PATENT DOCUMENT

Publication Number: US-9977460-B2
Application Number: US-201715476829-A
Country: US
Kind Code: B2

Title: Electronic device with contacts flush with housing

Abstract:
An electronic device comprising a device enclosure having an exterior surface; a contact area positioned at the exterior surface and having first and second ends, the contact area having a plurality of contacts arranged between the first and second ends and substantially flush with the exterior surface; and an alignment feature within the enclosure comprising first and second magnets positioned on opposing sides of the contact area, the first magnet positioned adjacent to the first end of the contact area and the second magnet positioned adjacent to the second end of the contact area.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 a device enclosure that forms a cavity, the device enclosure having a back wall and a sidewall extending away from the back wall; 
 a processor and a computer-readable memory positioned within the cavity; 
 a transparent cover glass coupled to the enclosure opposite the back wall; 
 a display positioned within the cavity adjacent to the cover glass; 
 a battery positioned within the enclosure and operatively coupled to the processor and the display; 
 a contact area positioned at the exterior surface and having first and second ends, the contact area having a plurality of sidewall openings formed through the device enclosure and spaced apart from each other in a single row between the first and second ends; 
 an insulative frame disposed within the cavity adjacent to the contact area and having a plurality of frame openings corresponding in number to the plurality of sidewall openings, wherein the insulative frame is positioned within the cavity such that each one of the plurality of frame openings is aligned with one of the plurality of sidewall openings; 
 a plurality of circular contacts corresponding in number to the plurality of sidewall openings, wherein each circular contact extends through one of the plurality of frame openings and through one of the plurality of sidewall openings; 
 a plurality of insulative rings corresponding in number to the plurality of circular contacts, each of the plurality of insulative rings surrounding one of the plurality of circular contacts to isolate the circular contact from the device enclosure, wherein an exterior surface of each of the plurality of circular contacts is flush with, or recessed less than one millimeter from, an exterior surface of the sidewall in the contact area; and 
 an alignment feature within the enclosure comprising first and second magnetic elements positioned on opposing sides of the contact area, the first magnetic element positioned adjacent to the first end of the contact area and the second magnetic element positioned adjacent to the second end of the contact area. 
 
     
     
       2. The electronic device set forth in  claim 1  wherein the device enclosure is generally rectangular in shape and includes four side walls that surround the transparent cover glass and extend from an upper surface of the electronic device defined at least in part by the transparent cover glass to a back surface. 
     
     
       3. The electronic device set forth in  claim 2  wherein each of the four side walls having a curved exterior surface and the contact area is positioned within a curved portion of one of the side surfaces. 
     
     
       4. The electronic device set forth in  claim 1  wherein the exterior surface of the enclosure and exterior surfaces of each circular contact and surrounding insulator combine to form a continuous surface without any visible gaps between the exterior surface of the enclosure and the exterior surfaces of each circular contact and the surrounding insulator. 
     
     
       5. The electronic device set forth in  claim 1  wherein the first magnetic element comprises a first magnet and the second magnetic element comprises a second magnet. 
     
     
       6. The electronic device set forth in  claim 1  wherein the first magnetic element comprises a first array of magnets and the second magnetic element comprises a second array of magnets. 
     
     
       7. The electronic device set forth in  claim 1  wherein the enclosure comprises aluminum. 
     
     
       8. The electronic device set forth in  claim 1  wherein the display comprises a capacitive touch sensitive layer configured to receive touch input. 
     
     
       9. The electronic device set forth in  claim 8  further comprising a force detection sensor configured to detect an amount of force applied to the touch sensitive display. 
     
     
       10. An electronic device comprising:
 a device enclosure having a generally rectangular back wall with rounded corners and four exterior walls including first and second opposing side walls along a length of the electronic device and third and fourth opposing side walls along a width of the electronic device; 
 a transparent cover glass coupled to the device enclosure at the four exterior side walls such that the four exterior side walls extend between the back wall and the cover glass, the transparent cover glass and device enclosure combining to form an interior device cavity; 
 a touch sensitive display positioned between the transparent cover glass and the back wall; 
 a processor and a computer-readable memory positioned within the interior device cavity; 
 a battery positioned within the interior device cavity and operatively coupled to the processor and the touch sensitive display; 
 an input button configured to receive an input corresponding to a command to the electronic device, the input button disposed at an exterior surface of the electronic device at a location surrounded by the cover glass and outside of the touch sensitive display and centered between the first and second opposing side walls and adjacent to the third side wall; 
 a receptacle connector positioned at an exterior surface of the third side wall, the receptacle connector having a plurality of receptacle connector contacts configured that enable the electronic device to receive power and data from another device; 
 a contact area positioned at an exterior surface of the first side wall, the contact area having first and second ends and a plurality of sidewall openings spaced apart from each other in a single row between the first and second end; 
 an insulative frame disposed adjacent to the contact area and having a plurality of frame openings corresponding in number to the plurality of sidewall openings, wherein the insulative frame is positioned within the cavity such that each one of the plurality of frame openings is aligned with one of the plurality of sidewall openings; 
 a plurality of contacts corresponding in number to the plurality of frame openings, wherein each one of the plurality of contacts includes a portion disposed within one of the plurality of sidewall openings and includes an exterior contact surface that is flush with, or recessed less than one millimeter from, an exterior surface of the device enclosure in the contact area, wherein each of the plurality of contacts is surrounded within its respective opening by an insulator that surrounds the contact isolating the contact from the device enclosure; and 
 an alignment feature within the enclosure comprising first and second magnets positioned on opposing sides of the contact area, the first magnet positioned adjacent to the first end of the contact area and the second magnet positioned adjacent to the second end of the contact area. 
 
     
     
       11. The electronic device set forth in  claim 10  wherein each of the four side walls has an exterior surface that is curved between the back wall and the cover glass and the contact area is positioned within a curved portion of the exterior surface of the third wall. 
     
     
       12. The electronic device set forth in  claim 11  wherein an exterior surface of each contact in the plurality of contacts has a curvature that matches the curvature of the third sidewall. 
     
     
       13. The electronic device set forth in  claim 11  wherein an exterior surface of each contact in the plurality of contacts is substantially flat. 
     
     
       14. The electronic device set forth in  claim 10  wherein the exterior surface of third wall and exterior surfaces of each contact in the plurality of contacts and surrounding insulator combine to form a continuous surface without any visible gaps between the exterior surface of the enclosure and the exterior surfaces of each contact in the plurality of contacts and its surrounding insulator. 
     
     
       15. The electronic device set forth in  claim 10  wherein the alignment feature comprising first and second arrays of magnets positioned on opposing sides of the contact area, the first array of magnets positioned between the first end of the contact area a first end of the electronic device and the second array of magnets positioned between the second end of the contact area and a second end of the electronic device opposite the first end. 
     
     
       16. The electronic device set forth in  claim 10  wherein the enclosure is a metal enclosure. 
     
     
       17. The electronic device set forth in  claim 16  wherein each insulator that surrounds one of the plurality of contacts comprises plastic. 
     
     
       18. The electronic device set forth in  claim 1  wherein the device enclosure has a generally rectangular shape and the sidewall includes first and second opposing sidewall segments along a length of the enclosure and third and fourth opposing sidewall segments along a width of the enclosure; the contact area is positioned along the first sidewall segment; and the electronic device further includes a receptacle connector having an opening disposed at an external surface of the third sidewall segment. 
     
     
       19. The electronic device set forth in  claim 18  wherein the plurality of circular contacts includes a data contact and a power contact and the receptacle connector includes a plurality of contacts configured to receive power and data from a second electronic device. 
     
     
       20. The electronic device set forth in  claim 1  wherein each of the plurality of insulative rings and the insulative frame are part of a monolithic structure. 
     
     
       21. The electronic device set forth in  claim 10  wherein insulator that surrounds one contact in the plurality of contacts isolating the contact from the device enclosure and the insulative frame are part of a monolithic structure.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation application of 15/256,432, filed Sep. 2, 2016, which claims the benefit of priority of U.S. Provisional Patent Application 62/215,688 filed on Sep. 8, 2015; U.S. Provisional Patent Application 62/215,714 filed on Sep. 8, 2015; U.S. Provisional Patent Application 62/254,033 filed on Nov. 11, 2015; U.S. Provisional Patent Application 62/215,592 filed on Sep. 8, 2015; and U.S. Provisional Patent Application 62/214,671 filed on Sep. 4, 2015; each of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     There are many different types of electronic devices including laptop computers, tablet computers, smart phones, among others. Such devices can work in cooperation with one or more accessory devices (e.g., a keyboard, a game controller, a clock radio, etc.) to expand the capabilities and functionality of the primary or host electronic device. To do so, a connection can be established between the host electronic device and the accessory electronic device. 
     Connections can be established with a variety of conventional physical connectors that adhere to pre-defined formats, such as USB 2.0, USB 3.0, Firewire, and the like, or connections can be established wirelessly using protocols such as Bluetooth, WiFi, etc. In some instances, a physical, wired connection can be beneficial to exchange power and exchange data. 
     Wired connections require some amount of real estate within the device. As an example, a USB receptacle connector typically requires a certain amount of surface area at an exterior surface of a host device along with a certain amount of volume within the host device for the cavity of the receptacle connector into which a plug connector can be inserted and for the associated contacts and circuitry of the receptacle connector. Physical connectors can also become a potential source of corrosion and may detract somewhat from the aesthetic appearance of the device. 
     BRIEF SUMMARY 
     Embodiments of the disclosure pertain to an electronic device, such as a host electronic device, that includes a physical connector that is highly corrosion resistant, requires a small amount of real estate and is aesthetically pleasing. Some embodiments provide an external physical connector that includes contacts that are substantially flush with an exterior surface of the electronic device. The exterior surface can be flat or can be curved and an exterior surface of the contacts can include a profile that matches that of the exterior surface. In some embodiments, for example where the enclosure is made from metal or another conductive material, a nonconductive material can surround the contacts in the connector to electrically insulate each contact from the other contacts as well as from the housing of the electronic device. 
     In some embodiments the connector does not provide alignment by itself for mating with a corresponding connector of an accessory electronic device. Instead, an alignment feature, such as a magnet or an array of magnets, can be incorporated into the connector. The alignment feature cooperates with a corresponding alignment feature in the accessory electronic device so that the contacts in the host electronic device are properly aligned with the contacts in the accessory electronic device during a mating event so that electric signals can be passed between the two devices through the mated contacts. 
     In some embodiments an electronic device is provided that includes a device enclosure having an exterior surface and a contact area positioned at the exterior surface. The contact area has first and second ends and a plurality of contacts arranged between the first and second ends that are substantially flush with the exterior surface. The electronic device further includes an alignment feature within the enclosure that includes first and second magnets positioned on opposing sides of the contact area with the first magnet being positioned adjacent to the first end of the contact area and the second magnet being positioned adjacent to the second end of the contact area. 
     In some embodiment the portion of the device enclosure in the contact can be made from an electrically conductive material that includes one or more openings in which the plurality of contacts are positioned. One or more insulators can also be positioned in the opening surrounding the plurality of contacts and electrically isolating the plurality of contact from the device enclosure. In some embodiments the one or more insulators include a plurality of insulation rings equal in number to the plurality of contacts. 
     In some embodiments the exterior surface of the device enclosure and exterior surfaces of the one or more contacts and the one or more insulators can combine to form a continuous smooth surface. And, in some embodiments, there are no gaps between the exterior surface of the housing and each of the one or more insulators and there are no gaps between each of the one or more contacts and the one or more insulators. In some embodiments the device enclosure can have a curved exterior surface within the contact area and each contact in the plurality of contacts has a curvature at an outer contact surface that corresponds to a curvature of the curved exterior surface. 
     In some embodiments, an electronic device according to the disclosure includes: a device enclosure having an exterior surface; a contact area positioned at the exterior surface and having first and second ends, the contact area having at least one contact positioned between the first and second ends and substantially flush with the exterior surface; and an alignment feature within the enclosure comprising at least one magnet positioned within the device enclosure within or adjacent to the contact area. 
     In still other embodiments, an electronic device according the disclosure includes: a device enclosure that forms a cavity; a processor and a computer-readable memory positioned within the cavity; a transparent cover glass coupled to the enclosure; a display positioned within the cavity adjacent to the cover glass; and a battery positioned within the enclosure and operatively coupled to the processor and the display. The electronic device can further include a contact area positioned at an exterior surface of the device enclosure, the contact area having having first and second ends. A plurality of circular contacts can be spaced apart from each other in a single row between the first and second ends with each of the plurality of circular contacts being positioned within an opening formed through device enclosure and having an exterior surface that is flush with, or recessed less than one millimeter from, an exterior surface of the device enclosure in the contact area. An insulating ring can be positioned in each of the plurality of openings that surrounds the contact in the opening and isolates the contact from the device enclosure where the exterior surface of the housing and exterior surfaces of the plurality of circular contacts and the exterior surface of the plurality of insulator rings can combine to form a continuous smooth surface. The electronic device can further include an alignment feature within the enclosure that includes first and second arrays of magnets positioned on opposing sides of the contact area with the first array of magnets positioned adjacent to the first end of the contact area and the second array of magnets positioned adjacent to the second end of the contact area. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an electronic system according to an embodiment of the disclosure; 
         FIG. 2  is a simplified isometric view of a host electronic device shown in  FIG. 1  according to some embodiments of the disclosure; 
         FIG. 3  illustrates a contact structure in a device enclosure according to some embodiments of the disclosure; 
         FIG. 4  is a simplified cross-sectional view of an individual contact within the contact structure shown in  FIG. 3  taken along line A′A′ according to some embodiments of the disclosure; 
         FIG. 5  is a simplified isometric view of an accessory electronic device having a keyboard attached to a cover that includes multiple contacts that can mate with the contact structure shown in  FIGS. 3 and 4  according to some embodiments of the disclosure; 
         FIG. 6  is a simplified perspective view of a contact structure according to some embodiments of the disclosure; 
         FIG. 7  is a simplified a side cross-sectional view of the contact structure shown in  FIG. 6  according to some embodiments of the disclosure; 
         FIG. 8  illustrates an exploded view of various components of the attachment feature shown in  FIG. 2  according to some embodiments of the disclosure; 
         FIG. 9  illustrates a cross sectional view of the attachment feature shown in  FIGS. 2 and 8  through the dashed line shown in  FIG. 8 ; 
         FIG. 10  illustrates a side view of the accessory device shown in  FIG. 5  coupled with the electronic device shown in  FIG. 2 , with the accessory device in a folded configuration to allow use of the keyboard assembly with the electronic device; 
         FIGS. 11-13  illustrate an enlarged view of the portion of  FIG. 10  shown in dotted lines, with the attachment feature of the accessory positioned in a retention feature of the accessory; 
         FIG. 14  illustrates the contact of  FIG. 4 ; 
         FIG. 15  illustrates a plastic insulator for the contact of  FIG. 4 ; 
         FIGS. 16-18  illustrate a method of assembling a contact structure in an electronic device according to an embodiment of the present disclosure; 
         FIG. 19  is a simplified cross-sectional view of an individual contact within the contact structure shown in  FIG. 3  taken along line A′-A according to another embodiment of the present disclosure; 
         FIG. 20  illustrates the contact of  FIG. 19 ; 
         FIG. 21  illustrates the contact of  FIG. 20  in a plastic insulator according to an embodiment of the present disclosure; 
         FIGS. 22  illustrates an assembled contact structure in an electronic device according to an embodiment of the present disclosure; 
         FIG. 23  is a simplified cross-sectional view of an individual contact within the contact structure shown in  FIG. 3  taken along line A′-A according to another embodiment of the present disclosure; 
         FIG. 24  illustrates the contact of  FIG. 23 ; 
         FIG. 25  illustrates the contact of  FIG. 24  in a plastic insulator according to an embodiment of the present disclosure; 
         FIG. 26  illustrates an assembled contact structure in an electronic device according to an embodiment of the present disclosure; 
         FIG. 27  illustrates a contact according to another embodiment of the present disclosure; 
         FIG. 28  illustrates contacts of  FIG. 27  in a plastic insulator according to an embodiment of the present disclosure; 
         FIGS. 29-34  illustrate a method of assembling a contact structure in an electronic device according to an embodiment of the present disclosure; 
         FIG. 35  illustrates a contact structure in a device enclosure according to an embodiment of the present disclosure; 
         FIG. 36  illustrates a cutaway side view of an individual contact that can be incorporated into the contact structure of  FIG. 35  according to an embodiment of the disclosure; 
         FIG. 37  illustrates a cutaway side view of another individual contact that can be incorporated into the contact structure of  FIG. 35  according to an embodiment of the disclosure; 
         FIG. 38  illustrates a portion of a contact structure according to an embodiment of the disclosure; 
         FIG. 39  is an exploded view of a contact structure according to an embodiment of the disclosure; 
         FIGS. 40-43  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the disclosure; 
         FIGS. 44-47  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the disclosure; and 
         FIGS. 48-52  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the disclosure. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings listed above and discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present disclosure described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments of the disclosure illustrated in the accompanying drawings. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting. To the contrary, the present disclosure is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments. It is to be understood that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to a host electronic device suitable for use with an accessory electronic device. The host electronic device can include a physical connector that is highly resistant to corrosion, requires a small amount of real estate and is aesthetically pleasing. In some embodiments the host electronic device can include an external physical connector having one or more contacts that are flush with, or slightly recessed from, an exterior surface of the host electronic device. The exterior surface can be flat or can be curved and an exterior surface of the contacts can include a profile that matches that of the exterior surface. In some embodiments, for example where the enclosure is made from metal or another conductive material, a nonconductive material can surround the contacts in the connector to electrically insulate each contact from the other contacts as well as from the housing of the electronic device. 
       FIG. 1  illustrates an electronic system  100  according to some embodiments of the present disclosure. System  100  includes a host electronic device  110  that can be connected to an accessory electronic device  120  in order to share data, power, or both between the accessory and the host. Specifically, one or more contacts  112  on host device  110  can be electrically connected to one or more contacts  122  on accessory device  120  by, for example, a cable connector  130 . In other embodiments of the present disclosure, contacts  112  on host device  110  can be directly and electrically connected to contacts  122  on accessory device  120  using connectors different than cable connector  130 . In still other embodiments of the present disclosure, one or more optical contacts supporting one or more optical connections between host device  110  and accessory device  120  can be included. 
     To facilitate a direct connection between contacts  112  on host electronic device  110  and contacts  122  on accessory electronic device  120 , contacts  112  can be part of a surface mount connector incorporated into the host device  110  in which the contacts are located at an external surface of device  110  and are either flush with, or recessed a limited amount relative to, an enclosure of device  110 . Some examples of a surface mount connector that includes contacts  112  are shown in the following figures and discussed below. 
       FIG. 2  illustrates an isometric view of an electronic device  200  according to some embodiments of the present disclosure. Electronic device  200  is representative of one the many different types of electronic devices that can be host electronic device  110  shown in  FIG. 1 . In some embodiments, electronic device  200  is a mobile communications device, such as a smartphone. In the embodiment shown in  FIG. 2 , electronic device  200  is a tablet computing device. Electronic device  200  can vary in shape and size. Also, electronic device  200  can include an enclosure  202  that forms a cavity (see  FIG. 4 , cavity  405 ) and is designed to enclose and protect various internal components of device  200  within the cavity, such as a battery  203 , one or more processors  205 , one or more computer-readable memories  207 , wireless interfaces  209 , etc. In some embodiments, enclosure  202  is formed from a metal, such as aluminum, or another electrically conductive material. 
     Electronic device  200  can also include a display assembly  204  designed to present visual content. In some embodiments, display assembly  204  includes a touch sensitive layer designed to receive a touch input and generate commands, in accordance with the touch input, to the electronic device  200 . Further, in some embodiments, display assembly  204  includes a capacitive touch sensitive layer designed to generate an input based upon a capacitive coupling with the display assembly  204 . An outer protective layer  206  made from a transparent material, can overlay display assembly  204  and be attached to enclosure  202  with an adhesive or other means thereby covering the display and the cavity formed by the enclosure. Outer protective layer  206  can be made from glass or similar materials and is sometimes referred to as a cover glass. In some embodiments, electronic device  200  can further include a force detection sensor (not shown) designed to detect an amount of force applied to display assembly  204  and/or outer protective layer  206 . 
     Electronic device  200  can include one or more input buttons, such as button  208 , designed to receive an input corresponding to a command to the electronic device (for example, to change the visual content shown on display assembly  204 ). Further, in some embodiments, electronic device  200  includes a receptacle connector  210  designed to receive power and/or data from another device. For example, power from a power source (not shown) can be supplied to device  200  through connector  210  in order to power internal components of electronic device  200  and/or power one or more power sources (not shown) disposed in electronic device  200 . Receptacle connector  210  can include a cavity in which the contacts of the receptacle connector are located. 
     Separate from connector  210 , electronic device  200  can further include one or more electrical contacts  212  within a contact area  211  located at an exterior surface of device  200 . Electrical contacts are designed to electrically couple with corresponding contacts associated with an accessory device, such as accessory device  500  (shown in  FIG. 5 ). Contacts  212  can allow for electrical communication between electronic device  200  and accessory device  500  just as contacts  112  can allow electrical communication between devices  110  and  120 . For example, in some embodiments contacts  212  can include one or more data contacts that enable the exchange of data between devices  200  and  500 . Contacts  212  can also include one or more power contacts that enable an accessory device to provide power to electronic device  200  or enable an accessory device to draw power from device  200  and/or ground contacts. 
     Contacts  212  can be substantially flush with an exterior surface of housing  202 . That is, in some embodiments contacts  212  are not formed within an exposed opening or other type of cavity in housing  202  that is typically required by a receptacle connector, such as connector  210 , and that might otherwise be a source for dust or other debris to collect. Instead, contacts  212  are part of a continuous exterior surface of the device housing  202  making the contacts less noticeable than when standard connectors are incorporated into housing  202 , which can be beneficial to the aesthetic appearance of electronic device  200 . As used herein, contacts  212  can be said to be “substantially flush” with an exterior surface of housing  202  when the exterior surface of the contacts is flush with (e.g., in the same plane as) the surrounding housing surface as well as when an exterior surface of each individual contact  212  is recessed a limited amount, such as  1  millimeter or less, from the surface of the exterior housing  202  that surrounds the contact. In other embodiments contacts  212  are recessed 0.5 mm or less and in still other embodiments, contacts  212  are recessed 0.25 mm or less from the surrounding exterior housing surface. When the contacts are substantially flush with the surrounding exterior surface of housing  202 , the contact and exterior housing can combine such that there is a continuous smooth transition between the portion of the housing exterior surface surrounding the contact and the exterior surface of the contact. 
     Since contacts  212  are not positioned within a cavity of housing  202  or other exposed opening of housing  202  that can provide alignment for a corresponding connector to mate and electrically connect to contacts  202 , in some embodiments electronic device  200  includes an alignment feature to facilitate connector mating. In some particular embodiments, the alignment feature can include a first array  214  of alignment magnets and a second array  216  of alignment magnets disposed along a sidewall  215  of enclosure  202  on opposite sides of contacts area  211 . Each of first array  214  and second array  216  of magnets can include several magnets having a magnetic polarity arrangement to magnetically couple the arrays with corresponding arrays of magnets in the accessory electronic device as explained below. The magnetic circuits formed by multiple magnetic couplings can allow electronic device  200  to magnetically couple with an accessory electronic device, such as accessory device  500  shown in  FIG. 5 , and align contacts  212  with contacts of the accessory electronic device. In other embodiments, the alignment feature can include fewer or more magnets or magnetic components or other types of alignments structures. 
       FIG. 3  illustrates a contact area  300  in a device enclosure according to an embodiment of the present disclosure. Contact area  300  can be, for example, contact area  211  shown in  FIG. 2 . In this example, contact area  300  includes three individual contacts  312  (labeled as contacts  312   a ,  312   b  and  312   c ) each of which is located at and substantially flush with a surrounding exterior surface of a device enclosure  310 . Embodiments of the disclosure are not limited to any particular number of contacts, however, and other embodiments can include fewer or more than three contacts within contact area  300 . Each of contacts  312  can be similar to or identical to contacts  212  while device enclosure  310  can be, for example, housing  202  of electronic device  200 . In some embodiments device enclosure  310  can be made from a metal or similar electrically conductive material in which case an insulating ring  320  can surround an outside edge of each individual contact  312  between each contact  312  and device enclosure  310 . The insulating rings  320  can be made from plastic or another nonconductive material and can electrically isolate contacts  312  from device enclosure  310 . In these and other embodiments of the present disclosure, contacts  312  and insulating rings  320  can be substantially flush with a surrounding surface of device enclosure  310 . These surfaces can be curved, they can be substantially flat, or they can have other contours. In some embodiments the exterior surfaces of contacts  312  and surrounding insulating rings  320  can combine such that, when the contacts and insulating ring are recessed by the limited amount, the exterior surfaces of the contact, insulating ring and device housing all combine to form a continuous smooth exterior surface that can be slightly recessed in the areas of the contact and/or insulating ring. forming three side-by-side dimples in the contact area, as shown in  FIG. 3 . 
       FIG. 4  illustrates a cutaway side view of a portion of contact area  300  along lines A-A′ in  FIG. 3 . In this example, a contact structure  400  is illustrated. Contact structure  400  includes an individual contact  312  (e.g., one of contacts  312   a - 312   c ) positioned in and filling a sidewall opening  402  in device enclosure  310 . Plastic insulating ring  320  is located between contact  312  and device enclosure  310  surrounding the contact. Plastic ring  320  closely abuts both device enclosure  310  and contact  312  such that no gaps are formed between the three components. Further, as evident from  FIG. 4 , the exterior surface of contact structure  400  is essentially a continuous, smooth (to a user&#39;s touch) and curved surface from the portion of enclosure  310  at the top of the figure, to the upper portion of insulating ring  320 , to contact  312 , to the lower portion of insulating ring  320 , and to the portion of enclosure  310  at the bottom of the figure. 
     As also shown in  FIG. 4 , a flexible circuit board  420  can connect to contact  312 , and a bracket  410  can be used to secure contact  312  in place in device enclosure  310 . In various embodiments of the present disclosure, various adhesives can be used to secure these structures in place. Specifically, adhesive layers  430  can be used to secure contact  312  to plastic insulator  320 . Adhesive layers  430  can also be used to secure plastic insulator  320  to device enclosure  310 . Also, adhesive layers  430  can be used to secure bracket  410  in place in device enclosure  310 . 
     Further details of contact structure  400  as well as examples of contacts and contact structures that can be incorporated into a host electronic device instead of contact structure  400  according to embodiments of the disclosure are discussed below with respect to  FIGS. 14-52 . Before turning to those additional details and examples, however, reference is made to  FIG. 5 , which illustrates an isometric view of an embodiment of an electronic device that is representative of accessory electronic device  120  shown in  FIG. 1 . As such, electronic device  500  can be connected to a host electronic, such as host electronic device  110  shown in  FIG. 1  or host electronic device  200  shown in  FIG. 2 . Accessory device  500  includes a cover  502  coupled with a keyboard assembly  504 . Cover  502  can be sized and shaped to overlay and cover an electronic device, such as device  110  or device  200 , that can be used with accessory device  500 . In some embodiments, cover  502  includes multiple sections, which can also be referred to as panels or segments. For example, as shown in  FIG. 5 , cover  502  can include a first segment  506 , a second segment  508 , and a third segment  510 . Each of first segment  506 , second segment  508 , and third segment  510  can be moveable or rotatable with respect to the remaining segment. In this regard, cover  502  may be referred to as a foldable cover. Further, as shown in  FIG. 5 , third segment  510  can be raised or elevated with respect to first segment  506  and second segment  508  such that when the keyboard assembly  504  is folded over and onto first segment  506  and second segment  508 , keyboard assembly  504  is generally co-planar, or flush, with respect to third segment  510 . 
     Each of the first, second and third segments can be covered or overlaid by a fabric layer  512 , such as a microfiber, or generally any material that provides a cosmetic enhancement while also not causing damage to a display assembly (e.g., display  204  shown in  FIG. 2 ) of the host electronic device that accessory keyboard  500  is designed to operate with. Also, each of the segments can include a rigid panel formed from a material, such as glass fiber, disposed below fabric layer  512 . Further, the segments previously described can be folded to define a folded configuration of cover  502  in which the electronic device that the accessory keyboard is designed to cooperate with can be positioned in a propped-up position. 
     Cover  502  can further include an attachment feature  514  designed to receive and secure a host electronic device, such host electronic device  110  or host electronic device  200 , with accessory device  500 . Attachment feature  514  can include several magnets, or arrays of magnets, (not shown in  FIG. 5 ) that can be aligned to magnetically couple to several magnets disposed in the host electronic device to accessory device  500  is to be attached. Further, accessory device  500  can include one or more electrical contacts within an accessory contact structure  515  designed to electrically couple with electrical contacts  312  of a host electronic device, such as host device  110  or  200 . Generally the number of electrical contacts in contact structure  515  will equal the number of contacts in the corresponding contact area  300  that accessory  500  is manufactured to be paired with. In some embodiments, for example as shown in  FIG. 5 , accessory contact structure  515  includes three contacts  516   a ,  516   b ,  516   c  that align with and can be electrically coupled to contacts  312   a ,  312   b ,  312   c , respectively. Embodiments of the disclosure are not limited to any particular number of contacts within accessory contact structure  515 , however, and can include more or fewer than three contacts in various embodiments. Further details of accessory contact structure  515  are discussed later in this application with respect to at least  FIGS. 6 and 7 . 
     Attachment feature  514  can be coupled with cover  502  by way of an exterior layer  518 , or outer layer, that extends along an exterior surface of cover  502  and wraps around the attachment feature  514  to define a top, or upper, surface of attachment feature  514 . In some embodiments, exterior layer  518  includes a polymer-based, low modulus elastomeric material that allows some flexibility of attachment feature  514  and cover  502 . Further, exterior layer  518  can include a mixture of polyurethane and coal tar and can come in a variety of colors. Also, the material forming exterior layer  518  can further include relatively high adhesion to other components and can further be abrasion-resistant. In this regard, exterior layer  518  can include a relatively high coefficient of friction, which can limit movement of the electronic device when engaged with attachment feature  514 . In order to lower the coefficient of friction, attachment feature  514  can include a first layer  522  and a second layer  524  surrounding the electrical contact. First layer  522  and second layer  524  can include a lower coefficient of friction relative to attachment feature  514 , which can facilitate alignment and coupling between an electronic device and attachment feature  514 . 
     Keyboard assembly  504  can include keys  526  disposed according to a QWERTY configuration commonly known in the art for a keyboard. However, in other embodiments, the keys  526  can include a different configuration according to a language or dialect. Keyboard assembly  504  can include a printed circuit board (not shown) that receives the keys  526 . Keyboard assembly  504  can further include a retention feature  528  disposed across, and protruding from, a top surface  530  of the keyboard assembly  504 . Retention feature  528  can be designed to receive attachment feature  514 , or at least a portion of attachment feature  514 , when cover  502  is in a particular folded configuration. Retention feature  528  can provide a mechanical stop for attachment feature  514  and an electronic device secured with attachment feature  514 . 
     As shown in  FIG. 5 , retention feature  528  includes a ring-like configuration protruding from a top surface  530 . However, in other embodiments, retention feature  528  includes two or more discontinuous features that provide the mechanical stop previously described. Still, in other embodiments, top surface  530  include a trough or “valley” in a location within retention feature  528  that positions a portion of attachment feature  514  below top surface  530 . Also, retention feature  528  can include an array of magnets designed to magnetically couple with magnets in attachment feature  514  that combines with the mechanical stop to further limit movement of attachment feature  514 . Further details of attachment feature  514  are discussed below with respect to  FIGS. 8-9 . 
     Reference is now made to  FIG. 6 , which is a simplified perspective view of accessory contact structure  515  according to some embodiments of the disclosure. As shown in  FIG. 6 , contact structure  515  can include a contact housing  605  (also shown in  FIG. 7 ) that includes a raised portion  610 . The raised portion  610  can be positioned within and extend through an opening in a device enclosure, such as enclosure  620  shown in  FIG. 7 , which can be part of the housing of the accessory device or can be, for example, an exterior surface of attachment feature  514 . Accessory contact structure  515  also includes three individual contacts  516   a ,  516   b  and  516   c , each of which can be made from metal or another conductive material. The raised portion  610  of the contact structure can include separate openings for each of the individual contacts  516   a ,  516   b  and  516   c.    
     Contacts  516   a - 516   c  can be low-profile contacts that allow contact structure  515  to provide contacts for a connector without consuming a large volume in the electronic device housed by enclosure  620 . In various embodiments, contacts  516   a - 516   c  can be spring-biased contacts. For example, contacts  516   a - 516   c  can be biased by a spring, flexible arm, or other flexible structure such that they can be pushed or depressed and may return to their original position once released. Spring-biased contacts can provide an amount of compliance with contacts in a corresponding connector, thereby assisting in forming electrical connections between multiple contacts  516   a - 516   c  and corresponding contacts of a second connector on a second device, such as contacts  312   a - 312   c  of host electronic device  200 . 
       FIG. 7  is a simplified side cross-sectional view of contact structure  515  according some embodiments of the present disclosure taken along the dotted plane, shown in  FIG. 6 . Contact structure  515  can be located in an accessory electronic device having a housing or enclosure  620 . As noted above, raised portion  610  of cover  210  of contact structure  515  can be located in an opening in device enclosure  620 . Contact housing  605  of contact structure  515  can support contacts  516   a ,  516   b ,  516   c  (e.g., opening  548  shown in  FIG. 8 ) having contacting portions  622   a ,  622   b , and  622   c , respectively. These contacting portions  622   a - 622   c  can be attached to ends of flexible lever arms  624   a ,  624   b , and  624   c , respectively. Each flexible arm may terminate in a second end and can include a barb, which may be inserted into notches or grooves in contact housing  605 . Specifically, flexible lever arm  624   a  can include barb  626   a , flexible lever arm  624   b  can include barb  626   b , and flexible lever arm  624   c  can include barb  626   c . In some embodiments, the center contact can have contact housing  605  insert molded around it and barb  626   b  may not be needed. 
     During assembly, the central contact including contact portion  622   b  can be inserted through an opening in a bottom of connector housing  605 . Without more, contacting portion  622   b  could be pushed deep into connector housing  605 . In some instances, contacting structure  622   b  could be pushed below a top surface of raised portion  610 . If contacting portion  622   b  were to be laterally offset at this time, contacting portion  622   b  may not emerge from its opening in contact housing  605 . Accordingly, a bottom stop portion  630  can be located under contacting portion  622   b . Bottom stop portion  630  can limit a depth to which contacting portion  622   b  canbe depressed, thereby preventing possible damage to contact structure  515 . In other embodiments, the center contact can have contact housing  605  insert molded around it and bottom stop portion  630  may not be needed. 
     Reference is now made to  FIG. 8 , which illustrates an exploded view of various components of attachment feature  514  according to some embodiments of the disclosure. For example, attachment feature  514  can include a first array  532  of magnets and a second array  534  of magnets. In some embodiments, first array  532  and second array  534  include several magnets (such as neodymium magnets) aligned together prior to assembly. In the embodiment shown in  FIG. 8 , first array  532  and second array  534  are formed form a composition of non-magnetized material and magnetized prior to an assembly of attachment feature  514 . First array  532  and second array  534  can be placed under a camera/sensor assembly (not shown) and aligned with a magnetizer (not shown) according to a desired alignment between electrical contacts  516 a-c and an electronic device (not shown). This allows for a custom magnetization that improves a magnetic alignment of an electronic device. 
       FIG. 8  further shows first array  532  and second array  534  having several magnetized regions. For example, first array  532  can include a first magnetized region  536  and a second magnetized region  538  adjacent to first magnetized region  136 . Also, the magnetized regions can include dissimilar magnetic regions, or magnetic region of different sizes. As known by one of ordinary skill in the art, a magnet generally includes magnetic polarity arrangement having a “North” facing polarity, or North Pole, and a region of a “South” facing polarity, or South Pole, with magnetic field lines extending in a direction from the North Pole to the South Pole. Also, it is also understood by one of ordinary skill in the art that a North Pole of a magnet can be magnetically attracted to a South Pole of a magnet, and that two North poles, or two South poles, can magnetically repel one another. In this regard, adjacent magnetic regions of first array  532  and second array  534  can include magnet polarity arrangements designed to produce magnetic field lines in opposite directions. For example, as shown in  FIG. 8 , first magnetized region  536  includes magnetic field lines (shown as dotted lines) extending in a first direction, indicative of a top surface have a North polarity and a bottom surface (not shown) opposite the top surface having a South polarity. Conversely, second magnetized region  538  includes magnetic field lines (shown as dotted lines) extending in a second direction opposite the first direction, indicative of a top surface have a South polarity and a bottom surface (not shown) opposite the top surface having a North polarity. This pattern can be representative of magnetized regions of first array and the second array. Further, in other embodiments, the pattern is reversed such that first magnetized region  536  and second magnetized region  538  include magnetic field lines in the opposite direction as those shown in  FIG. 8 . Also, first magnetized region  536  can be smaller than that of second magnetized region  538 . Similar, but complementary, magnet polarity arrangements can be employed in magnet arrays  214  and  216  of device  200  to facilitate magnet coupling of the attachment feature to device  200 . 
     Also, as shown in  FIG. 8 , electrical contact structure  515  can be disposed on a flexible circuit assembly  535 , and a magnetic shunt  537  can be disposed below first array  532  and second array  534 . Magnetic shunt  537  can be formed from a metal, including soft steel, magnetically attracted to first array  532  and second array  534 . Also, magnetic shunt  537  can alter the direction of the magnetic fields of the first and second arrays in a direction towards magnets in a host electronic device, such as magnet arrays  214  and  216  in electronic device  200 , to which attachment feature secures accessory  500 . Attachment feature  514  can further include a protective component  540  that include a metal layer (not shown) that can include stainless steel. An outer coating  542  can cover the metal layer and provide an aesthetic finish. In some embodiments, outer coating  542  includes a photothermolplastic (“PTP”) material that includes polyurethane plus a thermoplastic. 
     Attachment feature  514  can further include or receive several additional features. For example, an electrically conductive fabric  544  designed to carry electrical signals from an electronic device to a connector (not shown) of keyboard assembly  504  (shown in  FIG. 5 ), or vice versa. Electrically conductive fabric  544  can wrap around protective component  540  electrically couple with flexible circuit assembly  535 , and electrically conductive fabric  544  can be electrically coupled with one or more of the individual electrical contacts  516  within contact structure  515  (i.e., one or more of contacts  516   a - 516   c ). In some embodiments, electrically conductive fabric  544  is electrically conductive throughout (the electrically conductive fabric  544 ). In the embodiment shown in  FIG. 8 , electrically conductive fabric  544  includes an electrically conductive region  546  that includes three electrically independent signal traces (not shown) that electrically couple to respective ones of contacts  516   a - 516   c . Exterior layer  518  can also wrap around attachment feature  514  and combine with first layer  522  and second layer  524  to define a top surface of the attachment feature. As shown, exterior layer  518  can include an opening  548  that allows each individual electrical contact  516  to couple with an electrical contact of an electronic device. 
       FIG. 9  illustrates a cross-sectional view of attachment feature  514  through the dashed line shown in  FIG. 8  and with the various components shown in  FIG. 8  assembled together. As shown, metal layer  552 , surrounded by outer coating  542 , is generally U-shaped, but can vary according to a desired shape of attachment feature  514 . Also, exterior layer  518  and electrically conductive fabric  544  generally wrap around protective component  540 , with exterior layer  518  extending over a magnet  554  (of either first array  532  or second array  534 , shown in  FIG. 8 ) and electrically conductive fabric  544  extending below magnet  554 , between magnet  554  and magnetic shunt  537 . Also, electrically conductive fabric  544  can be covered by a cosmetic layer  556 , which further provides a protective cover to the electrically conductive fabric  544 . The cosmetic layer  556  can include PTP. 
     Also, cosmetic layer  556  can be adhesively secured with an upper portion of attachment feature  514 . For example, an adhesive layer  558  between cosmetic layer  556  and outer coating  542  can extend only along a fraction (less than half) of outer coating  542 . This allows for better ease of movement of the attachment feature in a clockwise and/or counterclockwise manner (denoted by arrow  560 ). Also, although not specifically shown, several features shown and described in  FIG. 9  can be adhesively secured together. 
     Referring now to  FIG. 10 , which illustrates a side view of accessory device  500  resting on a surface  1000  (e.g., a desktop) and coupled with electronic device  200 . As shown in  FIG. 5 , accessory device  500  is in a folded configuration to allow use of keyboard assembly  504  with electronic device  200 . In the folded configuration, attachment feature  514  of accessory device  500  couples cover  502  to the retention feature  128  portion of keyboard assembly  504 . At the same time, attachment feature  514  also couples accessory device  500  to host electronic device  200  such that contact area  300  in host device  200  is mated with and electrically connected to contact structure  515  in accessory device  500 . As shown, the folded configuration can include first segment  506 , second segment  508 , and third segment  510  folded to form a triangular support for the electronic device  200 . Further, the electronic device  200  can abut against third segment  510 . 
     In the configuration shown in  FIG. 10 , keyboard assembly  504  can be used as an input device in order to generate input or command to electronic device  300  and change the visual content (denoted as several diagonal lines) of display assembly  204  (shown in  FIG. 2 ) of electronic device  200 . This is due in part to electrically conductive fabric  544 , shown in the enlarged view, folding with cover  502 , and extending through cover. 
     While not shown in  FIG. 10 , one or more arrays of magnets are disposed below retention feature  528  of keyboard assembly  504  and couple with the magnets in the first array  532  and second array  534  of attachment feature  514  when attachment feature  114  is positioned, or nearly positioned, in retention feature  128 . In this regard, each magnet in first array  532  and second array  534  can include a magnetic polarity arrangement to magnetically couple with a magnet in one or more arrays of magnets (not shown) under retention feature  528 . This allows retention feature  528  to simultaneously secure attachment feature  514  and electronic device  300  coupled with attachment feature  514 . In some embodiments, the combined number of magnets in the one or more magnet arrays under retention feature  528  is equal to the combined number of magnets in first array  532  and second array  534 . 
     To more clearly illustrate the magnetic coupling associated with attachment feature  514  and both retention feature  528  and electronic device  200 , reference is made to  FIG. 11 , which illustrates an enlarged partial cross-sectional view of a portion of  FIG. 10  shown in dotted lines taken through portions of attachment feature  514  and retention feature  528  that include alignment magnets as discussed. As shown in  FIG. 11 , attachment feature  514  is positioned in retention feature  528  and the retention feature is used as a mechanical stop for attachment feature  514 . Also, as shown, attachment feature  514  can include a magnet  554  that can be part of first array  532  of magnets or second array  534  of magnets (shown in  FIG. 8 ) magnetically coupled with a magnet  1102  that can be part of the first array  214  or the second array  216  of magnets, respectively (shown in  FIG. 2 ). The magnetic field lines are shown as dotted lines having arrows. Magnet  554  in attachment feature  514  can further be magnetically coupled with a magnet  1104  that is part of an array of magnets in the keyboard assembly  504 . This magnetic coupling can, in combination with the retention feature  528 , maintain the attachment feature  514  and the electronic device  200  in a stationary position. 
     As discussed above, when accessory device is in the folded position shown in  FIG. 10  such that attachment feature  514  is properly aligned with and secured within retention feature  528 , each contact  516  is accessible to be electrically coupled to a respective contact  212  that is part of host device  200 . This connection sequence is illustrated in  FIGS. 12 and 13 , each of which represents the same enlarged partial cross-sectional view of  FIG. 10  that is shown in  FIG. 11  but through a pair mating contacts, a contact  212  (from electronic device  200 ) and a contact  516  (e.g., one of contacts  516   a - 516   c  from accessory device  500 ) instead of through the alignment magnets. Specifically,  FIG. 12  depicts host electronic device  200  in a position in which contact  212  is spaced apart from, and thus not yet mated with, contact  516 . As shown in  FIG. 12 , contact  516  protrudes slightly above an exterior surface  1202  of attachment feature  514 . 
     As shown in  FIG. 13 , as electronic device  200  is moved closer to attachment feature  514  and magnets  1102  and  554  pull device  200  into the attachment feature, contact  516  becomes physically and electrically connected to contact  212 . Contact  516  is attached to a flexible lever arm (e.g., one of lever arms  624   a - 624   c  discussed with respect to  FIG. 7 ) and is thus pushed into the enclosure  620  of the attachment feature by contact  212  (as shown by arrow  1302 ) until device  200  reaches its fully mated position in which exterior surface  1204  of device  200  is in physical contact with exterior surface  1202  of attachment feature  514  at an interface  1205 . 
     Turning our attention back to details of contact  212 , reference is made to  FIG. 14 , which illustrates an embodiment of contact  312  shown in  FIG. 4  as an example of a contact  212 . As shown in  FIG. 14 , contact  312  can include a contacting portion  1402  emerging from a front face  1404 . Contact  312  can further have a rear angle portion  1406  that can connect to flexible circuit board  320 . Contact  312  can be formed by machining, forging, printing, etching, stamping, or in other ways. In other embodiment of the present disclosure, contacts  312  can be formed by a deep drawn process. 
       FIG. 15  illustrates a plastic insulator  1500  according to an embodiment of the present disclosure. In this example, plastic insulator  1500  includes a ring  320  (also shown in  FIG. 3 ) that define an opening  1502  for accepting contact  312 . Rear surfaces  1504  can be covered with adhesives and contact  312  can be joined to plastic insulator  120  at those locations. 
       FIGS. 16-18  illustrate a method of assembling a set of contacts according to an embodiment of the present disclosure. In  FIG. 16 , a number of contacts  312  Can be mated to a flexible circuit board  420  according to an embodiment of the present disclosure. Contacts on flexible circuit board  420  can be attached to rear portions  1406  of contacts  312  by soldering, laser, spot, or resistance welding, or by other method. In this example, flexible circuit board  420  can have three portions, each connected to an angled portion  1406  of a contact  312 . Diodes  1610  can be connected between flexible circuit board traces in flexible circuit board  420  and the device enclosure  310  (shown in  FIG. 4 ) to provide ESD protection. In this example, flexible circuit board  420  can be split into three portions as shown to provide a greater flexibility in attaching flexible circuit board  420  to rear portions  1406  of contacts  312 . Contacts  312  can be aligned with openings  1502  in plastic insulators  1500 . 
     In  FIG. 17 , barrels including contacts  312  in plastic insulators  1500  (as shown in  FIG. 16 ) can be aligned with openings  1702  in device enclosure  310 . Plastic insulators  1500  can be glued in place. In  FIG. 18 , bracket  1810  can be glued in place in notch  1802  in device enclosure  310 . 
     In various embodiments of the present disclosure, different portions of these contact structures and other contact structures can be formed of various materials. For example, bracket  1810  and plastic insulators  1500  can be formed of the same or different materials, such as plastic, LPS, or other non-conductive or conductive material. Contacts  312  can be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. 
     In various embodiments of the present disclosure, different portions of these contact structures and other contact structures can be formed in various ways. For example, bracket  1810  and plastic insulators  1500  can be formed using injection or other molding, printing, or other technique. Contacts  312  can be machined, stamped, coined, forged, printed, or formed in different ways, such as by using a deep drawn process. Plastic insulator  1500  can be formed around contacts  312  using injection molding. 
       FIG. 19  illustrates a cutaway side view of another contact structure  1900  that can be used for the contact structure of  FIG. 3 . In this example, a contact  1912  can be located in an opening in device enclosure  310 . A plastic insulator  1920  can be located between contact  1912  and device enclosure  310  and the exterior surface of contact structure  1900  can be an essentially continuous, smooth (to a user&#39;s touch) and curved surface across the enclosure, insulating ring and contact. A flexible circuit board  1920  can connect to contact  1912  at rear portion  1914 . An optional bracket (not shown) can be used to secure contacts  1912  in place in device enclosure  310 , though in other embodiments of the present disclosure, contacts  1912  and insulators  1920  can be glued or otherwise fixed in place. In various embodiments of the present disclosure, various adhesives can be used to secure these structures in place. Specifically, an adhesive layer can be used to secure contact  1912  to plastic insulator  1920 . Adhesive layers can also be used to secure plastic insulator  1920  to device enclosure  310 . Also, adhesive layers can be used to secure an optional bracket in place in device enclosure  310 . Support  1910  can provide mechanical support for flexible circuit board  1920 . Support  1910  can include ESD diodes (as shown below in  FIG. 22 .) 
       FIG. 20  illustrates the contact structure of  FIG. 19 . In this example, a force can be applied at rear surface  2002  to form contacts  1912  in a deep drawn process. As before, contact  1912  can include a rear angle piece  1914  that can be mated with a flexible circuit board. In other embodiment of the present disclosure, contact  1912  can be formed by machining, forging, printing, etching, stamping, or in other ways. 
       FIG. 21  illustrates the contact of  FIG. 20  in a plastic insulator  2100  according to an embodiment of the present disclosure. In this example, plastic insulator  2100  can have openings  2122  for accepting contacts  1912 . Rear contact portions  1914  can extend from ring-shaped insulator  2120 . 
       FIG. 22  illustrates an assembled contact structure according to an embodiment of the present disclosure. A number of contacts  1912  (not shown) in insulators  2120  can be mated to flexible circuit board  420  according to an embodiment of the present disclosure. Contacts on flexible circuit board  420  can be attached to rear portions  1914  of contacts  1912  (as shown in  FIG. 19 ) by soldering, laser, spot, or resistance welding, or by other method. In this example, flexible circuit board  420  can have three portions, each connected to a rear portion  1914  of a contact  1912 . Diodes  1610  can be connected between flexible circuit board traces in flexible circuit board  420  and the device enclosure  310  to provide ESD protection. In this example, flexible circuit board  420  can be split into three portions as shown to provide a greater flexibility in attaching flexible circuit board  420  to rear portions  1914  of contacts  1912 . 
       FIG. 23  illustrates a cutaway side view of another contact structure  2300  that can be used for the contact structure of  FIG. 3 . In this example, contact  2312  can be located in an opening in device enclosure  310 . A plastic insulator  2320  can be located between contact  2312  and device enclosure  310  and, as evident from  FIG. 23 , the exterior surface of contact structure  2300  can be an essentially continuous, smooth (to a user&#39;s touch) and curved surface across the enclosure, insulating ring and contact. A bridging piece  2315  can connect flexible circuit board  2320  to contact  2312  at rear portion  2314 . An optional bracket (not shown) can be used to secure contacts  2312  in place in device enclosure  310 , though in other embodiments of the present disclosure, contacts  2312  and insulators  2320  can be glued or otherwise fixed in place. In various embodiments of the present disclosure, various adhesives can be used to secure these structures in place. Specifically, adhesive layers can be used to secure contact  2312  to plastic insulator  2320 . An adhesive layer can also be used to secure plastic insulator  2320  to device enclosure  310 . Also, adhesive layers can be used to secure an optional bracket in place in device enclosure  310 . Support  2310  can provide mechanical support for flexible circuit board  2320 . Support  2310  can include ESD diodes (as shown below in  FIG. 26 .) 
       FIG. 24  illustrates the contact of  FIG. 23 . In this example, a force can be applied at surface  2402  to form contacts  2312  in a deep drawn process. As before, contact  2312  can include a rear angle piece  2314  that can be mated with a flexible circuit board. In other embodiment of the present disclosure, contact  2312  can be formed by machining, forging, printing, etching, stamping, or in other ways. 
       FIG. 25  illustrates the contact of  FIG. 20  in a plastic insulator  2500  according to an embodiment of the present disclosure. In this example, plastic insulator  2500  can have openings  2522  for accepting contacts  2312 . Rear contact portions  2314  can extend from insulator  2500 . 
       FIG. 26  illustrates an assembled contact structure according to an embodiment of the present disclosure. A number of contacts  2312  (not shown) in insulators  2520  can be mated to flexible circuit board  2320  according to an embodiment of the present disclosure. Contacts on flexible circuit board  2320  can be attached to rear portions  2314  of contacts  2312  (as shown in  FIG. 9 ) by soldering, laser, spot, or resistance welding, or by other method. Diodes  1610  can be connected between flexible circuit board traces in flexible circuit board  2320  and the device enclosure  310  to provide ESD protection. In this example, flexible circuit board can be routed laterally along the backside of contacts  2312  to gain flexibility in attaching flexible circuit board  320  to bridging pieces  2315 . 
       FIG. 27  illustrates another contact according to an embodiment of the present disclosure. This contact  2712  can include a contacting portion emerging from a front face  2713 . Contacts  2712  can further have a rear angle portion  2714  that can connect to flexible circuit board  320 . Contact  2712  can be formed by machining, forging, printing, etching, stamping, or in other ways. In other embodiment of the present disclosure, contacts  2712  can be formed by a deep drawn process. 
       FIG. 28  illustrates contacts of  FIG. 27  in a plastic insulator (sometimes referred to herein as an “insulative frame”) according to an embodiment of the present disclosure. In this example, insulative frame  2820  can have frame openings  2822  for accepting contacts  2712 . Rear contact portions  2714  (not shown) can extend from insulative frame  2820 . 
       FIGS. 29-34  illustrate a method of making another contact structure according to an embodiment of the present disclosure. In  FIG. 29 , a plurality of contacts  2712  can be stamped at ends of a carrier  29110 . Each contact  2712  can include a rear angled portion  2714 . The contacts can be blasted and plated. In  FIG. 30 , portions  2911  of the carrier  2910  can be split and placed on a dummy carrier  3000  such that contacts  2712  can have the same special relationship to each other as they will when placed in a device enclosure. In  FIG. 31 , plastic insulators  2820  can be formed around contacts  2712 . In other embodiments of the present disclosure, plastic insulators  2820  can be formed in a separate step and then placed around contacts  2712 . In these and other embodiments of the present disclosure, instead of one plastic insulator  2820 , three plastic insulators or insulators can be used, each around one of the contacts  2712 . Plastic insulators  2820  can be glued or otherwise fixed to contacts  2712 . Dummy carrier  3000  can be removed. 
     In  FIG. 32 , flexible circuit board  320  can be attached, for example by soldering, to rear angled pieces  2714  of contacts  2712 . Contacts  2712  can be insulated by plastic insulator  2820 . In  FIG. 33 , contacts  2712  can be aligned with openings  3302  in device enclosure  310 . Plastic insulating piece  2820  can be arranged to fit in notch  3304  in device enclosure  310  and can be glued in place. In  FIG. 34 , bracket can be placed behind contacts  2712  in notch  3304  of device enclosure  310  to secure contacts  2712  in place. Bracket  3410  can be glued in place to further secure contacts  2712  to device enclosure  310 . 
       FIG. 35  illustrates a contact area  3500  in a device enclosure according to an embodiment of the present disclosure. In this example, contact area  3500  include three contacts  3512  at a surface of a device enclosure  3530 . An insulating ring formed by a plastic insulator  3520  can surround an outside edge of contacts  3512  and can be located between contacts  3512  and device enclosure  3530 . As shown in  FIG. 35  contacts  3512  and the insulating ring formed by plastic insulator  3520  can be substantially flush with a surrounding surface of device enclosure  1730 . These surfaces can be curved, they can be substantially flat, or they can have other contours and the contacts, insulating ring and surrounding exterior surface can combine to form a continuous smooth exterior surface of the device that contact area  3500  is incorporated into. 
       FIG. 36  illustrates a cutaway side view of a contact structure that can be used as the contact structure of  FIG. 35 . Again, contacts  3512  can be located in openings in device enclosure  3530 . Plastic insulator  3520  can be located between contact  3512  and device enclosure  3530 . A surface of contact  3512  and a surface of plastic insulator  3520  can be substantially flush with a surface of device enclosure  3530 . These surfaces can be curved, substantially flat, or they can have other contours. A silicone gasket or other seal  3610  can be located between plastic insulator  3520  and device enclosure  3530 . Silicone gasket  3610  can prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  3512  can include a contacting portion  3513  that can be soldered or otherwise attached to a trace on flexible circuit board  3620 . A heat-activated film or adhesive  3630  can be used to fix flexible circuit board  3620  to plastic insulator  3520 . Contact  3512  can further include tabs  3515  (of which contacting portion  3513  may be one of) and handle  3514 . Bracket  3640  can be located behind flexible circuit board  3620  and can hold contact  3512  in place in device enclosure  3530 . 
     In various embodiments of the present disclosure, it may be desirable that a surface of contacts in a contact structure to be at least substantially flush with a surface of a device housing the contacts. But the sizes of the various components of this connector structure each have a manufacturing tolerance associated with them. The accumulation of these tolerances can lead to the surface of one or more contacts not being flush with a surface of the device. Accordingly, embodiments of the present disclosure can employ shims or other adjustments features to account for the errors that these tolerances can create. An example is shown in the following figures. 
       FIG. 37  illustrates a cutaway side view of another contact structure that can be used as the contact structure of  FIG. 35 . Again, contacts  3512  can be located in openings in device enclosure  3530 . Plastic insulator  3520  can be located between contact  3512  and device enclosure  3530 . A surface of contact  3512  and a surface of plastic insulator  3520  can be substantially flush with, or recessed a limited amount relative to, a surface of device enclosure  3530 . The surface of contact  3512 , the surface of plastic insulator  3520 , and the surface of device enclosure  3530  can be curved, substantially flat, or they can have other contours. A silicone gasket or other seal  3610  can be located between plastic insulator  3520  and device enclosure  3530 . Silicone gasket  3610  can prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  3512  can include a contacting portion  3513  that can be soldered or otherwise attached to a trace on flexible circuit board  3620 . A heat-activated film or adhesive  3630  can be used to fix flexible circuit board  3620  to plastic insulator  3520 . Contact  3512  can further include tabs  3515  (of which contacting portion  3531  can be one of) and handle  3514 . Bracket  3640  can be located behind flexible circuit board  3620  and can hold contact  3512  in place in device enclosure  3530 . 
     Again, it may be desirable that the surface of contact  3512  and a surface of plastic insulator  3520  be substantially flush with a surface of device enclosure  3530 . But the sizes of the various components of this connector structure each have a manufacturing tolerance associated with them. The accumulation of these tolerances can lead to the surface of one or more contacts  3512  not being flush with a surface  3530  of the device. Accordingly, embodiments of the present disclosure can employ shims  3710 . Shim  3710  can be selected from a set of shims having different sizes. Shim  3710  can have a size that is selected to compensate for the accumulated tolerances of the sizes of the different components in this connector structure such that the surface of contact  3512  and a surface of plastic insulator  3520  can be substantially flush with a surface of device enclosure  3530 . 
       FIG. 38  illustrates a portion of contact structure according to an embodiment of the present disclosure. This contact structure portion can include a number of contacts  3512  surrounded by plastic insulator  3520 . 
       FIG. 39  is an exploded view of a contact structure according to an embodiment of the present disclosure. Contacts  3512  (shown in  FIG. 38 ) can be housed in plastic insulator  3520 , and can be located in openings in device enclosure  3530 . A silicone gasket or other seal  3610  can be located between plastic insulator  3520  and device enclosure  3530 . Silicone gasket  3610  can prevent the ingress of liquids, moisture, or debris into the electronic device. Contacts  3512  can include a contacting portion  3513  (shown in  FIG. 28 ) that can be soldered or otherwise attached to a trace on flexible circuit board  3620 . A heat-activated film or adhesive (not shown) can be used to fix flexible circuit board  3620  to plastic insulator  3520 . Bracket or cowling  3640  can be located behind flexible circuit board  3620  and can hold contacts  3512  in place in device enclosure  3530 . Shim  3710  can be placed between plastic insulator  3520  and device enclosure  3530 . Shim  3710  can be selected from a set of shims having different sizes. Shim  3710  can have a size that is selected to compensate for the accumulated tolerances of the sizes of the different components in this connector structure such that the surface of contact  3512  and a surface of plastic insulator  3520  can be substantially flush with a surface of device enclosure  3530 . 
     These contacts structures portions including contacts  3512  and plastic insulators  3520  can be formed in various ways. Examples are shown in the following figures. 
       FIGS. 40-43  illustrates a method of manufacturing a portion of a contact structure according to an embodiment of the present disclosure. In  FIG. 40 , contacts  3512  can be coined. The coining process can leave tab  3513  and handle  3514  in place. Contacts  3512  can be formed at ends of carrier  4000 . Carrier  4000  can include openings  4010 . In  FIG. 41 , a carrier  4100  can be provided. Openings  4100  having raised edges can be stamped in carrier  4100 . In  FIG. 42 , carrier  4000  can be fixed to carrier  4100 . Specifically, raised edges of opening  4110  can be placed in openings  4010  of carrier  4000 . In  FIG. 43 , plastic insulator  3520  can be formed around contacts  3512 . In other embodiments of the present disclosure, plastic insulator  3520  can be formed elsewhere and glued or otherwise fixed to contacts  3512 . The carrier structure can be removed leaving behind handle  3514  (not shown). 
       FIGS. 44-47  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the present disclosure. In  FIG. 44 , contacts  3512  can be turned or machined. In  FIG. 45 , a carrier  4500  can be stamped. Carrier  4500  can include paddles  4510 . In  FIG. 46 , contacts  3512  can be attached to paddles  4510  of carrier  4500 . In  FIG. 47 , plastic insulator  3520  can be formed around contacts  3512 . In other embodiments of the present disclosure, plastic insulator  3520  can be formed elsewhere and then fixed to contacts  3512 , by using an adhesive or other technique. Carrier  4500  can be removed, again leaving behind handle  3514  (not shown.) 
       FIGS. 48-52  illustrates another method of manufacturing a portion of a contact structure according to an embodiment of the present disclosure. In  FIG. 48 , contacts  3512  and first carrier  4700  can be turned, or machined, forged, or formed in other ways. In  FIG. 49 , second carrier  4900  can be stamped or formed in other ways. Second carrier  4900  can include paddles  4910 . In  FIG. 50 , contacts  3512  can be attached to paddles  4910  of second carrier  4900  by spot, laser, or resistance welding, or other technique. In  FIG. 51 , the first carrier  4700  can be detached, and the contacts  3512  can be polished, blasted, and plated. In  FIG. 52 , plastic insulator  3520  can be formed around contacts  3512  using an overmold or other process. In other embodiments of the present disclosure, plastic insulator  3520  can be formed elsewhere and then fixed to contacts  3512 , by using an adhesive or other technique. Carrier  4900  can be removed, again leaving behind handle  3514  (not shown.) 
     Embodiments of the present disclosure can provide contacts that are resistant to corrosion. These contacts can include a top, electrically conductive plate to match a color of a device enclosure around the contacts. This top plate can be between 0.25 to 1.0 microns, between 0.5 to 1.0 microns, between 0.5 to 0.85 microns, between 0.75 to 0.85 microns thick, or it can have another thickness. At an exposed surface of the contact, gold plating layer can be below the top plate. On other portions of the contact, the top plate can be omitted and the gold plating layer can be the first layer. This layer can be between 0.01 to 0.5 microns or between 0.05 and 0.1 microns thick, or it can have another thickness. A copper layer in the range of 1.0, 2.0, 3.0 or 4.0 microns in thickness can be used. An optional palladium layer can be used above the copper layer. This layer can have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it can have another thickness. An optional SnCu layer can be used between a gold layer and a copper layer in areas where contacts can be soldered to flexible circuit boards. This optional SnCu layer can be between 4, 5, and 6 microns in thickness, for example, between 4 and 6 or between 5 and 6 microns in thickness, though it can have other thicknesses consistent with embodiments of the present disclosure. Another embodiment of the present disclosure can include a base layer of copper in the range of 1.0, 2.0, 1.0-2.0, 2.0-3.0, 3.0 or 4.0 microns in thickness. A palladium layer can be used above the copper layer. This layer can have a thickness between 0.15 and 2.0 microns, 1.0 and 1.5 microns, 1.0 and 2.0 microns, or it can have another thickness. A gold flash can be placed on that layer. This can be followed by a top plating to match a color of a device enclosure around the contacts and/or to improve electrical conductivity. This top plate can be between 0.25 to 1.0 microns, between 0.5 to 1.0 microns, between 0.5 to 0.85 microns, between 0.75 to 0.85 microns thick, or it can have another thickness. Other portions of the contacts can have the copper layer, a thinner Pd layer in the range of one, two, or threes tenth of a micron can be used, followed by a gold flash. 
     In various embodiments of the present disclosure, different portions of these contact structures and other contact structures can be formed of various materials. For example, bracket  3640  and plastic insulators  1720  can be formed of the same or different materials, such as plastic, LPS, or other non-conductive or conductive material. Contacts  1712  can be formed of noncorrosive materials, such as gold, gold plated copper, gold plated nickel, gold-nickel alloy, and other materials. Also, in various embodiments of the present disclosure, different portions of these contact structures and other contact structures can be formed in various ways. For example, bracket  3640  and plastic insulators  3520  can be formed using injection or other molding, printing, or other technique. Contacts  3512  can be machined, stamped, coined, forged, printed, or formed in different ways. Plastic insulator  3520  can be formed around contacts  3512  using injection molding or other technique. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20170331
Publication Date: 20180522
Grant Date: 20180522
Priority Date: 20150904
Inventors: WAGMAN, DANIEL
ROSS, Oliver
JOL, ERIC S.
Esmaeili, Hani
DEGNER, BRETT
Kamei, Ibuki
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1615", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/166", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1679", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1643", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/40", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/6205", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1683", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1607", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1679", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1615", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1683", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1679", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1607", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/1656", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1681", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/0202", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/2442", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1632", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/1626", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 56855361