PATENT DOCUMENT

Publication Number: US-9331422-B2
Application Number: US-201414299921-A
Country: US
Kind Code: B2

Title: Electronic device with hidden connector

Abstract:
An electronic device has a self-healing elastomer applied over one or more external electronic connectors. The self-healing elastomer may obscure the electronic connectors from the user as well as provide environmental protection for the connector and the electronic device. Electronic probes may temporarily penetrate the self-healing elastomer to mate with the electronic connector. After removal of the probes the self-healing elastomer may elastically reform and self-heal.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a housing having an opening; 
 electronic circuitry disposed within the housing; 
 an electrical connector operatively coupled to the electronic circuitry, the electrical connector comprising a plurality of contacts accessible through the opening in the housing; and a layer of self-healing elastomer having one or more conductively doped regions, the layer arranged to cover the opening and the plurality of contacts. 
 
     
     
       2. The electronic device of  claim 1  wherein a sidewall of the opening has a retention feature formed in it to anchor the self-healing elastomer to the housing. 
     
     
       3. The electronic device of  claim 1  wherein there is one conductively doped region for each contact of the plurality of contacts. 
     
     
       4. The electronic device of  claim 1  wherein the self-healing elastomer comprises silicone. 
     
     
       5. The electronic device of  claim 1  wherein the self-healing elastomer regains at least 50 percent of its tensile strength in a penetration region after penetration by an electronic probe. 
     
     
       6. The electronic device of  claim 1  wherein the self-healing elastomer reforms a water resistant barrier in a penetration region after penetration by an electronic probe. 
     
     
       7. The electronic device of  claim 1  wherein the plurality of contacts comprises a power contact, a ground contact and a pair of data contacts. 
     
     
       8. The electronic device of  claim 1  wherein the plurality of contacts are disposed on a substrate and are connected by electrical traces to the electronic circuitry. 
     
     
       9. The electronic device of  claim 1  further comprising a display operatively coupled to the electronic circuitry. 
     
     
       10. The electronic device of  claim 1  wherein the electronic device is a portable media player. 
     
     
       11. The electronic device of  claim 1  wherein the electronic device is a wearable device. 
     
     
       12. The electronic device of  claim 11  wherein the housing is curved and shaped to be worn on a user&#39;s wrist. 
     
     
       13. The electronic device of  claim 1  wherein the electrical connector includes a plurality of contacts spaced apart along a depth of the connector. 
     
     
       14. The electronic device of  claim 13  wherein the one or more conductively doped regions within the self-healing elastomer are disposed over each of the plurality of the contacts. 
     
     
       15. An electronic device comprising:
 a housing having an opening; 
 electronic circuitry disposed within the housing; 
 
       an electrical connector operatively coupled to the electronic circuitry, the electrical connector comprising a cavity having a plurality of contacts sequentially positioned within and spaced apart along a depth of the cavity and accessible through the opening in the housing; and 
       a layer of self-healing elastomer that includes one or more conductively doped regions is disposed over each of the plurality of contacts. 
     
     
       16. The electronic device of  claim 15  wherein the one or more conductively doped regions are disposed over each of the plurality of the contacts. 
     
     
       17. The electronic device of  claim 15  wherein a layer of self-healing elastomer is disposed over the opening. 
     
     
       18. An electronic device comprising;
 a housing having an opening; 
 a substrate disposed adjacent to the housing, the substrate having one or more electrically conductive contacts arranged to be accessible through the opening; and 
 a self-healing elastomer disposed over the one or more contacts and comprising one or more conductively doped regions, the elastomer having a penetration region that is temporarily penetrable by one or more probes, the elastomer capable of reforming chemical bonds in the penetration region after the one or more probes are removed such that at least 50 percent of the self-healing elastomer&#39;s tensile strength is regained in the penetration region. 
 
     
     
       19. The electronic device of  claim 1  wherein one of the one or more conductively doped regions is in electrical contact with one of the plurality of contacts and extends from the contact through a thickness of the self-healing elastomer to a location that is below an exterior surface of the self-healing elastomer. 
     
     
       20. The electronic device of  claim 1  wherein the one or more conductively doped regions comprise electrically conductive particulates.

Description:
FIELD 
     The present invention relates generally to electronic devices and in particular to electronic devices that include one or more electrical connectors that enable connection to an external device. 
     BACKGROUND 
     A wide variety of electronic devices are available for consumers today that employ a broad range of external electronic connectors to facilitate communication with other devices and/or charging of the device. 
     As an example, audio jack and data connectors are sometimes positioned on one or more of the external surfaces of an electronic device and mounted to a printed circuit board (PCB) within the device. As smart-phones, media players, charging stations and other electronic devices are reduced in size, external connectors may consume a large proportion of the outside surface of the device, marring its aesthetic appeal. Additionally, as electronic devices become more indispensable to their operators, the devices are with their operators more frequently and are more likely to be exposed to harsh environments that may damage the connectors and the electronic device. 
     For example, miniature portable media players may be equipped with wireless communication and/or charging systems to increase their appeal to consumers. As wireless connections become more and more prevalent, an electrical connector on a device may be used less frequently. In some applications electronic devices may still require at least one external electrical connector for data exchange or charging when a wireless connection is not available and/or for diagnostic and repair purposes. In addition, the portable media player may frequently be with the consumer and exposed to rain and other harsh environments. 
     SUMMARY 
     Embodiments of the invention pertain to electrical connectors for use with a variety of electronic devices. In some embodiments, the electrical connectors are configured to be equipped with a self-healing barrier layer providing an aesthetic covering for the connector as well as protection for the contacts within the connector and for circuitry within the device housing. 
     One particular embodiment employs a connector having a plurality of contacts accessible through an opening in the housing of the electronic device. The connector is operatively coupled to electronic circuitry within the housing. A layer of self-healing elastomer covers the opening in the housing providing an aesthetic covering for the connector as well as environmental protection for the connector and the electronic device. In some embodiments the self-healing elastomer extends over the housing beyond the opening. In other embodiments the self-healing elastomer may be disposed only within the opening in the housing. One or more electrical probes may temporarily penetrate the self-healing elastomer to make contact with the connector contacts. After the electrical probes are removed, the self-healing elastomer may heal, regaining all, most or at least some of its aesthetic and protective properties. 
     Other embodiments may incorporate one or more conductively doped regions within the self-healing elastomer. The conductively doped regions may be disposed over each of the plurality of contacts of the connector. The electrical probes may then penetrate the self-healing elastomer and make contact with the conductively doped regions. The conductively doped regions may include conductive particulates such as, but not limited to, silver, gold, palladium, copper or metal coated spheres. In this embodiment, electrical current may pass through the electrical probe, through the conductively doped region to the connector contact. 
     In further embodiments an electronic connector with a plurality of contacts may be installed within the housing of an electronic device. The plurality of contacts may be accessible through an opening in the housing. The connector may have a cavity wherein the plurality of contacts are sequentially positioned within and spaced apart along the depth of the cavity. A layer of self-healing elastomer may be disposed over each of the plurality of contacts. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front perspective view of an electronic device according to an embodiment of the invention; 
         FIG. 2  is a rear perspective view of the electronic device shown in  FIG. 1  with an audio connector and a data connector; 
         FIG. 3  is a plan view of the electrical connector shown in  FIG. 1  covered by a self-healing elastomer and accessible through an opening in the device housing; 
         FIG. 4  is a cross-sectional view of the electrical connector shown in  FIG. 3  before probe penetration; 
         FIG. 5  is a cross-sectional view of the electrical connector shown in  FIG. 3  during probe penetration; 
         FIG. 6  is a cross-sectional view of the electrical connector shown in  FIG. 3  after probe penetration; 
         FIG. 7  is a plan view of an electrical connector covered by a self-healing elastomer with conductively doped regions according to an embodiment of the invention; 
         FIG. 8  is a cross-sectional view of the electrical connector shown in  FIG. 7  before probe penetration; 
         FIG. 9  is a cross-sectional view of the electrical connector shown in  FIG. 7  during probe penetration; 
         FIG. 10  is a cross-sectional view of the electrical connector shown in  FIG. 7  after probe penetration; 
         FIG. 11  is a cross-sectional view of an opening in a housing filled with a self-healing elastomer according to an embodiment of the invention; 
         FIG. 12  is a cross-sectional view of an opening in a housing filled with a self-healing elastomer according to an embodiment of the invention; 
         FIG. 13A  is a side view of an electrical probe according to an embodiment of the invention; 
         FIG. 13B  is a side view of an electrical probe according to an embodiment of the invention; 
         FIG. 13C  is a side view of an electrical probe according to an embodiment of the invention; 
         FIG. 14  is a perspective view of an audio plug connector according to an embodiment of the invention; 
         FIG. 15  is a perspective view of an audio plug connector according to an embodiment of the invention; 
         FIG. 16  is an exploded perspective view of an audio receptacle connector according to an embodiment of the invention; 
         FIG. 17  is a cross-sectional view of an audio connector installed in a housing having a self-healing elastomer barrier layer according to an embodiment of the invention; 
         FIG. 18  is a cross-sectional view of an audio connector installed in a housing having a self-healing elastomer barrier layer with conductively doped regions over the connector contacts according to an embodiment of the invention; 
         FIG. 19  is a cross-sectional view of an audio connector installed in a housing having a self-healing elastomer barrier layer with conductively doped regions over the connector contacts according to an embodiment of the invention; and 
         FIG. 20  is a method for mating a data or audio connector with an external connector on an electronic device having a self-healing layer. 
     
    
    
     DETAILED DESCRIPTION 
     Certain embodiments of the present invention relate to electronic devices. While the present invention can be useful for a wide variety of electronic devices, some embodiments of the invention are particularly useful for electronic devices that have a layer of self-healing elastomer disposed over one or more external electronic connectors, as described in more detail below. 
       FIG. 1  depicts a simplified diagram of an example electronic device  100  that may incorporate an embodiment. Device  100  is used for illustration only; the concepts/techniques of the invention can be employed in myriad electronic devices. For example, it is understood that embodiments of the invention are not limited to smartphones and may be employed in any type of electronic device including, but not limited to, wrist watches, portable media players, notebook computers, docking stations, desktop computers, portable radios, televisions, and set top boxes. 
     In the embodiment depicted in  FIG. 1 , electronic device  100  includes a front face  105  having a display screen  110 , a sensor  115 , a speaker  120 , a home button  125 , an audio connector  130  and a microphone  131 . In some embodiments sensor  115  may be a camera, an infra-red detector or an ultrasonic detector. Although the embodiment in  FIG. 1  shows only one display screen, sensor, speaker, home button, audio connector and microphone, it is understood that myriad configurations and quantities of these features are possible without departing from the invention. Electronic device  100  also includes on/off switch  132  and volume buttons  133   a ,  133   b.    
       FIG. 2  depicts a simplified diagram of the rear of electronic device  100 . Electronic device  100  includes housing  150  configured to be a rectangular prism having a back face  135  positioned opposite front face  105 . In other embodiments, housing  150  may be shaped differently, for example in one embodiment the housing is curved and shaped to be worn on a user&#39;s wrist. Electronic circuitry  134  is disposed within housing  150  and is coupled to display screen  110 , sensor  115 , speaker  120 , home button  125 , audio connector  130 , microphone  131 , on/off switch  132  and volume buttons  133   a ,  133   b .  FIG. 2  also depicts an audio plug connector  145  that is matable with audio connector  130 , and data plug connector  155  that is matable with data connector  140 . In certain embodiments, one or more of connectors  130 ,  140  may employ an embodiment of the invention. Embodiments of the invention may be used on a variety of different electrical connectors. 
       FIG. 3  depicts a simplified close up plan view of data connector  140  and a portion of housing  150  (see  FIG. 2 ), and  FIG. 4  illustrates a simplified cross-section (see section A-A in  FIG. 3 ) through one of plurality of contacts  310 . Housing  150  has an opening  305 . Data connector  140  is operatively coupled to electronic circuitry  134  (see  FIG. 2 ) within housing  150 . Data connector  140  includes plurality of contacts  310  disposed on a substrate  410  and accessible through opening  305 . Although plurality contacts  310  are illustrated as four circular pads arranged in a linear pattern, the plurality of contacts may be of any number, any shape and any pattern. Further, in some embodiments, plurality of contacts  310  may not be pads, but may be other electrical contacts, such as, but not limited to blade-type connectors, sliding-type connectors or cylindrical-type pin and socket connectors. Substrate  410  may be a part of electronic circuitry  134  (see  FIG. 2 ) disposed within housing  150 . 
     Unlike in a typical electrical connector in which the contacts are exposed for an electrical connection to a corresponding connector, contacts  310  are buried beneath a layer of self-healing elastomer  315  which covers opening  305  and plurality of contacts  310 . Elastomer  315  thus provides a strong environmental seal that protects contacts  310  from the environment including dust, debris, moisture and gas and prevents the contacts from being accessed without a tool or corresponding connector that can penetrate self-healing elastomer  315 . In some embodiments, self-healing elastomer  315  may be filled with a pigment and blended with housing  150  such that it may appear contiguous with the housing and be substantially imperceptible thus hiding the connector such that a user may not even realize the electronic device even has an external connector. 
     In some embodiments self-healing elastomer  315  extends over housing  150 , beyond opening  305 . In other embodiments self-healing elastomer  315  may be disposed only within opening  305  and may not extend over housing  150 . The size and thickness of self-healing elastomer  315  may depend on the size of opening  305 , which in turn is dependent on the size and shape of connector  140  and the thickness of housing  150 . In some embodiments where it is desirable for electronic device  100  to be thin, self-healing elastomer  315  may be less than 0.5 mm thick. In other embodiments self-healing elastomer  315  may be between 0.5 mm to 0.1 mm thick. In further embodiments self-healing elastomer  315  may be between 0.1 mm to 0.2 mm thick. In yet further embodiments self-healing elastomer  315  may be greater than 0.2 mm thick. In other embodiments the thickness of self-healing elastomer  315  may be greater than 0.5 mm. 
     Self-healing elastomer  315  may be a polymer with elastic properties such as a low Young&#39;s modulus and a high failure strain. In further embodiments, self-healing elastomer  315  may comprise a silicone material, also known as a polymerized siloxane. In some embodiments, the polymerized siloxane may be mixed inorganic-organic polymers with the chemical formula [R2SiO]n, where R is an organic group such as methyl, ethyl, or phenyl. In these embodiments the silicone material may comprise an inorganic silicon-oxygen backbone with organic side groups attached to the silicon atoms. In further embodiments self-healing elastomer  315  may include one or more materials that change its color. In some embodiments self-healing elastomer  315  may approximately match a color of housing  150 . Other formulations may be used without departing from the invention. 
     As illustrated in  FIG. 4 , plurality of contacts  310  may be disposed on substrate  410  and connected by electrical traces  415  to electronic circuitry  134  (see  FIG. 2 ). During normal operation self-healing elastomer  315  may provide an aesthetic cover over connector  140  and opening  305 . That is, the user may not be able to discern connector  140  upon a casual inspection of electronic device  100 . In some embodiments, self-healing elastomer  315  may provide a protective barrier for and/or a hermetic around opening  305  thus providing protection for connector  140 , contacts  310  and housing  150  against debris, water, water vapor, and/or gasses. moisture and such that water and debris may not penetrate the self-healing elastomer. 
     To manufacture electronic device  100  with self-healing elastomer  315 , the self-healing elastomer may be applied to housing  150  in liquid form and cured in place. In other embodiments, self-healing elastomer  315  may be insert-molded on housing  150 . In further embodiments, self-healing elastomer  315  may be pre-molded and subsequently attached to housing  150  with an adhesive or by other means. In some embodiments, housing  150  includes one or more retention features formed in the sidewall of the housing around opening  150  that helps improve adhesion between the elastomer and sidewall thus better secure self-healing elastomer  315  to the housing as described below in conjunction with  FIG. 11 . Myriad methods may be used to form self-healing elastomer  315  and attach it to housing  150  without departing from the invention. 
     Reference is now made to  FIGS. 5 and 6 , which illustrate simplified cross-sectional views of connector  140  and self-healing elastomer  315  during penetration by an electronic probe  405  and after removal of the electronic probe, respectively. In some embodiments, electronic probe  405  may be integrated within data plug connector  155  (see  FIG. 2 ) while in other embodiments it may be a separate device. In further embodiments there may be as many electronic probes within data plug connector  155  (see  FIG. 2 ) as there are contacts  310 . 
     As illustrated in  FIGS. 5 and 6 , electronic probe  405  may be relatively thin and generally pointed with a sharp tip to penetrate self-healing elastomer  315  and make an electrical connection with contacts  310 . In some embodiments, contacts  310  may be metallic and may be plated with one or more layers of metal including, but not limited to gold, silver, palladium or tin. 
     When electrical probe  405  is engaged with connector contact  310 , electrical current may pass between electrical probe  405  and contact  310  through trace  415  to electrical circuitry  134  (see  FIG. 2 ) disposed within housing  150 . In some embodiments data and/or power may be transferred to and from electronic device  100  by one or more electrical probes  405  disposed within data plug  155  (see  FIG. 2 ). More specifically, in some embodiments plurality of contacts  310  may comprise a power contact, a ground contact and a pair of data contacts. Other embodiments may have different configurations for contacts  310 . For example, in one embodiment contacts  310  may not transfer data or power, but may simply be shorted together to perform a reset function or other operation on electronic device  100  (see  FIG. 1 ). Contacts  310  may have myriad configurations and purposes without departing from the scope of the invention. 
       FIG. 6  illustrates self-healing elastomer  315  after electrical probe  405  has been removed. As illustrated, self-healing elastomer  315  heals in the penetration region after removal of electrical probe  405 . As defined herein, heals shall mean that self-healing elastomer  315  may reseal itself and regain at least some of its aesthetic, mechanical and/or protective properties. That is, in some embodiments self-healing elastomer  315  may elastically resume its prior shape, resuming its aesthetic appearance prior to penetration. In further embodiments, self-healing elastomer  315  may also resume providing a water resistant barrier and/or debris protection for contacts  310  and housing  150 . 
     Because of its self-healing nature, elastomer  315  may be penetrated multiple times by electrical probe  405  while retaining its protective properties. In some embodiments, self-healing elastomer may “heal” by reforming chemical bonds, regaining at least some of its mechanical properties in the penetration region. In yet further embodiments, self-healing elastomer  315  may reform covalent bonds in the penetration region and regain at least 30 percent of its tensile strength in the penetration region. In other embodiments, it may regain at least 50 percent of its tensile strength in the penetration region. In further embodiments it may regain at least 70 percent of its tensile strength in the penetration region. In yet further embodiments it may regain at least 90 percent of its tensile strength in the penetration region. In some embodiments the recovery of tensile strength may be temperature dependent. For example, in some embodiments recovery may occur between 44 and 92 degrees centigrade. In other embodiments the recovery of tensile strength may be temperature dependent and may improve with an increase in temperature. In some embodiments the recovery of tensile strength may occur between 52 and 84 degrees centigrade. In other embodiments the recovery of tensile strength may occur between 60 and 76 degrees centigrade. In further embodiments the recovery of tensile strength may occur at approximately 68 degrees centigrade. In some embodiments self-healing elastomer  315  may be applied to housing  150 , and while in a partially cured condition it may be penetrated by electrical probe  405  and fully cured after removal of the electrical probe. 
       FIG. 7  depicts a simplified close up plan view of another embodiment of the invention showing data connector  740  having a plurality of contacts  710  and a self-healing elastomer  715 . Data connector  740  may be employed on electronic device  100  (see  FIG. 1 ) or any other electronic device. Electronic device  100  is used for example only and is not intended to be limiting. In this embodiment, plurality of contacts  710  are conductively doped regions  716 , which will be described in more detail below.  FIG. 8  illustrates a simplified cross-section (see section B-B in  FIG. 7 ) through one of plurality of contacts  710 . Housing  150  has an opening  705 . Data connector  740  is operatively coupled to electronic circuitry within housing  150 . Data connector  740  includes a plurality of contacts  710  connected to substrate  810  and accessible through opening  705 . Although plurality contacts  710  are illustrated as four circular conductively doped regions  716  arranged in a linear pattern, the plurality of contacts may be of any number, any shape and any pattern. Substrate  810  may be a part of electronic circuitry  134  (see  FIG. 2 ) disposed within housing  150 . 
     A layer of self-healing elastomer  715  covers opening  705  and plurality of contacts  710 . In some embodiments self-healing elastomer  715  extends over housing  150 , beyond opening  705 . In other embodiments self-healing elastomer  715  may be disposed only within opening  705  and may not extend over housing  150 . The size and thickness of self-healing elastomer  715  may depend on the size of opening  705 , which in turn is dependent on the size and shape of connector  740  and the thickness of housing  150 . Self-healing elastomer  715  may entirely cover opening  705  such that plurality of contacts  710  cannot be seen. In further embodiments, self-healing elastomer  715  may be filled with a pigment and blended with housing  150  such that it may appear contiguous with the housing and substantially imperceptible. In some embodiments where the thickness of the electronic device is critical, self-healing elastomer  715  may be less than 0.5 mm thick. In other embodiments self-healing elastomer  715  may be between 0.5 mm to 0.1 mm thick. In further embodiments self-healing elastomer  715  may be between 0.1 mm to 0.2 mm thick. In yet further embodiments self-healing elastomer  715  may be greater than 0.2 mm thick. In other embodiments the thickness of self-healing elastomer  715  may be greater than 0.5 mm. 
     As discussed above, self-healing elastomer  715  may be a polymer with elastic properties such as a low Young&#39;s modulus and a high failure strain. In further embodiments self-healing elastomer  715  may include one or more materials that change its color. In some embodiments self-healing elastomer  715  may approximately match a color of housing  150 . Other formulations may be used without departing from the invention. 
     To manufacture electronic device  100  (see  FIG. 1 ) with self-healing elastomer  715 , the self-healing elastomer may be applied to housing  150  in liquid form and cured in place. In other embodiments, self-healing elastomer  715  may be insert-molded on housing  150 . In further embodiments, self-healing elastomer  715  may be pre-molded and subsequently attached to housing  150  with an adhesive or by other means. To form plurality of contacts  710  using conductively doped regions  716 , conductive particulates such as, but not limited to, silver, gold, palladium, copper or metal coated spheres may be introduced into self-healing elastomer  715 . 
     More specifically, in one embodiment, electrically conductive particulates may be dispersed in self-healing elastomer  715  by a dispenser or other method before it is cured. In another embodiment a mixture of an elastomer and conductive particulates may be dispersed in self-healing elastomer  715  by a dispenser or other method before it is cured. In other embodiments, conductively doped regions  716  may be formed by first casting or molding the conductively doped regions, then forming self-healing elastomer  715  around the conductively doped regions. In yet further embodiments, self-healing elastomer  715  and conductively doped regions  716  may be manufactured from multiple sequentially deposited layers in a laminate format. That is, in one embodiment each layer may be 0.1 mm thick and thus a 0.5 mm thick self-healing elastomer  715  may be made from approximately five layers. The layers may employ the self-healing nature of elastomer  715  to bond together. Myriad methods may be used to form self-healing elastomer  715  and attach it to housing  150  without departing from the invention. Conductively doped regions  716  may be in electrical contact with an exposed region  706  of trace  725 . Conductively doped regions  716  may not be visible from the outside of electronic device  100  (see  FIG. 1 ). 
       FIG. 8  illustrates a cross-sectional view self-healing elastomer  715  on device  100  (see  FIG. 1 ) while in a normal operating state, and  FIGS. 9 and 10  illustrate cross-sectional views of the self-healing elastomer during penetration by electronic probe  905  and after removal of the electronic probe, respectively. In some embodiments, electronic probe  905  may be integrated within data plug connector  155  (see  FIG. 2 ) while in other embodiments it may be a separate device. In further embodiments there may be as many electronic probes within data plug connector  155  (see  FIG. 2 ) as there are contacts  710 . 
     As illustrated in  FIG. 8 , plurality of contacts  710  may be connected to substrate  810  and coupled by electrical traces  725  to electronic circuitry  134  (see  FIG. 2 ). During normal operation self-healing elastomer  715  may provide an aesthetic cover over connector  740  including plurality of contacts  710  and opening  705 . That is, one may not be able to discern connector  740  upon a casual inspection of electronic device  100  (see  FIG. 1 ). 
     In other embodiments, self-healing elastomer  715  may provide moisture and debris protection for connector  740 , contacts  710  and housing  150  such that water and debris may not penetrate the self-healing elastomer. In further embodiments, self-healing elastomer  715  may provide a barrier against water vapor and in yet further embodiments may provide a hermetic seal (i.e., impervious to gasses). Self-healing elastomer  715  may be sufficiently bonded to housing  150  such that the self-healing elastomer also provides a protective barrier for opening  705  against debris, water, water vapor, and/or gasses. 
     As illustrated in  FIGS. 9 and 10  electronic probe  905  may be generally pointed with a sharp tip to penetrate self-healing elastomer  715  and make an electrical connection with contacts  710 . In this embodiment, contacts  710  may consist of one or more conductively doped regions  716  within self-healing elastomer  715  and may be disposed over one or more of each of exposed regions  706  of traces  725 . In some embodiments, exposed regions  706  may be metallic and may be plated with one or more layers of metal including, but not limited to gold, silver, palladium or tin. 
     When electrical probe  905  is engaged with contact  710 , electrical current may pass through electrical probe  905 , through conductively doped region  716  to exposed region  706  and through trace  725  to electrical circuitry  134  (see  FIG. 2 ) disposed within housing  150 . Electrical conduction within conductively doped regions  716  may occur by conduction from one conductive particle to another conductive particle. In some embodiments data and/or power may be transferred to and from electronic device  100  by one or more electrical probes  905  disposed within data plug  155  (see  FIG. 2 ). More specifically, in some embodiments plurality of contacts  710  may comprise a power contact, a ground contact and a pair of data contacts. Other embodiments may have different configurations for contacts  710 . For example, in one embodiment contacts  710  may not transfer data or power, but may simply be shorted together to perform a reset function or other operation on electronic device  100  (see  FIG. 1 ). Contacts  710  may have myriad configurations and purposes without departing from the scope of the invention. 
       FIG. 10  illustrates self-healing elastomer  715  after electrical probe  905  has been removed. As discussed above, self-healing elastomer  715  heals in the penetration region after removal of electrical probe  905 . Further, in some embodiments, conductively doped regions  716  may also include a self-healing elastomer that heals after removal of probe  905 . The healing may restore all or some of the aesthetic, protective and/or mechanical properties of self-healing elastomer  715  and conductively doped regions  714 . 
     In another embodiment, self-healing elastomer  715  may contain one or more conductively doped regions  716  for the purposes of improving and/or enhancing electrical contact between electrical probe  905  and exposed region  706  of trace  725 . More specifically, in such embodiments, electrical probe  905  may partially or nearly contact exposed region  706  and conductively doped region  716  may make the electrical connection more reliable and consistent by compressing conductive particulates against the electrical probe and the exposed region. 
       FIG. 11  illustrates another embodiment of a housing  1150  that may be employed on an electronic device such as device  100  (see  FIG. 1 ). This embodiment includes one or more retention features  1151  that are formed in one or more sidewalls of opening  1105  that may provide access to an electronic connector such as connector  140  (see  FIG. 1 ). Similar to the previous embodiments, opening  1105  is filled with self-healing elastomer  1115  such that one or more probes may temporarily penetrate it to access one or more contacts (not shown) of the electrical connector. Self-healing elastomer  1115  may or may not contain conductively doped regions, as discussed above. In addition, in this particular embodiment, edges  1152  of self-healing elastomer  1115  are flush with housing  1150 . 
     Retention features  1151  formed in sidewalls of opening  1105  may improve the adhesion of self-healing elastomer  1115  to housing  1150 . In some embodiments, retention features  1151  may be formed by an injection molding process while in other embodiments the features may be formed by a post-processing operation on housing  1150  such as machining, melting or grinding. In further embodiments, other manufacturing methods may be used to form retention features  1151 . Improved adhesion of self-healing elastomer  1115  may result in more reliable retention of the self-healing elastomer in housing  1150 . Additionally, retention features  1151  may result in an improved barrier against water, water vapor, debris and/or gas penetration by creating an improved mechanical lock between self-healing elastomer  1115  and housing  1150  such that delamination does not occur. In further embodiments retention features  1151  may be different than those illustrated and may be a roughened surface or other type of mechanical locking feature. In other embodiments, a primer or surface treatment may be used on housing  1150  prior to application of self-healing elastomer  1115  to improve the adhesion of the self-healing elastomer to the housing. 
     Edges  1152  of self-healing elastomer  1115  that are flush with housing  1150  may improve the blending of the self-healing elastomer with the housing. The improved blending may result in improved aesthetics, making self-healing elastomer  1115  more difficult to discern from housing  1150 . This feature may be beneficial when it is desirable to obscure the connector from the user. For example, an electronic device may be so small that it may be undesirable to have an external connector consume a significant portion of the outside surface, marring the aesthetics of the device. In addition, it may be desirable to deliver an electronic device that is completely wireless, however an external connector may be required for manufacturing and/or diagnostics so methods to obscure the connector from view may at least provide the appearance of a completely wireless device. Further, flush edges  1152  may reduce the likelihood of self-healing elastomer  1115  from being torn or disassociated from housing  1150 . Other edge  1152  designs may be employed on self-healing elastomer  1115  such as tapered edges, illustrated in  FIG. 12 . Flush edge  1152  may be formed during formation of self-healing elastomer  1115 , or after formation with a material removal process such as cutting, lasering, melting, grinding or the like. 
       FIG. 12  illustrates another embodiment of a housing  1150  that may be employed on an electronic device such as device  100  (see  FIG. 1 ), similar to the embodiment described in  FIG. 11 . This embodiment also includes one or more retention features  1151  formed in opening  1105  that is filled with self-healing elastomer  1115 . However, this embodiment has tapered edges  1153  on self-healing elastomer  1115 . 
     Tapered edges  1153  of self-healing elastomer  1115  may improve the blending of the self-healing elastomer with housing  1150 . The improved blending may result in improved aesthetics, making self-healing elastomer  1115  more difficult to discern from housing  1150 . As discussed above, this feature may be beneficial when it is desirable to obscure the connector from the user and/or reduce the likelihood of self-healing elastomer  1115  from being torn or disassociated from housing  1150 . Other edge  1153  designs may be employed on self-healing elastomer  1115  such as, for example, a radius, a chamfer or a sub-flush edge. A sub-flush edge is where self-healing elastomer  1115  is disposed below an outer surface of housing  1150 . 
       FIGS. 13A through 13C  illustrate various embodiments of electrical probes that may be used to temporarily penetrate the self-healing elastomer to connect with the connector contacts. In some embodiments the electrical probes may be designed to minimize damage to the self-healing elastomer, and/or to make electrical contact with the connector contacts. In further embodiments the probes may be made from an electrically conductive material such as, but not limited to, brass, copper, bronze, steel or nickel. In other embodiments, the electrical probes may have one or more layers of plating such as, but not limited to, nickel, gold, silver, tin or palladium. The plating may be used to decrease contact resistance between the probe and the contact and/or to improve the durability of the probe. Myriad probe designs may be used without departing from the invention. In further embodiments, the electrical probes may not be oriented perpendicular to the contacts (as illustrated in  FIGS. 4-6 ) during penetration and may approach the contacts at an obtuse angel. In other embodiments, the electrical probes may be guided to the electrical contacts by the opening in the housing or another alignment feature on the electronic device. In further embodiments, external fixturing may align the electrical probes with the contacts. 
       FIG. 13A  illustrates electrical probe  1300  having a shaft  1305  with a shoulder  1310  and a tapered nose portion  1315  terminating in a blunt tip  1320 . Blunt tip  1320  may increase the physical contact area with contact  310  (see  FIG. 3 ) and may minimize penetration of probe  1300  into the contact. 
       FIG. 13B  illustrates an electrical probe  1330  having a shaft  1335  with a tapered nose portion  1345  terminating in a sharp tip  1350 . Sharp tip  1350  may decrease the damage to self-healing elastomer and may allow probe  1330  to penetrate contact  310  (see  FIG. 3 ) making a more reliable electrical connection. 
       FIG. 13C  illustrates an electrical probe  1360  having a shaft  1365  with an enlarged shoulder  1370 , a short tapered nose portion  1375  terminating in a sharp tip  1380 . Sharp tip  1380  may allow probe  1360  to penetrate contact  310  (see  FIG. 3 ) making a more reliable electrical connection, and enlarged shoulder  1370  may limit the penetration depth of probe  1360  into contact  310  (see  FIG. 3 ). 
     Embodiments of the present invention may include a connector disposed in an electronic device for receiving an audio plug such as plug  145  in  FIG. 2 . Standard audio plugs, such as those illustrated in  FIGS. 14 and 15 , are available in three sizes according to the outside diameter of the plug: a 6.35 mm (¼″) plug, a 3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. Plugs  1410  and  1520  include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions or “rings” located between the tip and sleeve, resulting in the connectors often being referred to as TRS (tip, ring and sleeve) connectors. 
     More specifically,  FIGS. 14 and 15  illustrate examples of audio plugs  1410  and  1520  having three and four conductive portions, respectively. As shown in  FIG. 14 , plug  1410  includes a conductive tip  1412 , a conductive sleeve  1416  and a conductive ring  1414  electrically isolated from tip  1412  and sleeve  1416  by insulating rings  1417  and  1418 . The three conductive portions  1412 ,  1414 ,  1416  are for left and right audio channels and a ground connection, respectively. 
     Plug  1520 , shown in  FIG. 15 , includes four conductive portions: a conductive tip  1522 , a conductive sleeve  1526  and two conductive rings  1524 ,  1525  and is thus sometime referred to as a TRRS (tip, ring, ring, sleeve) connector. The four conductive portions  1522 ,  1524 ,  1525  and  1526  are electrically isolated by insulating rings  1527 ,  1528  and  1529  and are typically used for left and right audio, ground and microphone signals, respectively. 
     When plugs  1410  and  1520  are 3.5 mm miniature connectors, the outer diameter of conductive sleeve  1416 ,  1526  and conductive rings  1414 ,  1524 ,  1525  is 3.5 mm and the insertion length of the connector is 14 mm. For 2.5 mm subminiature connectors, the outer diameter of the conductive sleeves is 2.5 mm and the insertion length of the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MP3 players and smart phones as well as other electronic devices. 
     Plugs  1410  and  1520  may interface with a connector, such as connector  1600  in  FIG. 16 , mounted in an electronic device such as device  100  in  FIG. 2 . Because connector  1600  is accessible from the exterior of electronic device  100 , it may be exposed to moisture or debris that pose little or no risk to the consumer, but present a harsh environment for the connector contacts and electronic circuitry within the electronic device. For example, electronic devices and their connectors regularly come into contact with water, sweat, and other elements that may corrode or contaminate the contacts and may penetrate the electronic device, harming circuitry within its housing. Embodiments of the invention may include the use of a self-healing elastomer on such audio connectors to provide improved reliability and/or improved resistance to liquid, moisture and/or gas ingression. However, these embodiments should in no way limit the applicability of the invention to other connectors. 
       FIG. 16  is a simplified exploded perspective view of audio connector  1600 , in accordance with one embodiment of the invention. Connector  1600  may include a body having an opening  1655  that communicates with a cavity  1665  having height, width and depth dimensions. Connector  1600  may have a receiving face  1650  with front opening  1655  to receive a plug portion of a mating audio plug connector  145  (e.g.,  FIGS. 14 and 15 ) and rear face  1660  disposed opposite of the receiving face. Housing  1605 ,  1610  may extend between receiving face  1650  and rear face  1660  and define a cavity  1665  that communicates with front opening  1655 . A plurality of sequentially arranged contacts  1622   a ,  1624   a ,  1625   a ,  1626   a , may be sequentially positioned within and spaced apart along a depth of the cavity and each may have external portions  1622   c ,  1624   c ,  1625   c ,  1626   c  disposed outside of housing  1605 ,  1610 . External portions  1622   c ,  1624   c ,  1625   c ,  1626   c  may be configured to mount connector  1600  to a printed circuit board or similar structure and provide an electrical path from contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  to circuitry within the electronic device. Other types and configurations of audio connectors may be used without departing from the invention. 
       FIG. 17  illustrates a cross-sectional view of audio connector  1600  (see  FIG. 16 ) installed within housing  1605  of an electronic device such as device  100  in  FIG. 2 . Contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  are accessible through opening  1610  in housing  1605 . A layer of self-healing elastomer  1615  is disposed over opening  1610  in housing  1605 . Self-healing elastomer  1615  may provide a protective barrier for contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and housing  1605 . More specifically, in some embodiments, self-healing elastomer  1615  may provide moisture and debris protection to contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and housing  1605  such that water and debris may not penetrate the self-healing elastomer. In further embodiments, self-healing elastomer  1615  may provide a barrier against water vapor and in further embodiments may provide a hermetic seal (i.e., impervious to gasses). Self-healing elastomer may be bonded to housing  1605  and may have flush or tapered edges as discussed above. In other embodiments, self-healing elastomer  1615  may be filled with one or more pigments to obscure contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and opening  1610  as also discussed above. 
     Audio connectors such as those illustrated in  FIGS. 14 and 15  may penetrate self-healing elastomer  1615  to make electrical contact with contacts  1622   a ,  1624   a ,  1625   a  and  1626   a . Once the audio connector is removed, self-healing elastomer  1615  may self-heal, regaining at least some of its aesthetic, protective and/or mechanical properties. 
       FIG. 18  illustrates another embodiment showing a cross-sectional view of audio connector  1600  (see  FIG. 16 ) installed within housing  1805  of an electronic device such as device  100  in  FIG. 2 . In this embodiment, a self-healing elastomer  1815  with conductively doped regions  1820  is disposed inside of audio connector  1600 . Contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  are accessible through opening  1810  in housing  1805 . A layer of self-healing elastomer  1815  is disposed in a cylindrical shape over the interior of audio connector  1600 . Self-healing elastomer  1815  may provide a protective barrier for contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and housing  1805 . More specifically, in some embodiments, self-healing elastomer  1815  may provide moisture and debris protection to contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and housing  1805  such that water and debris may not penetrate the self-healing elastomer. In further embodiments, self-healing elastomer  1815  may provide a barrier against water vapor and in further embodiments may provide a hermetic seal (i.e., impervious to gasses). Self-healing elastomer may be bonded to housing  1805  and may have flush or tapered edges as discussed above. In other embodiments, self-healing elastomer  1815  may be filled with one or more pigments to obscure contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and opening  1810  as also discussed above. 
     As further illustrated, one or more conductively doped regions  1820  may be disposed over each of contacts  1622   a ,  1624   a ,  1625   a ,  1626   a . Thus, when conductive sleeves  1416 ,  1526  and conductive rings  1414 ,  1524 ,  1525  of audio connectors  1410  and  1520  (see  FIGS. 14 and 15 ) come into contact with conductively doped regions  1820 , electrical contact is made between the audio connectors and the circuitry within housing  1805 . In some embodiments an additional layer of self-healing elastomer may be placed over opening  1810 . 
     In some embodiments self-healing elastomer  1820  may be manufactured as discussed above, and subsequently inserted into cavity  1665  (see  FIG. 16 ) of connector  1600 . In other embodiments, self-healing elastomer may be molded around contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and installed as an assembly into housing  1605 ,  1610  (see  FIG. 16 ). Other methods may be used to manufacture the embodiment illustrated in  FIG. 18  without departing from the invention. 
       FIG. 19  illustrates another embodiment showing a cross-sectional view of audio connector  1600  (see  FIG. 16 ) installed within housing  1905  of an electronic device such as device  100  in  FIG. 2 . Similar to the embodiment described in  FIG. 18 , a self-healing elastomer  1915  having conductively doped regions  1920  is disposed inside of audio connector  1600 . However, in this embodiment substantially the entire cavity  1665  (see  FIG. 16 ) of connector  1600  is filled with self-healing elastomer  1915 . Contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  are accessible through opening  1910  in housing  1905 . Layers of self-healing elastomer  1915  are disposed in a cylindrical shape in the interior of audio connector  1600 . Layers of conductively doped regions  1920  are also disposed in cylindrical shapes in the interior of audio connector  1600 . Layers of self-healing elastomer  1915  are disposed between layers of conductively doped regions  1920  to provide electrical isolation. 
     As further illustrated, one or more conductively doped regions  1920  may be disposed over each of contacts  1622   a ,  1624   a ,  1625   a ,  1626   a . Thus, when conductive sleeves  1416 ,  1526  and conductive rings  1414 ,  1524 ,  1525  of audio connectors  1410  and  1520  (see  FIGS. 14 and 15 ) come into contact with conductively doped regions  1920 , electrical contact is made between the audio connectors and the circuitry within housing  1905 . In some embodiments an additional layer of self-healing elastomer may be placed over opening  1910 . 
     Displacement ports  1925  may be disposed within the audio connector housing to provide for displacement of self-healing elastomer  1910  and conductively doped regions  1920  when an audio connector plug (e.g.,  FIGS. 14 and 15 ) is inserted in audio connector  1600 . Upon removal of audio connector plug, self-healing elastomer  1910  and conductively doped regions  1920  may regain at least some of their aesthetic, protective and/or mechanical properties. 
     As discussed above, self-healing elastomer  1910  may provide a protective barrier for contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and housing  1905 . Self-healing elastomer  1910  may be bonded to housing  1905  and may have flush or tapered edges as discussed above. In other embodiments, self-healing elastomer  1910  may be filled with one or more pigments to obscure contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and opening  1910  as also discussed above. 
     In some embodiments self-healing elastomer  1920  may be manufactured as discussed above, and subsequently inserted into cavity  1665  (see  FIG. 16 ) of connector  1600 . In other embodiments, self-healing elastomer  1920  may be molded around contacts  1622   a ,  1624   a ,  1625   a ,  1626   a  and installed as an assembly into housing  1605 ,  1610  (see  FIG. 16 ). In further embodiments, layers of self-healing elastomer  1920  may be deposited within cavity  1556  and alternated with layers of conductively doped regions  1920 . Other methods may be used to manufacture the embodiment illustrated in  FIG. 19  without departing from the invention. 
       FIG. 20  depicts a simplified flowchart  2000  illustrating a general method for interfacing with an electronic device equipped with a hidden connector. The particular series of processing steps depicted in  FIG. 20  is not intended to be limiting. 
     As depicted in  FIG. 20 , the method may be initiated at  2010  when an electronic device equipped with one or more external connectors requires communication, charging or service using a wired connection. The external connector may have a self-healing elastomer disposed over the connector to improve the device aesthetics and/or to protect the connector and the device from damage. 
     In some embodiments, such an electronic device may require programming at the manufacturing facility and a wired communication system may be the most tractable method. In other embodiments, such an electronic device may require a wired connection for charging or servicing. More specifically, in some embodiments, an electronic device may be completely wireless (e.g., equipped with wireless communication and charging capabilities) except for a single connector covered by a self-healing elastomer. Thus, in some scenarios the most tractable method to service the device may be through a wired connection, such as, for example, when the internal battery is drained and the wireless communication system is unavailable. In other embodiments an audio system may require a wired connection to the electronic device. 
     At  2020 , a data or audio connector may be mated with the external connector on the electronic device. The data or audio connector may have one or more probes, each having a relatively pointed tip to effectively penetrate the self-healing elastomer to make contact with the external connector&#39;s electrical contacts. In some embodiments the external connector contacts are metallic pads on a substrate while in other embodiments the external connector contacts may be conductively doped regions within the self-healing elastomer. The data or audio plug may be aligned with the external connector using alignment features in the electronic device and/or external fixtures. The probes within the data or audio connector may pierce the self-healing elastomer in a penetration region, temporarily displacing the self-healing elastomer to make an electrical connection with the external connector contacts. 
     At  2030 , the data or audio connectors are mated with the external connector on the electronic device and the power and/or data transfer occurs. Current may flow through the electronic probes, through the external connector contacts and to the circuitry within the electronic device. 
     At  2040 , the data or audio connectors may be de-mated from the external connector of the electronic device. More specifically, the probes may be removed from the self-healing elastomer and the elastomer may elastically resume its shape prior to the penetration. 
     At  2050 , the self-healing elastomer heals in the penetration region. More specifically, self-healing elastomer may reseal itself and regain at least some of its aesthetic, mechanical and/or protective properties. That is, in some embodiments the self-healing elastomer may resume providing an aesthetic covering, a water resistant barrier and/or debris protection for the external connector and the electronic device. 
     In further embodiments, the self-healing elastomer may “heal” by reforming chemical bonds, regaining at least some of its mechanical properties in the penetration region. In yet further embodiments, the self-healing elastomer may reform covalent bonds in the penetration region and regain at least 30 percent of its tensile strength in the penetration region. In other embodiments, it may regain at least 50 percent of its tensile strength in the penetration region. In further embodiments it may regain at least 70 percent of its tensile strength in the penetration region. In yet further embodiments it may regain at least 90 percent of its tensile strength in the penetration region. In some embodiments the recovery of tensile strength may occur at approximately 68 degrees centigrade. In other embodiments the recovery of tensile strength may be temperature dependent and may improve with an increase in temperature. In some embodiments the recovery of tensile strength may occur between 60 and 76 degrees centigrade. In other embodiments the recovery of tensile strength may occur between 52 and 84 degrees centigrade. In further embodiments the recovery of tensile strength may occur between 44 and 92 degrees centigrade. In some embodiments the self-healing elastomer may only be penetrated once by the electrical probes, while in further embodiments it may be penetrated numerous times, self-healing after each penetration. In some embodiments the self-healing elastomer may be applied to the device housing, and while in a partially cured condition it may be penetrated by the electrical probes and fully cured after removal of the electrical probes. 
     In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the invention, and what is intended by the applicants to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction.

Metadata:
Filing Date: 20140609
Publication Date: 20160503
Grant Date: 20160503
Priority Date: 20140609
Inventors: NAZZARO DAVID I.
BUSHNELL TYLER S.
KAMEI IBUKI
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R24/58", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/453", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/52", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/46", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/5216", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/46", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/44", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/52", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 54770333