 11A-D , and plug  1300  may include many of the same elements as plug  1100 . For example, plug  1200  can include contact pads  1351 - 1354  (see, e.g., contact pads  1151 - 1154  of plug  1100 ), trace  1363  (see, e.g., trace  1163  of plug  1100 ), and conductive path  1373  (see, e.g., conductive path  1173  of plug  1100 ). 
     Unlike plug  1100 , plug  1300  may include a conductive path coupling the core structural member of the plug with a contact. For example, plug  1300  may include conductive path  1371  through outer insulating layer  1330  and inner insulating layer  1320 . Accordingly, plug  1300  may not include a conductive path for contact pad  1351  between inner insulating layer  1320  and outer insulating layer  1330  because that electrical signal is being routed through conductive structural member  1310 . 
     Traces  1161 - 1164  may extend at least partially along plug axis  1105  towards proximal end  1102  of plug  1100 . For example, trace  1161  may couple with contact pad  1151 , through conductive path  1171 , and extend directly along plug axis  1105  towards proximal end  1102 . In the embodiment shown in  FIGS. 11B-11D , each of traces  1161 - 1164  may extend directly along plug axis  1105  towards proximal end  1102  because conductive paths  1171 - 1174  are each on different sides of plug  1100 . However, in embodiments, where two or more conductive paths are on the same side of a plug, the trace coupled with the more distal conductive path may extend at least partially around the plug axis to avoid the other conductive path and trace before extending along the plug axis towards the proximal end of the plug. 
     In embodiments where conductive paths are located below the surface of the plug, the plug&#39;s terminating point may include one or more conductive paths for coupling a cable, printed circuit board, or other suitable device (e.g., cable  189  of  FIG. 1A ) with the conductive paths below the surface.  FIG. 14  includes plug  1400  with termination point  1480  in accordance with one embodiment. Plug  1400  can be provided on any male connector for coupling with a female connector. Plug  1400  can be similar to plug  1100  of  FIGS. 11A-11D , plug  1200  of  FIG. 12 , and plug  1300  of  FIG. 13 . Plug  1400  may include many of the same elements as plugs  1100 ,  1200 , and  1300 . For example, plug  1400  can include contact pads  1451 - 1454  (see, e.g., contact pads  1151 - 1154  of plug  1100 ) and traces underneath the outer surface of the plug (see, e.g., traces  1161 - 1164  of plug  1100 , traces  1261  and  1263  of plug  1200 , and traces  1363  of plug  1300 ). Each of the traces underneath the surface of plug  1400  can extend along plug axis  1405  towards proximal end  1402  of plug  1400 . Plug  1400  may include termination point  1480  at proximal end  1402  of the plug. Termination point  1480  may include conductive paths through insulating layer  1430  to electrically couple the traces underneath the surface of plug  1400  with a cable, printed circuit board, or other suitable device. The conductive paths through insulating layer  1430  may be substantially similar to conductive path  771  of plug  700 , and the description of the latter can be applied to the former. In some embodiments, termination point  1480  may include conductive vias and solder pads  1481 - 1483  to couple traces under the surface of plug  1400  with lines in cable  1489 . In embodiments where a plug&#39;s core structural member serves as a conductive path (see, e.g., structural member  1310  of plug  1300 ), termination point  1480  can include a conductive path through all insulating layers (see, e.g., outer insulating layer  1330  and inner insulating layer  1320  of plug  1300 ) to electrically couple the conductive structural member with a cable, printed circuit board, or other suitable device. Moreover, rather than providing a conductive path through an insulating layer, the structural member, inner insulating layer and traces may simply extend beyond the outer insulating layer in some embodiments, and a line in a cable, printed circuit board, or other suitable device can be directly coupled with the exposed traces. While the embodiment shown in  FIG. 14  include solder pads for coupling with lines in a cable, it is understood that any other suitable connection technique can be used to couple a termination point with a cable, printed circuit board, or other suitable device. 
       FIG. 15  includes process  1500  for manufacturing a plug in accordance with one embodiment. Process  1500  can be used to form an orientation-specific plug such as, for example, plug  200  of  FIGS. 2A and 2B , plug  400  of  FIG. 4 , or plug  600  of  FIGS. 6A and 6B . Prior to performing process  1500 , a structural member (see, e.g., structural member  210  of plug  200  or structural member  610  of plug  600 ) can be formed. For example, a structural member can be formed by turning, machining, forging, casting, any other suitable manufacturing technique, or any combination thereof. 
     At block  1510 , a layer of dielectric material may be applied to an outer surface of a structural member to cover a portion of the structural member that extends along a plug axis. For example, a layer of dielectric material (see, e.g., insulating layer  220 ) can be applied to the outer surface of a structural member (see, e.g., structural member  210 ) to cover the portion of the member that extends along the plug axis towards the distal end of the plug (see, e.g., plug axis  205  and distal end  204 ). In some embodiments, a layer of dielectric material can be applied to the entire outer surface of a structural member to cover the entire structural member. A layer of dielectric material may be applied to an outer surface of a structural member using any suitable technique at block  1510 . For example, dielectric material may be sprayed or painted onto the outer surface of the structural member to create a layer. In another example, the structural member may be at least partially dipped into a pool of liquid dielectric material and then, after the member is removed from the pool, heat may be applied to harden the liquid coating and form a layer. 
     At block  1520 , a conductive material may be applied to the layer of dielectric material to form contact pads and traces. For example, a conductive material can be applied to the surface of the layer of dielectric material (see, e.g., insulating layer  220 ) to form contact pads for coupling with a female connector (see, e.g., contact pads  251 - 254 ) and traces that serve as conductive paths (see, e.g., traces  261 - 264 ). At least one of the traces formed at block  1520  can electrically couple with one of the contact pads and extend along the plug axis (see, e.g., trace  261  coupling with contact pad  251  and extending along plug axis  205 ). In some embodiments, at least one of the traces formed at block  1520  may extend at least partially around the plug in addition to extending along the plug axis (see, e.g., trace  261  extending partially around plug  200  to avoid the other contact pads and traces). 
     Any suitable technique for applying a conductive material can be used to form contact pads and traces at block  1520 . For example, a conductive material can be applied using a technique that includes depositing, sputtering, painting, gluing, adhering, spray-coating, immersion-coating, any other suitable technique, or any combination thereof. Moreover, in some embodiments, contact pads may be formed at block  1520  using a technique different from the technique used to form traces at block  1520 . 
     In some embodiments, a conductive material can be applied to the layer of dielectric material to form contact pads and/or traces by sputter deposition or physical vapor deposition (PVD). In some embodiments, the layer of dielectric material can be selectively etched in locations for contact pads and/or traces and the etched areas can be plated with conductive material (e.g., a metal or an alloy) at block  1520 . For example, the layer of dielectric material can be selectively etched using a laser. In some embodiments, one or more indentations may be created in the layer of dielectric material before applying conductive material at block  1520 . For example, one or more indentations may be etched into the dielectric material at the locations for contact pads and traces and conductive material can be applied to fill in the indentations and form contact pads and traces. 
     In some embodiments, a mask with apertures corresponding to the locations for contact pads and/or traces can applied to the layer of dielectric material at block  1520 . Conductive material can then be applied over the mask, and the mask can be removed to form contact pads and/or traces. In other embodiments, a uniform coat of conductive material can be applied to the layer of dielectric material at block  1520 , and then sections of the conductive material can be removed (e.g., using chemical or laser etching) to form contact pads and/or traces. In some embodiments, conductive ink can be printed in a pattern on the layer of dielectric material to form contact pads and/or traces at block  1520 . For example, a printer can print conductive ink onto the layer of dielectric material and an oven can be used to heat the structural member and harden the conductive ink. 
     In some embodiments, the contact pads and traces formed at block  1520  may have the same thickness. For example, the contact pads (see, e.g., contact pads  251 - 254 ) and traces (see, e.g., traces  261 - 264 ) may protrude the same distance from the dielectric material (see, e.g., insulating layer  220 ). In other embodiments, the contact pads may be thicker than the traces because the contact pads may need to withstand forces from mating with a female connector (e.g., frictional forces from inserting plug  200  in a jack and withdrawing plug  200  from a jack). 
     In some embodiments, process  1500  can include applying multiple layers of material to form contact pads and/or traces. For example, process  1500  can include providing multiple layers of the same conductive material to form contact pads and/or traces. In some embodiments, process  1500  can include providing multiple layers of different materials to form contact pads and/or traces. For example, process  1500  can include applying a first type of material to form a bottom layer of contact pads and/or traces and then applying a second type of material to form a top layer of contact pads and/or traces. In one example, the first type of material can be a material that forms a texture for receiving the second type of material that serves as the primary conductor. In another example, the first type of material can be a primary conductor and the second type of material can be relatively smooth to reduce frictional forces when the plug is inserted and removed from jacks. 
     A trace formed at block  1520  may electrically couple with one of the contact pads using any suitable physical connection. In some embodiments, a trace may be a continuous extension of a contact pad and may, therefore, be electrically coupled with the contact pad. In some embodiments, a trace may abut the edge of a contact pad to electrically couple with the contact pad. In some embodiments, a contact pad may overlap at least a portion of a trace to electrically couple with the trace. For example, conductive material may be applied to form the trace before conductive material is applied to form the contact pad, and the contact pad may overlap at least a portion of the trace. 
     In some embodiments, a plug can include a structural member with insulating properties (see, e.g., structural member  410  of plug  400 ). Accordingly, a process for forming a plug in accordance with such embodiments may not include applying a layer of dielectric material to an outer surface of a structural member (see, e.g., block  1510 ). For example, a process for forming a plug with a structural member having insulating properties (see, e.g., structural member  410  of plug  400 ) may simply include applying a conductive material to the structural member to form contact pads and traces. At least one of the traces may be electrically coupled with one of the contact pads and extend along a plug axis. 
       FIG. 16  includes process  1600  for manufacturing a plug in accordance with one embodiment. Process  1600  can be used to form a plug that is not orientation-specific. For example, process  1600  can be used to form plug  1100  of  FIGS. 11A-11D . Prior to performing process  1600 , a structural member (see, e.g., structural member  210  of plug  200  or structural member  1110  of plug  1100 ) can be formed. For example, a structural member can be formed by turning, machining, forging, casting, any other suitable manufacturing technique, or any combination thereof. 
     At block  1610 , a first layer of dielectric material (see, e.g., layer  1120  of plug  1100 ) may be applied to an outer surface of a structural member to cover a portion of the structural member that extends along a plug axis. Block  1610  may be substantially similar to block  1510  of process  1500  and the previous description of the latter can be applied to the former. 
     At block  1620 , a conductive material can be applied to the first layer of dielectric material to form traces. At least one of the traces formed at block  1620  may extend along the plug axis. For example, a conductive material can be applied on top of the first layer of dielectric material (see, e.g., layer  1120  of plug  1100 ) to form traces that serve as conductive paths along the plug axis (see, e.g., traces  1161 - 1164  extending along plug axis  1105 ). In some embodiments, at least one of the traces formed at block  1620  may extend at least partially around the plug in addition to extending along the plug axis. Any suitable method for applying a conductive material can be used to form traces at block  1620  (see, e.g., discussion related to applying a conductive material to form contact pads and traces at block  1520  of process  1500 ). 
     At block  1630 , a second layer of dielectric material (see, e.g., layer  1130  of plug  1100 ) can be applied over the first layer and the traces. In some embodiments, the second layer of dielectric material can be applied in block  1630  using a method substantially similar to the method used to apply dielectric material in block  1510  of process  1500 . Accordingly, the previous description of applying dielectric material in block  1510  can be applied to applying a second layer of dielectric material in block  1630 . After block  1630 , the traces formed at block  1620  may be below the surface of the plug (see, e.g., traces  1161 - 1164  below layer  1130 ). 
     At block  1640 , a conductive material can be applied to the second layer of dielectric material to form contact pads (see, e.g., contact pads  1151 - 1154  of plug  1100 ). For example, a conductive material can be applied on top of the second layer of dielectric material (see, e.g., layer  1130 ) to form contact pads for coupling with a female connector (see, e.g., contact pads  1151 - 1151 ). Any suitable method for applying a conductive material can be used to form contact pads at block  1640  (see, e.g., discussion related to applying a conductive material to form contact pads and traces at block  1520  of process  1500 ). 
     At least one of the contact pads formed at block  1640  can electrically couple with one of the traces formed at block  1620  through the second layer of dielectric material. For example, one or more conductive paths (see, e.g., conductive paths  1171 - 1174 ) may extend through the second layer of dielectric material to electrically couple a contact pad with one of the traces. Like the traces formed at block  1620  and the contact pads formed at block  1640 , conductive paths through the second layer of dielectric material can be formed from conductive material. For example, after a second layer of dielectric material is applied at block  1630 , through-holes can be created at specific points in the second layer (e.g., by chemical or laser etching) and conductive material can be applied to fill the through-holes and create conductive paths. At block  1640 , conductive material can be applied to create contact pads on top of such conductive paths through the second layer of dielectric material. It is understood that any suitable structure for conducting electrical current through specific points in a dielectric layer can function as a conductive path through the second layer of dielectric material. Moreover, such conductive paths can be formed using any suitable process. 
     While the above description occasionally refers to embodiments of audio plugs and methods for manufacturing audio plugs, it is understood that the plug and methods of manufacture can be applied to any type of plug for transmitting any type of electrical signal. For example, the above description can be applied to plugs for transmitting electrical power, data, audio, or any combination of the above between electronic devices. 
     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. 
     The above described embodiments are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20090605
Publication Date: 20110419
Grant Date: 20110419
Priority Date: 20090605
Inventors: PREST CHRISTOPHER D.
ROHRBACH MATTHEW
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/035", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/59", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/035", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/59", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 42310669