PATENT DOCUMENT

Publication Number: US-9276392-B2
Application Number: US-201113013540-A
Country: US
Kind Code: B2

Title: Compression molded cable structures and methods for making the same

Abstract:
Compression molded cable structures and systems and methods for manufacturing molded cable structures are disclosed.

Claims:
What is claimed is: 
     
       1. A cable structure, comprising:
 a conductor bundle; 
 a cured resin that encompasses the conductor bundle; 
 a tube sleeve having an inner surface and an outer surface, the tube sleeve encompassing the cured resin; and 
 a variable diameter bi-component sheath compression molded from two urethane sheets that encompasses the tube sleeve, the cured resin, and the conductor bundle; wherein 
 each component of the bi-component sheath defines at least a portion of an external surface of the cable structure; 
 the outer surface of the tube sleeve mates to an inner surface of the bi-component sheath: 
 the inner surface of the tube sleeve mates to an outer surface of the cured resin; and 
 the bi-component sheath comprises interface region, a bump region, and a non-interface region, the bump region existing between the interface and non-interface regions and having a variable diameter. 
 
     
     
       2. The cable structure of  claim 1 , wherein the bump region has a curved profile. 
     
     
       3. The cable structure of  claim 1 , wherein the variable diameter bi-component sheath comprises three legs coupled together at a bifurcation region, each leg comprising an interface region, a bump region, and a non-interface region, wherein the bump region exists between the interface and non-interface regions and has a variable diameter. 
     
     
       4. The cable structure of  claim 1 , wherein the bi-component sheath comprises a top sheath component formed from a first of the two urethane sheets and a bottom sheath component formed from a second of the two urethane sheets, wherein the top and bottom sheath components each have a smooth outer surface. 
     
     
       5. The cable structure of  claim 1 , wherein the conductor bundle comprises at least one conductor and at least one superelastic rod. 
     
     
       6. A cable structure, comprising:
 a variable diameter bi-component sheath compression molded from two urethane sheets; 
 a tube sleeve disposed within the sheath such that a cavity exists within the tube sleeve disposed within the sheath, wherein the bi-component sheath comprises at least one leg having an interface region, a bump region, and a non-interface region, the bump region existing between the interface and non-interface regions and having a variable diameter; and 
 a support structure positioned at one end of the non-interface region and comprising:
 a central ring portion; and 
 a leg portion attached to the central ring portion, the leg portion extending to the external surface of the cable structure; 
 
 wherein:
 each of the two urethane sheets defines at least a portion of a smooth external surface of the cable structure; and 
 the tube sleeve is mated to an inner surface of the sheath. 
 
 
     
     
       7. The cable structure of  claim 6 , wherein the bi-component sheath comprises three legs joined together at a bifurcation region, and the cavity exists with all three legs. 
     
     
       8. The cable structure of  claim 7 , wherein each of the three legs has an interface region, a bump region, and a non-interface region, wherein the bump region exists between the interface and non-interface regions and has a variable diameter. 
     
     
       9. The cable structure of  claim 8 , wherein dimensions of the interface regions, bump regions, and non-interface regions for at least two of the three legs are substantially the same. 
     
     
       10. A cable structure, comprising:
 an inlaid component comprising:
 a central ring portion; and 
 a leg portion attached to the central ring portion; 
 
 a resin that encompasses the inlaid component, the resin having an outer surface, the resin comprising:
 an interface region; 
 a bump region; and 
 a non-interface region, the bump region existing between the interface and non-interface regions and having a variable diameter; and 
 
 a tube sleeve that at least partially encompasses the outer surface of the resin; wherein 
 the resin permanently secures the inlaid component in place. 
 
     
     
       11. The cable structure of  claim 10 , wherein the bump region comprises a curve. 
     
     
       12. The cable structure of  claim 10 , wherein the resin comprises three legs coupled together at a bifurcation region, each leg comprising an interface region, a bump region, and a non-interface region, wherein the bump region exists between the interface and non-interface regions and has a variable diameter. 
     
     
       13. The cable structure of  claim 12 , wherein each bump region comprises a curve. 
     
     
       14. The cable structure of  claim 10 , wherein the inlaid component further comprises at least one conductor and at least one superelastic rod. 
     
     
       15. The cable structure of  claim 10 , wherein the inlaid component comprises a conductor bundle. 
     
     
       16. The cable structure of  claim 10 , wherein an interface between the resin and the inlaid component minimizes movement of the inlaid component within the resin. 
     
     
       17. The cable structure of  claim 16 , wherein the resin is pulled around the inlaid component by a vacuum.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of previously filed U.S. Provisional Patent Application No. 61/298,087, filed Jan. 25, 2010, entitled “Small Diameter Cable with Splitter Assembly,” U.S. Provisional Patent Application No. 61/384,103, filed Sep. 17, 2010, entitled “Molded Splitter Structures and Systems and Methods for Making the Same,” U.S. Provisional Patent Application No. 61/319,772, filed Mar. 31, 2010, entitled “Thin Audio Plug and Coaxial Routing of Wires,” U.S. Provisional Patent Application No. 61/384,097, filed Sep. 17, 2010, entitled “Cable Structures and Systems Including Super-Elastic Rods and Methods for Making the Same,” U.S. Provisional Patent Application No. 61/326,102, filed Apr. 20, 2010, entitled “Audio Plug with Core Structural Member and Conductive Rings,” U.S. Provisional Patent Application No. 61/349,768, filed May 28, 2010, entitled “Molding an Electrical Cable Having Centered Electrical Wires,” U.S. Provisional Patent Application No. 61/378,311, filed Aug. 30, 2010, entitled “Molded Cable Structures and Systems and Methods for Making the Same,” and U.S. Provisional Application No. 61/378,314, filed Aug. 30, 2010, entitled “Extruded Cable Structures and Systems and Methods for Making the Same.” Each of these provisional applications is incorporated by reference herein in their entireties. 
    
    
     BACKGROUND 
     Wired headsets are commonly used with many portable electronic devices such as portable music players and mobile phones. Headsets can include non-cable components such as a jack, headphones, and/or a microphone and one or more cables that interconnect the non-cable components. The cables can be manufactured using different approaches. 
     SUMMARY 
     Compression molded cable structures and methods for manufacturing molded cable structures are disclosed. 
     A cable structure can interconnect various non-cable components of a headset such as, for example, a plug, headphones, and/or a communications box to provide a headset. The cable structure can include several legs (e.g., a main leg, a left leg, and a right leg) that each connect to a non-cable structure, and each leg may be connected to one another at a bifurcation region (e.g., a region where the main leg appears to split into the left and right legs). Cable structures according to embodiments of this invention provide aesthetically pleasing interface connections between the non-cable components and legs of the cable structure, for example such that the interface connections appear to have been constructed jointly as a single piece, thereby providing a seamless interface. 
     In addition, because the dimensions of the non-cable components typically have a dimension that is different than the dimensions of a conductor bundle being routed through the legs of the cable structure, one or more legs of the cable structure can have a variable diameter. The change from one dimension to another can exhibit a substantially smooth variation in diameter along the length of the legs of the cable structure. 
     The interconnection of the three legs at the bifurcation region can vary depending on how the cable structure is manufactured. In one approach, the cable structure can be a single-segment unibody cable structure. In this approach, all three legs are jointly formed, for example using an extrusion process, and no additional processing is required to electrically couple the conductors contained therein. In another approach, the cable structure can be a multi-segment unibody cable structure. In this approach, the legs may be manufactured as discrete segments, but require additional processing to electrically couple conductors contained therein. In some embodiments, the segments can be joined together using a splitter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and advantages of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIGS. 1A and 1B  illustrate different headsets having a cable structure that seamlessly integrates with non-cable components in accordance with some embodiments of the invention; 
         FIGS. 1C and 1D  show illustrative cross-sectional views of a portion of a leg in accordance with some embodiments of the invention; 
         FIG. 2  shows cross-sectional views of a cable structure manufactured using urethane sheets in accordance with embodiments of the invention; 
         FIGS. 3A-C  show illustrative views of a mold used to manufacture a cable structure in accordance with embodiments of the invention. 
         FIGS. 4A-B  show illustrative views of a mold used to manufacture a single-segment cable in accordance with embodiment of the invention. 
         FIGS. 5A-B  show illustrative views of a mold used to manufacture multiple legs of a multi-segment cable in accordance with embodiment of the invention. 
         FIGS. 6A-B  show illustrative views of a mold used to manufacture a single-segment cable in accordance with embodiment of the invention. 
         FIGS. 7A-B  show illustrative views of a mold used to manufacture a leg of a multi-segment cable in accordance with embodiment of the invention. 
         FIG. 8  shows a cross-sectional view of a cable structure manufactured using a resin in accordance with embodiment of the invention; 
         FIG. 9  shows cross-sectional views of a cable structure manufactured with silicon sheets in accordance with embodiments of the invention; 
         FIGS. 10A-B  show different molds in accordance with embodiments of the invention; 
         FIGS. 11A-C  show different views of an illustrative silicon sheet in accordance with an embodiment of the invention; 
         FIGS. 12A-B  show different views of an illustrative silicon sheet in accordance with an embodiment of the invention; and 
         FIGS. 13-15  show flowcharts of illustrative steps that may be performed to manufacture a cable structure in accordance with embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Cable structures for use in headsets are disclosed. The cable structure interconnects various non-cable components of a headset such as, for example, a plug, headphones, and/or a communications box to provide a headset. The cable structure can include multiple legs (e.g., a main leg, a left leg, and a right leg) that each connect to a non-cable structure, and each leg may be connected to each other at a bifurcation region (e.g., a region where the main leg appears to split into the left and right legs). Cable structures according to embodiments of this invention provide aesthetically pleasing interface connections between the non-cable components and legs of the cable structure. The interface connections between a leg and a non-cable component are such that they appear to have been constructed jointly as a single piece, thereby providing a seamless interface. 
     In addition, because the dimensions of the non-cable components typically have a dimension that is different than the dimensions of a conductor bundle being routed through the legs of the cable structure, one or more legs of the cable structure can have a variable diameter. The change from one dimension to another is accomplished in a manner that maintains the spirit of the seamless interface connection between a leg and the non-cable component throughout the length of the leg. That is, each leg of the cable structure exhibits a substantially smooth surface, including the portion of the leg having a varying diameter. In some embodiments, the portion of the leg varying in diameter may be represented mathematically by a bump function, which requires all aspects of the variable diameter transition to be smooth. In other words, a cross-section of the variable diameter portion can show a curve or a curve profile. 
     The interconnection of the three legs at the bifurcation region can vary depending on how the cable structure is manufactured. In one approach, the cable structure can be a single-segment unibody cable structure. In this approach, all three legs are jointly formed and no additional processing is required to electrically couple the conductors contained therein. Construction of the single-segment cable may be such that the bifurcation region does not require any additional support. If additional support is required, an over-mold can be used to add strain relief to the bifurcation region. 
     In another approach, the cable structure can be a multi-segment unibody cable structure. In this approach, the legs may be manufactured as discrete segments, but require additional processing to electrically couple conductors contained therein. The segments can be joined together using a splitter. Many different splitter configurations can be used, and the use of some splitters may be based on the manufacturing process used to create the segment. 
     The cable structure can include a conductor bundle that extends through some or all of the legs. The conductor bundle can include conductors that interconnect various non-cable components. The conductor bundle can also include one or more rods constructed from a superelastic material. The superelastic rods can resist deformation to reduce or prevent tangling of the legs. 
     The cable structure can be constructed using many different manufacturing processes. The processes include injection molding, compression molding, and extrusion. In injection and compression molding processes, a mold is formed around a conductor bundle or a removable rod. The rod is removed after the mold is formed and a conductor bundle is threaded through the cavity. In extrusion processes, an outer shell is formed around a conductor bundle. 
       FIG. 1A  shows an illustrative headset  10  having cable structure  20  that seamlessly integrates with non-cable components  40 ,  42 ,  44 . For example, non-cable components  40 ,  42 , and  44  can be a male plug, left headphones, and right headphones, respectively. Cable structure  20  has three legs  22 ,  24 , and  26  joined together at bifurcation region  30 . Leg  22  may be referred to herein as main leg  22 , and includes the portion of cable structure  20  existing between non-cable component  40  and bifurcation region  30 . In particular, main leg  22  includes interface region  31 , bump region  32 , and non-interface region  33 . Leg  24  may be referred to herein as left leg  24 , and includes the portion of cable structure  20  existing between non-cable component  42  and bifurcation region  30 . Leg  26  may be referred to herein as right leg  26 , and includes the portion of cable structure  20  existing between non-cable component  44  and bifurcation region  30 . Both left and right legs  24  and  26  include respective interface regions  34  and  37 , bump regions  35  and  38 , and non-interface regions  36  and  39 . 
     Legs  22 ,  24 , and  26  generally exhibit a smooth surface throughout the entirety of their respective lengths. Each of legs  22 ,  24 , and  26  can vary in diameter, yet still retain the smooth surface. 
     Non-interface regions  33 ,  36 , and  39  can each have a predetermined diameter and length. The diameter of non-interface region  33  (of main leg  22 ) may be larger than or the same as the diameters of non-interface regions  36  and  39  (of left leg  24  and right leg  26 , respectively). For example, leg  22  may contain a conductor bundle for both left and right legs  24  and  26  and may therefore require a greater diameter to accommodate all conductors. In some embodiments, it is desirable to manufacture non-interface regions  33 ,  36 , and  39  to have the smallest diameter possible, for aesthetic reasons. As a result, the diameter of non-interface regions  33 ,  36 , and  39  can be smaller than the diameter of any non-cable component (e.g., non-cable components  40 ,  42 , and  44 ) physically connected to the interfacing region. Since it is desirable for cable structure  20  to seamlessly integrate with the non-cable components, the legs may vary in diameter from the non-interfacing region to the interfacing region. 
     Bump regions  32 ,  35 , and  38  provide a diameter changing transition between interfacing regions  31 ,  34 , and  37  and respective non-interfacing regions  33 ,  36 , and  39 . The diameter changing transition can take any suitable shape that exhibits a fluid or smooth transition from any interface region to its respective non-interface region. For example, the shape of the bump region can be similar to that of a cone or a neck of a wine bottle. As another example, the shape of the taper region can be stepless (i.e., there is no abrupt or dramatic step change in diameter, nor a sharp angle at an end of the bump region). Bump regions  32 ,  35 , and  38  may be mathematically represented by a bump function, which requires the entire diameter changing transition to be stepless and smooth (e.g., the bump function is continuously differentiable). 
       FIGS. 1C and 1D  show illustrative cross-sectional views of a portion of main leg  22  in accordance with embodiments of the invention. Both  FIGS. 1C and 1D  show main leg  22  with a center axis (as indicated by the dashed line) and symmetric curves  32   c  and  32   d . Curves  32   c  and  32   d  illustrate that any suitable curve profile may be used in bump region  32 . Thus the outer surface of bump region  32  can be any surface that deviates from planarity in a smooth, continuous fashion. 
     Interface regions  21 ,  34 , and  37  can each have a predetermined diameter and length. The diameter of any interface region can be substantially the same as the diameter of the non-cable component it is physically connected to, to provide an aesthetically pleasing seamless integration. For example, the diameter of interface region  21  can be substantially the same as the diameter of non-cable component  40 . In some embodiments, the diameter of a non-cable component (e.g., component  40 ) and its associated interfacing region (e.g., region  31 ) are greater than the diameter of the non-interface region (e.g., region  33 ) they are connected to via the bump region (e.g., region  32 ). Consequently, in this embodiment, the bump region decreases in diameter from the interface region to the non-interface region. 
     In another embodiment, the diameter of a non-cable component (e.g., component  40 ) and its associated interfacing region (e.g., region  31 ) are less than the diameter of the non-interface region (e.g., region  33 ) they are connected to via the bump region (e.g., region  32 ). Consequently, in this embodiment, the bump region increases in diameter from the interface region to the non-interface region. 
     The combination of the interface and bump regions can provide strain relief for those regions of headset  10 . In one embodiment, strain relief may be realized because the interface and bump regions have larger dimensions than the non-interface region and thus are more robust. These larger dimensions may also ensure that non-cable portions are securely connected to cable structure  20 . Moreover, the extra girth better enables the interface and bump regions to withstand bend stresses. 
     The interconnection of legs  22 ,  24 , and  26  at bifurcation region  30  can vary depending on how cable structure  20  is manufactured. In one approach, cable structure  20  can be a single-segment unibody cable structure. In this approach all three legs are manufactured jointly as one continuous structure and no additional processing is required to electrically couple the conductors contained therein. That is, none of the legs are spliced to interconnect conductors at bifurcation region  30 , nor are the legs manufactured separately and then later joined together. Some single-segment unibody cable structures may have a top half and a bottom half, which are molded together and extend throughout the entire unibody cable structure. For example, such single-segment unibody cable structures can be manufactured using injection molding and compression molding manufacturing processes (discussed below in more detail). Thus, although a mold-derived single-segment unibody cable structure has two components (i.e., the top and bottom halves), it is considered a single-segment unibody cable structure for the purposes of this disclosure. Other single-segment unibody cable structures may exhibit a contiguous ring of material that extends throughout the entire unibody cable structure. For example, such a single-segment cable structure can be manufactured using an extrusion process. 
     In another approach, cable structure  20  can be a multi-segment unibody cable structure. A multi-segment unibody cable structure may have the same appearance of the single-segment unibody cable structure, but the legs are manufactured as discrete components. The legs and any conductors contained therein are interconnected at bifurcation region  30 . The legs can be manufactured, for example, using any of the processes used to manufacture the single-segment unibody cable structure. 
     The cosmetics of bifurcation region  30  can be any suitable shape. In one embodiment, bifurcation region  30  can be an overmold structure that encapsulates a portion of each leg  22 ,  24 , and  26 . The overmold structure can be visually and tactically distinct from legs  22 ,  24 , and  26 . The overmold structure can be applied to the single or multi-segment unibody cable structure. In another embodiment, bifurcation region  30  can be a two-shot injection molded splitter having the same dimensions as the portion of the legs being joined together. Thus, when the legs are joined together with the splitter mold, cable structure  20  maintains its unibody aesthetics. That is, a multi-segment cable structure has the look and feel of single-segment cable structure even though it has three discretely manufactured legs joined together at bifurcation region  30 . Many different splitter configurations can be used, and the use of some splitters may be based on the manufacturing process used to create the segment. 
     Cable structure  20  can include a conductor bundle that extends through some or all of legs  22 ,  24 , and  26 . Cable structure  20  can include conductors for carrying signals from non-cable component  40  to non-cable components  42  and  44 . Cable structure  20  can include one or more rods constructed from a superelastic material. The rods can resist deformation to reduce or prevent tangling of the legs. The rods are different than the conductors used to convey signals from non-cable component  40  to non-cable components  42  and  44 , but share the same space within cable structure  20 . Several different rod arrangements may be included in cable structure  20 . 
     In yet another embodiment, one or more of legs  22 ,  24 , and  26  can vary in diameter in two or more bump regions. For example, the leg  22  can include bump region  32  and another bump region (not shown) that exists at leg/bifurcation region  30 . This other bump region may vary the diameter of leg  22  so that it changes in size to match the diameter of cable structure at bifurcation region  30 . This other bump region can provide additional strain relief. 
     In some embodiments, another non-cable component can be incorporated into either left leg  24  or right leg  26 . As shown in  FIG. 1B , headset  60  shows that non-cable component  46  is integrated within leg  26 , and not at an end of a leg like non-cable components  40 ,  42  and  44 . For example, non-cable component  46  can be a communications box that includes a microphone and a user interface (e.g., one or more mechanical or capacitive buttons). Non-cable component  46  can be electrically coupled to non-cable component  40 , for example, to transfer signals between communications box  46  and one or more of non-cable components  40 ,  42  and  44 . 
     Non-cable component  46  can be incorporated in non-interface region  39  of leg  26 . In some cases, non-cable component  46  can have a larger size or girth than the non-interface regions of leg  26 , which can cause a discontinuity at an interface between non-interface region  39  and communications box  46 . To ensure that the cable maintains a seamless unibody appearance, non-interface region  39  can be replaced by first non-interface region  50 , first bump region  51 , first interface region  52 , communications box  46 , second interface region  53 , second bump region  54 , and second non-interface region  55 . 
     Similar to the bump regions described above in connection with the cable structure of  FIG. 1A , bump regions  51  and  54  can handle the transition from non-cable component  46  to non-interface regions  50  and  55 . The transition in the bump region can take any suitable shape that exhibits a fluid or smooth transition from the interface region to the non-interface regions. For example, the shape of the taper region can be similar to that of a cone or a neck of a wine bottle. 
     Similar to the interface regions described above in connection with the cable structure of  FIG. 1A , interface regions  52  and  53  can have a predetermined diameter and length. The diameter of the interface region is substantially the same as the diameter of non-cable component  46  to provide an aesthetically pleasing seamless integration. In addition, and as described above, the combination of the interface and bump regions can provide strain relief for those regions of headset  10 . 
     In some embodiments, non-cable component  46  may be incorporated into a leg such as leg  26  without having bump regions  51  and  54  or interface regions  52  and  53 . Thus, in this embodiment, non-interfacing regions  50  and  55  may be directly connected to non-cable component  46 . 
     Cable structures  20  can be constructed using many different manufacturing processes. The processes discussed herein include those that can be used to manufacture the single-segment unibody cable structure or legs for the multi-segment unibody cable structure. In particular, these processes include injection molding, compression molding, and extrusion. Embodiments of this invention use compression molding processes to manufacture a single-segment unibody cable structure or multi-segment unibody cable structures. 
     In one embodiment, a cable structure can be manufactured by compression molding two urethane sheets together to form the sheath of the cable structure. Using this manufacturing method, the finished cable structure has a bi-component sheath that encompasses a resin and a conductor bundle. The resin further encompasses the conductor bundle and occupies any void that exists between the conductor bundle and the inner wall of the bi-component cable. In addition, the resin secures the conductor bundle in place within the bi-component sheath. 
       FIG. 2  shows illustrative cross-sectional views of two different cable structures that can be manufactured by compression molding two urethane sheets in accordance with embodiments of the invention. The illustrated cross-sectional views represent a cross-sectional view of a leg of either a single-segment or multi-segment cable structure. Cable structure  200  shows top sheath component  202  and bottom sheath component  203  formed together at mold interface regions  204 . Molded together, components  202  and  203  form the bi-component sheath that encompasses resin  206  and conductor bundle  207 . As shown, resin  206  encompasses conductor bundle  207  and directly interfaces with the inner wall of the bi-component sheath. Conductor bundle  207  can be co-axially aligned with a center axis of cable structure  200 , though it is understood that due to manufacturing tolerances, conductor bundle  207  may be positioned off center in various portions of the bi-component sheath. Cable structure  200  can be manufactured using a direct wire inlaid bi-component sheath molding process, which is discussed below in more detail. 
     Cable structure  210  is similar in every respect to cable structure  200 , except for the addition of tube sleeve  212 . Tube sleeve  212  directly interfaces with the inner diameter of the bi-component sheath and resin  206 . Cable structure  210  can be manufactured using a tube-inlaid bi-component sheath molding process, which is discussed below in more detail. 
       FIG. 3A  shows a simplified exploded cross-sectional view of top mold  302 , bottom mold  304 , top urethane sheet  306 , bottom urethane sheet  308 , and inlaid component  310  used to manufacture a urethane-based cable structure according to an embodiment of the invention. Top and bottom molds  302  and  304  can be constructed to mold either a single-segment cable structure or a multi-segment cable structure. Top and bottom molds  302  and  304  each have a cavity for shaping the cable structure. 
     For example,  FIG. 3B  shows an illustrative bottom mold for jointly forming all three legs of a bottom-component sheath of a cable structure. As shown, bottom mold  304  includes main leg  322 , which includes interface region  331 , bump region  332 , non-interface region  333 , left leg  324 , which includes interface region  334 , bump region  335 , non-interface region  336 , and right leg  326 , which includes interface region  337 , bump region  338 , and non-interface region  339 . Legs  322 ,  324 , and  326  are connected together at bifurcation region  340 . If desired, the single-segment bottom mold can be constructed to yield more than one single-segment cable structure. 
     As another example,  FIG. 3C  shows an illustrative bottom mold for forming bottom-component sheath for one leg of a cable structure. As shown, this bottom mold is constructed to manufacture multiple legs. The molds can all be the same to produce multiple copies of the same cable structure (e.g., multiple main legs  22 ) or different cable structures (e.g., one of each leg  22 ,  24 , and  26 ). Regardless of which leg is molded, the mold includes interface region  350 , bump region  351 , and non-interface region  352 . 
     Referring back to  FIG. 3A , top and bottom molds  302  and  304  can be constructed from any suitable material capable of permitting a vacuum to be pulled in the directions shown the by arrows  312 . Top and bottom molds  302  and  304  may be constructed from a porous material (e.g., aluminum) or can include illustrative vacuum channels  314 . A vacuum is applied to pull top sheet  306  onto top mold  302  and another vacuum is applied to pull bottom sheet  308  onto bottom mold  304 . The vacuum can hold top and bottom sheets  306  and  308  in place when top and bottom molds  302  and  304  are pressed together. 
     Top and bottom molds  302  and  304  can be heated to promote molding of sheets  306  and  308 . The heat and vacuum and can cause sheets  306  and  308  to deform into respective mold cavities of top and bottom molds  302  and  304 . Top and bottom molds  302  and  304  can be heated, for example, by being inserted into an oven or by using internal heating elements (not shown). When molds  302  and  304  are compressed together, the heat and pressure can cause sheets  306  and  308  to mold together, thereby forming the bi-component cable structure. After the bi-component cable structure is molded, the excess urethane is stripped away. 
     Inlaid component  310  represents any component or combination of components placed into the cavity of bottom mold  304  prior to formation of the bi-component sheath. In one embodiment, inlaid component  310  can be a conductor bundle. The conductor bundle can be secured in place to maintain a predetermined position within the cavity existing between the bi-component sheath during the mold formation process, including during a resin application stage. For example, tension members (not shown) may used to hold the conductor bundle taut. In addition, an inlaid support member (not shown) may be used to further stabilize the conductor bundle. In another embodiment, inlaid component  310  can include one or more removable rods. The rods are used to form the shape of the bi-component sheath during compression. The rods can be secured in place using various support members, including an inlaid component support member. 
     Urethane sheets  306  and  308  form the top sheath component and the bottom sheath component, respectively of any cable structure manufactured using this method. Sheets  306  and  308  may be preformed or precut to assist inlaid component support members (not shown) in holding inlaid component  310  in place during cable structure manufacture. For example, the sheets may have one or more holes cut therein to permit inlaid component support member (not shown) direct access to inlaid component  310 . 
       FIG. 4A  shows an illustrative top view of bottom mold  404  constructed to mold the bottom sheath component of a jointly formed multi-leg cable structure in which conductor bundle  410  is inlaid prior to formation of the bi-component sheath. Assume a urethane sheath (not shown) is impressed in mold cavity  405 . Conductor bundle  410  is secured above the urethane sheet by tension members  414 . Tension members  414  secure conductor bundle  410  at all three legs of the cable to ensure adequate tension is provided during the molding process—this is to ensure that conductor bundle  410  is maintained in a concentric position within mold cavity  407  (of  FIG. 4B ) during the resin injection stage. 
     Conductor bundle  410  can also be secured by inlaid component support structure  416 . Support structure  416  can secure conductor bundle  410  at the bifurcation region of mold  404 . This can further ensure that conductor bundle remains in a concentric position within mold cavity  407 . Support structure  416  can be any suitable structure such as pins, a ring, or rods. 
       FIG. 4B  shows an illustrative cross-sectional view of top mold  402  and bottom mold  404  compressed together. The cross-section may be taken along the line A-A of  FIG. 4A  (assuming the top mold is on top of the bottom mold). Top urethane sheet  406  and bottom urethane sheet  408  are shown. Resin  418  is shown being drawn by a low pressure vacuum through one end (e.g., main leg end) of mold cavity  407  existing within the bi-component sheath to the other ends (e.g., headphone ends). When the resin cures, it yields a cable having a cross-section such as cable structure  200  (of  FIG. 2 ). 
     Top mold  402  and bottom mold  404  are compressed together using a relatively low pressure. For example, compression molding pressures are typically less than pressures used in injection molding processes. In addition, use of a low pressure vacuum to drawn resin in through mold cavity  407  also minimizes movement of bundle  410  and assists in maintaining an equal distribution of resin around the periphery of bundle  410 . 
       FIG. 5A  shows an illustrative top view of bottom mold  504  constructed to mold the bottom sheath component of a leg (e.g., a main leg) in which conductor bundle  510  is inlaid prior to formation of the bi-component sheath. Mold  504  has two mold cavities  505  for producing two cable structures. Conductor bundle  510  is secured by tension members  514 . An inlaid support structure may not be needed because conductor bundle  510  does not pass through a bifurcation region. 
       FIG. 5B  shows an illustrative cross-section of top mold  502  and bottom mold  504  when compressed. Top urethane sheet  506  and bottom urethane sheet  508  are shown. Resin  518  is shown being drawn by a low pressure vacuum through one end of mold cavity  407  existing within the bi-component sheath to the other end. When the resin cures, it yields a cable having a cross-section such as cable structure  200 . 
       FIG. 6A  shows an illustrative top view of bottom mold  604  constructed to mold the bottom sheath component of a jointly formed multi-leg cable structure in which removable rods are inlaid prior to formation of the bi-component sheath. Assume a urethane sheath (not shown) is impressed in mold cavity  605  before removable rods  620 ,  622 , and  624  are placed into mold  604 . Rods  620 ,  622 , and  624  are used to assist forming the shape of the bi-component sheath during compression. After the bi-component sheath is formed, the rods are removed, yielding a hollow cable structure. A conductor bundle is inserted into the hollow cavity, secured in place (using tension members), and subjected to a resin application stage. The rods may be covered with a low friction coating (e.g., Teflon) to promote ease of removal from the bi-component sheath. In another approach, which is shown in  FIGS. 7A and 7B , the rods may be jacketed with a tube sleeve, which becomes affixed to the inner wall of the bi-component sheath, but enables the rod to be easily extracted. 
     Rod  620 ,  622 , and  624  may be secured in place to prevent them from moving during formation of the bi-component sheath. The rods for each leg can be secured in place by support structure remote from the mold and internal to the mold. For example, a fixture can hold one end of rod  620  in place and an inlaid support structure can hold the other end of rod  620  in place. Holding the rods in place can assist in forming a bi-component sheath of uniform thickness. 
       FIG. 6B  shows an illustrative cross-section of top mold  602  and bottom mold  604  when compressed. Top urethane sheet  606  and bottom urethane sheet  608  are shown wrapped around rods  620  and  622 . Rods  620  and  622  (and  624  not shown) can be constructed to seamlessly interface with each other at the bifurcation region. The seamless integration may prevent sheets  606  or  608  from seeping into any joints or cracks between the rods during the bi-component sheath mold formation. Alternatively, the integration of the rods at the bifurcation region may constructed to permit controlled seepage of sheets  606  and  608  to form an inlaid component support structure. This support structure can be used to assist in securing a conductor bundle. 
       FIG. 7A  shows an illustrative top view of bottom mold  704  constructed to mold the bottom sheath component of a leg of a cable structure in which removable rod  720  is inlaid prior to formation of the bi-component sheath. Rod  720  is jacketed with tube sleeve  722 , which is constructed to permit rod  720  to be easily removed after the bi-component sheath is formed.  FIG. 7B  shows a cross-sectional view of mold  702  and  704  compressed together to form the bi-component sheath from top and bottom sheets  706  and  708 . If an inlaid support member is used, it preferably does not pierce the tube. After rod  720  is removed and a conductor bundle (not shown) is inserted, secured, and subjected to resin application, the resulting cross-section can be similar to cable structure  210  of  FIG. 2 . 
       FIG. 8  shows illustrative cross-sectional view of a cable structure that can be manufactured using a low-pressure vacuum to draw a resin through a mold in accordance with an embodiment of the invention. The illustrated cross-sectional view represents a cross-sectional view of a leg of a cable structure. Cable structure  800  shows resin  802  encapsulating conductor bundle  810 . No urethane sheet is used to form a sheath of cable structure  800 . Rather, resin  802  forms the sheath of cable structure  800 . 
     Cable structure  800  can be manufactured using a direct wire inlaid resin sheath molding process. This process is similar to the process discussed above in connection with  FIG. 3A  and  FIGS. 4A and 4B , except that the urethane sheets are not used. In particular, cable structure  800  can be manufactured as follows. A conductor bundle is secured in place above a bottom mold, and a top mold is mated flush against the bottom mold. When the two molds are mated together, a low pressure vacuum is applied to draw a resin from one side of the flush mated mold to the other side of the mold. The resin is cured, and the mold halves are separated, thereby yielding cable structure  800 . 
     The resin used in various embodiments discussed herein can be a polyurethane, a thermoset polyurethane, or a dual liquid set polyurethane. 
       FIG. 9  shows illustrative cross-sectional views of a cable structure that can be manufactured by compression molding two silicon or thermoplastic sheets in accordance with embodiments of the invention. The illustrated cross-sectional views represent a cross-sectional view of a leg of a cable structure. Cable structure  900  shows silicon  902  encapsulating conductor bundle  910 . Silicon  902  forms a bi-component sheath around bundle  910  that directly interfaces with bundle  910 . Mold interface region  903  illustrates the region where a top silicon sheet is molded to a bottom silicon sheet. Cable structure  910  can be manufactured using a direct wire inlaid bi-component sheath molding process, which is similar to the same process discussed above. 
     Cable structure  920  has bi-component silicon sheath  902  filled with resin  904 , which encapsulates bundle  910 . Cable structure  930  is similar in every respect to cable structure  920 , except for the addition of tube sleeve  906 . Tube sleeve  906  directly interfaces with the inner diameter of the bi-component sheath and resin  206 . Cable structures  920  can be manufactured using a tube-inlaid bi-component sheath molding process, which is similar to the same process discussed above. 
       FIG. 10A  shows a simplified exploded cross-sectional view of top mold  1002 , bottom mold  1004 , top silicon sheet  1006 , bottom silicon sheet  1008 , and inlaid component  1010  (e.g., conductor bundle or removable rod) used to manufacture a silicon-based cable structure according to an embodiment of the invention. Top and bottom molds  1002  and  1004  can be constructed to mold either a single-segment cable structure or a multi-segment cable structure. Top and bottom molds  1002  and  1004  each have a cavity for shaping the cable structure. For example, the molds can be same as those shown in  FIGS. 3B and 3C . If desired, the molds can be constructed to yield multiple cable structures. 
     Many of the same attributes discussed above in connection with  FIGS. 3-7  are applicable to various manufacturing processes for making silicon based cable structures, with a few exceptions. Silicon material requires higher heat and pressure to form the bi-component sheath than urethane. Therefore, molds  1002  and  1004  may be constructed to handle higher temperatures. In addition, a vacuum may not be needed to hold the silicon sheets in place during a compression event, therefore solid, non-porous materials can be used. 
       FIG. 10B  shows an illustrative cross-sectional view of a mold that be used to compress silicon sheets in accordance with an embodiment of the invention. Top and bottom molds  1012  and  1014  are constructed with cavities  1013  and  1015  conducive for holding inlaid component  1010  in place. For example, cavity  1015  can be deeper than cavity  1013  so that inlaid component can be securely held in place in the bottom mold. 
     The silicon sheets can have preformed channels or can be cut prior to being compression molded together.  FIGS. 11A-C  and  FIGS. 12A-B  illustrate different preformed sheets. Referring now to  FIG. 11A , a preformed silicon sheet having a cavity for forming a single-segment cavity structure is shown.  FIG. 11B  is an enlarged view of bifurcation region  1102 . As shown, an inlaid support structure  1104  is constructed in the silicon sheet.  FIG. 11C  shows a cross-sectional view taken along lines C-C of  FIG. 11A .  FIG. 11C  shows legs  1105  and ring  1106  of inlaid structure  1104 . Ring  1106  may secure a conductor bundle in place during a compression molding event. 
       FIG. 12A  shows illustrative top and bottom silicon sheets  1202  and  1204 , and  FIG. 12B  shows a perspective view of bottom sheet  1204 . Top and bottom sheets  1202  and  1204  may be used to form a leg of a cable structure. The non-cavity portions  1205  of sheets  1202  and  1204  can be constructed to have a flush fit when compressed together. Cavity  1207  and cavity  1206  form a hollow tube, in which an inlaid component (not shown) can be contained. The hollow cavity secures the inlaid component in place during the molding process. 
     Another silicon sheet that can be used in the silicon-based molding process can be a sheet with a conductor bundle integrated within the sheet. For example, a silicon sheet can be injected molded around a conductor bundle. This sheet is then placed in a mold to obtain the desired shape needed for the single-segment cable structure or leg of a multi-segment cable structure. 
       FIG. 13  illustrates steps that may be performed to manufacture a cable structure in accordance with an embodiment of the invention. Starting at step  1310 , two urethane sheets are compression molded around an inlaid component to produce a variable diameter bi-component sheath that encapsulates the inlaid component. At step  1320 , the inlaid component can be secured in a predetermined position during the compression molding event. If the inlaid component is a conductor bundle, the process can jump to step  1350 , which applies a low-pressure vacuum to draw a resin through a cavity existing within the bi-component sheath. At step  1360 , the resin is cured to permanently position the conductor bundle within the bi-component sheath. If the inlaid component is a removable rod, the process proceeds to step  1330 , where the removable rod is removed. Then at step  1340 , a conductor bundle in secured in placed within the bi-component sheath. After the conductor bundle is secured, the process proceeds to step  1350 . 
       FIG. 14  illustrates steps that may be performed to manufacture a cable structure in accordance with an embodiment of the invention. Starting at step  1410 , a conductor bundle is secured within a compressed mold having a cavity that has a varying diameter. At step  1420 , a low pressure vacuum is applied to draw a resin through the cavity, the resin conforming to the varying diameter of the cavity. Then, at step  1430 , the resin is cured to takes the shape of the cavity and permanently position the conductor bundle. 
       FIG. 15  illustrates steps that may be performed to manufacture a cable structure in accordance with an embodiment of the invention. Starting at step  1510 , at least one silicon sheet is compression molded around an inlaid component to produce a bi-component sheath that encapsulates the inlaid component. The bi-component sheath has a varying diameter. At step  1520 , the inlaid component is secured in a predetermined position during the compression molding. The inlaid component can be a conductor bundle or a removable rod. 
     It should be understood that processes of  FIGS. 13-15  are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added, without departing from the scope of the invention. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20110125
Publication Date: 20160301
Grant Date: 20160301
Priority Date: 20100125
Inventors: AASE JONATHAN
CHOINIERE PAUL
DUNHAM GREG
Assignee: APPLE INC
CPC Classifications: [{"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3665", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02G15/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C43/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3621", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/14131", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2105/256", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2045/1409", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C33/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C33/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29K2105/256", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3665", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3621", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14073", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C39/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C39/42", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C33/10", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C43/36", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2105/256", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29L2031/3462", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C2043/3605", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C43/18", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3665", "inventive": false, "first": false, "tree": "[]"}, {"code": "B29C45/14073", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29K2705/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02G15/18", "inventive": true, "first": true, "tree": "[]"}, {"code": "B29C39/42", "inventive": true, "first": false, "tree": "[]"}, {"code": "B29C2043/3621", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 44308097