PATENT DOCUMENT

Publication Number: US-8235756-B2
Application Number: US-201113092575-A
Country: US
Kind Code: B2

Title: Low profile plugs

Abstract:
Apparatus, systems, and methods for assembling a plug with a low profile for use with an electronic device are provided. In some embodiments, a 4-pin plug may include a diameter similar to the diameter of a 3-pin plug. In some embodiments, the fourth pin may be coupled to the plug such that a portion of the fourth pin may be coupled to any suitable device on an internal surface of the plug. In some embodiments, the fourth pin may dive into the plug at the same depth as one of the other three pins of the plug. The pins within the plug may be coupled (e.g., soldered) at the ends that may emerge underneath an overmold to any other suitable device to form electrical connections. The plug may be used to transmit audio or transfer data to a user of the electronic device.

Claims:
1. A plug comprising:
 an innermost pin extending between a first innermost end and a second innermost end about a longitudinal axis; 
 a mid-inner pin extending between a first mid-inner end and a second mid-inner end about the longitudinal axis and about a portion of the innermost pin; 
 an inner pin extending between a first inner end and a second inner end about the longitudinal axis and about a portion of the mid-inner pin; and 
 an outer pin extending between a first outer end and a second outer end about the longitudinal axis and about a portion of the inner pin, wherein:
 the first outer end of the outer pin extends a first distance beyond the first inner end of the inner pin in a first direction parallel to the longitudinal axis; 
 the first outer end of the outer pin extends a second distance beyond the first mid-inner end of the mid-inner pin in the first direction parallel to the longitudinal axis; 
 the first outer end of the outer pin extends a third distance beyond the first innermost end of the innermost pin in the first direction parallel to the longitudinal axis; and 
 the shortest distance between the first outer end of the outer pin and the longitudinal axis is one of equal to and less than the shortest distance between the first inner end of the inner pin and the longitudinal axis. 
 
 
     
     
       2. The plug of  claim 1 , wherein the first distance is greater than the second distance. 
     
     
       3. The plug of  claim 2 , wherein the second distance is greater than the third distance. 
     
     
       4. The plug of  claim 1 , wherein:
 the innermost pin comprises a first innermost end contact portion at the first innermost end; 
 the mid-inner pin comprises a first mid-inner end contact portion at the first mid-inner end; 
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the outer pin comprises a first outer end contact portion at the first outer end; 
 the first outer end contact portion of the outer pin extends the first distance beyond the first inner end contact portion of the inner pin in the first direction parallel to the longitudinal axis; 
 the first outer end contact portion of the outer pin extends the second distance beyond the first mid-inner end contact portion of the mid-inner pin in the first direction parallel to the longitudinal axis; and 
 the first outer end contact portion of the outer pin extends the third distance beyond the first innermost end contact portion of the innermost pin in the first direction parallel to the longitudinal axis. 
 
     
     
       5. The plug of  claim 1 , wherein:
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the first inner end contact portion faces away from the longitudinal axis; 
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 the first outer end contact portion faces towards the longitudinal axis. 
 
     
     
       6. The plug of  claim 1 , wherein:
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 the plug further comprises an overmold of nonconductive material disposed about the first outer end contact portion and the first inner end contact portion. 
 
     
     
       7. The plug of  claim 1 , wherein:
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 the shortest distance between the first outer end contact portion and the longitudinal axis is equal to the shortest distance between the first inner end contact portion and the longitudinal axis. 
 
     
     
       8. The plug of  claim 1 , wherein:
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 the shortest distance between the first outer end contact portion and the longitudinal axis is less than the shortest distance between the first inner end contact portion and the longitudinal axis. 
 
     
     
       9. The plug of  claim 1 , further comprising a layer of nonconductive material disposed at least between the outer pin and the portion of the inner pin. 
     
     
       10. The plug of  claim 9 , wherein a portion of the outer pin is disposed within the layer. 
     
     
       11. The plug of  claim 1 , wherein the maximum diameter of the plug is 3.5 millimeters. 
     
     
       12. The plug of  claim 1 , further comprising an overmold of nonconductive material disposed about the first outer end, the first inner end, the first mid-inner end, and the first innermost end. 
     
     
       13. The plug of  claim 12 , wherein the maximum diameter of the overmold is 4.0 millimeters. 
     
     
       14. The plug of  claim 13 , wherein the maximum diameter of the plug is 3.5 millimeters. 
     
     
       15. The plug of  claim 1 , wherein:
 the inner pin comprises a first inner end contact portion at the first inner end; 
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 each of the first outer end contact portion and the first inner end contact portion is configured to couple to a respective wire of a cable. 
 
     
     
       16. The plug of  claim 1 , wherein:
 the outer pin comprises a first outer end contact portion at the first outer end; and 
 the first outer end contact portion is on the inside of the plug. 
 
     
     
       17. The plug of  claim 1 , wherein the longitudinal axis does not intersect any portion of the outer pin. 
     
     
       18. The plug of  claim 1 , wherein:
 the outer pin comprises a first outer end contact portion at the first outer end; 
 the inner pin comprises a first inner end contact portion at the first inner end; and 
 both the first inner end contact portion and the first outer end contact portion face a first side of the plug. 
 
     
     
       19. The plug of  claim 18 , wherein:
 the first inner end contact portion is between the longitudinal axis and the first side of the plug; and 
 the longitudinal axis is between the first outer end contact portion and the first side of the plug. 
 
     
     
       20. The plug of  claim 19 , wherein:
 the mid-inner pin comprises a first mid-inner end contact portion at the first mid-inner end; 
 the first mid-inner end contact portion faces the first side of the plug; and 
 the first mid-inner end contact portion is between the longitudinal axis and the first side of the plug. 
 
     
     
       21. The plug of  claim 1 , wherein
 the mid-inner pin comprises a first mid-inner end contact portion at the first mid-inner end; and 
 the first mid-inner end contact portion faces away from the longitudinal axis. 
 
     
     
       22. The plug of  claim 1 , wherein the longitudinal axis does not intersect any portion of the inner pin. 
     
     
       23. The plug of  claim 1 , wherein the longitudinal axis does not intersect any portion of the mid-inner pin. 
     
     
       24. A plug comprising:
 a mid-inner pin extending between a first mid-inner end and a second mid-inner end about a longitudinal axis, the mid-inner pin comprising a first mid-inner end contact portion at the first mid-inner end; 
 an inner pin extending between a first inner end and a second inner end about the longitudinal axis and about a portion of the mid-inner pin, the inner pin comprising a first inner end contact portion at the first inner end; and 
 an outer pin extending between a first outer end and a second outer end about the longitudinal axis and about a portion of the inner pin, the outer pin comprising a first outer end contact portion at the first outer end, wherein:
 each of the first outer end contact portion and the first inner end contact portion is configured to be coupled to a respective wire of a cable; 
 each of the second outer end and the second inner end is configured to be inserted into a jack; 
 the shortest distance between the first inner end contact portion and the longitudinal axis is one of equal to and greater than the shortest distance between the first outer end contact portion and the longitudinal axis; and 
 the shortest distance between the first mid-inner end contact portion and the longitudinal axis is one of equal to and greater than the shortest distance between the first inner end contact portion and the longitudinal axis. 
 
 
     
     
       25. The plug of  claim 24 , wherein the first outer end contact portion dives towards the longitudinal axis at the first outer end. 
     
     
       26. The plug of  claim 24 , further comprising a layer of nonconductive material disposed at least between the outer pin and the portion of the inner pin. 
     
     
       27. The plug of  claim 24 , wherein a portion of the outer pin is disposed within the layer. 
     
     
       28. The plug of  claim 24 , further comprising an overmold of nonconductive material disposed about the first outer end contact portion and the first inner end contact portion. 
     
     
       29. The plug of  claim 24 , further comprising an innermost pin extending between a first innermost end and a second innermost end about the longitudinal axis, wherein:
 the mid-inner pin extends about a portion of the innermost pin; 
 the innermost pin includes a first innermost end contact portion at the first innermost end; and 
 the shortest distance between the first innermost end contact portion and the longitudinal axis is one of equal to and greater than the shortest distance between the first mid-inner end contact portion and the longitudinal axis. 
 
     
     
       30. The plug of  claim 24 , further comprising an innermost pin extending between a first innermost end and a second innermost end about the longitudinal axis, wherein:
 the mid-inner pin extends about a portion of the innermost pin; 
 the innermost pin includes a first innermost end contact portion at the first innermost end; and 
 the plug further comprises an overmold of nonconductive material disposed about the first outer end contact portion, the first inner end contact portion, the first mid-inner end contact portion, and the first innermost end contact portion. 
 
     
     
       31. The plug of  claim 30 , wherein the maximum diameter of the plug is 3.5 millimeters without the overmold. 
     
     
       32. The plug of  claim 30 , wherein the maximum diameter of the plug with the overmold is 4.0 millimeters. 
     
     
       33. The plug of  claim 24 , wherein a plane that is perpendicular to the longitudinal axis intersects the first outer end contact portion and the first inner end contact portion. 
     
     
       34. The plug of  claim 24 , wherein the first outer end contact portion extends a first distance beyond the first inner end contact portion in a first direction parallel to the longitudinal axis. 
     
     
       35. The plug of  claim 24 , wherein the longitudinal axis does not intersect any portion of the outer pin. 
     
     
       36. The plug of  claim 24 , wherein the shortest distance between the first inner end contact portion and the longitudinal axis is equal to the shortest distance between the first outer end contact portion and the longitudinal axis. 
     
     
       37. The plug of  claim 24 , wherein the shortest distance between the first inner end contact portion and the longitudinal axis is greater than the shortest distance between the first outer end contact portion and the longitudinal axis. 
     
     
       38. A method for assembling a plug having a longitudinal axis, the method comprising:
 inserting an outer pin having a first outer end and a second outer end opposite the first outer end at least partially within an outermost pin having a first outermost end and a second outermost end opposite the first outermost end; 
 inserting an inner pin at least partially within the outer pin; and 
 inserting an innermost pin at least partially within the inner pin, wherein:
 the first outer end of the outer pin comprises a first outer contact portion facing away from the longitudinal axis; 
 the first outermost end of the outermost pin comprises a first outermost contact portion facing towards the longitudinal axis; 
 the first outermost contact portion extends a first distance beyond the first outer contact portion in a first direction parallel to the longitudinal axis; and 
 the first outer contact portion is one of farther away from and the same distance from the longitudinal axis as the first outermost contact portion is from the longitudinal axis. 
 
 
     
     
       39. The method of  claim 38 , further comprising disposing nonconductive material between the innermost pin, the inner pin, and the outer pin. 
     
     
       40. The method of  claim 39 , wherein the nonconductive material is polypropylene. 
     
     
       41. The method of  claim 39 , further comprising disposing additional nonconductive material about at least a portion of the innermost pin, at least a portion of the inner pin, the first outer contact portion, and the first outermost contact portion. 
     
     
       42. The method of  claim 38 , wherein the outer pin and the outermost pin are centered about the longitudinal axis. 
     
     
       43. The method of  claim 42 , wherein the first outer contact portion is the same distance from the longitudinal axis as the first outermost contact portion. 
     
     
       44. The method of  claim 38 , wherein the maximum diameter of the plug is 4.0 millimeters. 
     
     
       45. The method of  claim 38 , wherein the maximum diameter of the plug is 3.5 millimeters.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of co-pending, commonly-assigned U.S. Nonprovisional patent application Ser. No. 12/211,034, filed Sep. 15, 2008, which claims the benefit of prior filed U.S. Provisional Application No. 61/011,587, filed Jan. 18, 2008, and prior filed U.S. Provisional Application No. 61/094,734, filed Sep. 5, 2008, each of which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This can relate to apparatus, systems, and methods for assembling a plug with a low profile for use with an electronic device. 
     BACKGROUND OF THE DISCLOSURE 
     Electronic devices provide audio or other types of data to a user of the electronic device using different approaches, including through an accessory device (e.g., a headset) that includes a 3-pin or a 4-pin plug inserted into a jack of the electronic device. A 4-pin plug may provide additional capability over a 3-pin plug, such as by providing not only left and right stereo audio channels, but also a microphone or the ability to transfer data. Whereas existing 3-pin plugs generally have a diameter of about 3.5 millimeters and include three pins soldered within the plug, existing 4-pin plugs generally have a diameter of about 4.6 millimeters and include a fourth pin soldered to the outer dimension of the plug. This design may make the 4-pin plug incompatible with electronic devices designed to accommodate the diameter of 3-pin plugs. 
     Therefore, it would be beneficial to provide a 4-pin plug with a reduced profile or diameter to enhance the aesthetic appearance of the plug to the user and to enable the plug to be used with a wider range of electronic devices. In addition, it would also be beneficial to secure the fourth pin to the plug using conventional soldering processes. 
     SUMMARY OF THE DISCLOSURE 
     Apparatus, systems, and methods for assembling a plug with a low profile for use with an electronic device are provided. In one embodiment, a plug is provided. The plug may include an inner pin extending between a first inner end and a second inner end about a longitudinal axis, wherein the inner pin includes a first inner end contact portion at the first inner end. The plug may include an outer pin extending between a first outer end and a second outer end about the longitudinal axis and about a portion of the inner pin, wherein the outer pin includes a first outer end contact portion at the first outer end. The plug also may include a layer of nonconductive material disposed at least between the outer pin and the portion of the inner pin, wherein the first outer end contact portion extends a first distance beyond the first inner end contact portion in a first direction parallel to the longitudinal axis. 
     In one embodiment, a plug is provided. The plug may include an inner pin extending between a first inner end and a second inner end about a longitudinal axis, wherein the inner pin includes a first inner end contact portion at the first inner end. The plug may include an outer pin extending between a first outer end and a second outer end about the longitudinal axis and about a portion of the inner pin, wherein the outer pin includes a first outer end contact portion at the first outer end. The plug also may include a layer of nonconductive material disposed at least between the outer pin and the portion of the inner pin, wherein the shortest distance between the first inner end contact portion and the longitudinal axis is at least equal to the shortest distance between the first outer end contact portion and the longitudinal axis. The plug also may include an overmold of nonconductive material disposed about the first outer end contact portion and the first inner end contact portion. 
     In one embodiment, a plug is provided. The plug may include an inner pin extending between a first inner end and a second inner end about a longitudinal axis, wherein the inner pin includes a first inner end contact portion at the first inner end. The plug may include an outer pin extending between a first outer end and a second outer end about the longitudinal axis and about a portion of the inner pin, wherein the outer pin includes a first outer end contact portion at the first outer end. The plug also may include a layer of nonconductive material disposed at least between the outer pin and the portion of the inner pin, wherein a first plane that is perpendicular to the longitudinal axis intersects the first outer end contact portion and the first inner end contact portion. 
     In one embodiment, a method for assembling a plug having a longitudinal axis is provided. The method may include inserting an innermost pin at least partially within an inner pin, inserting an outer pin at least partially within the inner pin, wherein the outer pin has a first outer end and a second outer end opposite the first outer end, and wherein the first outer end has a first outer contact portion, disposing nonconductive material between the innermost pin, the inner pin, and the outer pin, and coupling an outermost pin to the plug about the outer pin, wherein the outermost pin has a first outermost end and a second outermost end opposite the first outermost end, the first outermost end has a first outermost contact portion, and the first outermost contact portion extends a first distance beyond the first outer contact portion in a first direction parallel to the longitudinal axis. 
     In an embodiment, a plug that extends between a cable end and a jack end is provided. The plug may include an inner pin having an inner cable contact at a first inner end and an inner jack contact at a second inner end, and an outer pin having an outer cable contact at a first outer end and an outer jack contact at a second outer end, wherein the distance between the outer cable contact and the cable end is shorter than the distance between the inner cable contact and the cable end. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and features of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a cross-sectional view of an inverted contact plug in accordance with some embodiments of the invention; 
         FIG. 2  is a perspective view of the inverted contact plug of  FIG. 1  in accordance with some embodiments of the invention; 
         FIG. 3  is a cross-sectional view of a diving contact plug in accordance with some embodiments of the invention; 
         FIG. 4  is a perspective view of the diving contact plug of  FIG. 3  in accordance with some embodiments of the invention; and 
         FIG. 5  is a flowchart of an illustrative process for assembling a plug and coupling the plug to a cable in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     In some embodiments, a 4-pin plug may include any suitable features and any suitable dimensions. For example, the plug may include four pins that may be arranged such that each pin is at least partially nested within the next closest pin. The plug also may have any suitable diameter, including, for example, a diameter equal to 3.5 millimeters along its length, which may increase to 4.0 millimeters where an overmold may be disposed around the plug. The fourth pin may be coupled (e.g., soldered) to the plug in any suitable manner and in some embodiments, may be coupled to the plug after the first three pins have been coupled together. In some embodiments, the fourth pin may be soldered to the plug such that a wire of a cable may be soldered to the fourth pin on the internal surface of the plug. The fourth pin also may include a contact point (e.g., a flange) that may extend beyond the contact point of at least one other pin within the plug and that may be inverted away from the contact point of the at least one other pin. In some embodiments, the fourth pin may be shaped such that it includes a contact point at the same distance from one end of the plug as at least one other pin. In some embodiments, the fourth pin may be shaped such that it dives into the plug at the same depth as at least one other pin and obstructs at least a portion of the at least one other pin from emerging underneath the overmold. In such embodiments, the diameter of the plug may not be increased by the inclusion of the fourth pin. Portions of the fourth pin may be thinner than one or more of the other pins, such as at the point where the pins are exposed (e.g., the face of the pin) to a user of the plug. However, the face of the fourth pin may have the same outward appearance as the other pins in the plug. 
     The plug also may include any suitable number of nonconductive or isolating regions to separate the conductive pins. In some embodiments, the nonconductive regions may be made from polypropylene. The plug also may include any suitable nonconductive overmold that may be disposed around one end of the plug to protect the coupling of the pins to any suitable device (e.g., a cable of an accessory device). In some embodiments, any other suitable member, such as a strain relief member or a hard plastic member may also be molded over the plug. 
     One contact end or flange of each pin that may emerge underneath the overmold may be coupled (e.g., soldered) to any other suitable device to form an electrical connection. For example, the plug may be coupled to a cable that in turn may be coupled to a pair of headphones. The plug may be inserted into a jack of an electronic device and may be configured to receive audio information from the electronic device via the jack and may be configured to transmit the audio information to the user via the cable and the headphones. Alternatively, the plug may be used with an electronic device to transfer data and power, similar to a Universal Serial Bus (“USB”) connector. 
     Apparatus, systems, and methods for assembling a plug with a low profile for use with an electronic device are provided and described with reference to  FIGS. 1-5 . 
       FIG. 1  is a cross-sectional view of an inverted contact plug in accordance with some embodiments of the invention. Plug  100  may include any suitable number of conductive contacts or pins. For example, plug  100  may include four pins  110 ,  130 ,  150 , and  170 , each of which may include any suitable conductive material (e.g., metal) and may be of any suitable length N 1  from end A to end B of plug  100 . Pin  110  may be solid or hollow (not shown), whereas pins  130 ,  150 , and  170  may be hollow (e.g., hollow cylinders). In some embodiments, pins  110 ,  130 ,  150 , and  170  may extend along and about longitudinal axis L 1  and may be nested within one another. For example, as shown in  FIGS. 1 and 2 , pin  110  (e.g., an innermost pin) may extend along and about axis L 1  at least partially within the hollow of pin  130 , pin  130  (e.g., a mid-inner pin or an inner pin) may extend along and about axis L 1  at least partially within the hollow of pin  150 , and pin  150  (e.g., an inner pin or an outer pin) may extend along and about axis L 1  at least partially within the hollow of pin  170  (e.g., an outer pin or an outermost pin). At one end A of plug  100 , a conductive portion of each one of pins  110 ,  130 ,  150 , and  170 , respectively, may be exposed, such as, for example, end  110   a , and flanges  130   a ,  150   a , and  170   a , which may be coupled to respective portions of any other suitable device to form an electrical connection. Towards end B, each one of pins  110 ,  130 ,  150 , and  170  may present face  110   b ,  130   b ,  150   b , and  170   b , respectively, to a user of plug  100  that may be inserted in the direction of arrow b within a jack of an electronic device. 
     In some embodiments, at least a portion of pin  170  may have an inner facing solder pad such that a wire of a cable (e.g., a cable coupled to headphones) may be soldered to pin  170  on the internal surface of plug  100 , rather than being soldered to an outside surface of plug  100 . Before pin  170  may be soldered to plug  100 , however, any suitable portion of pin  170  may be removed, including, for example, 75% of the area containing the soldering component of the pin (e.g., 75% of the weight) that creates pin  170 . In another embodiment, pin  170  may be formed such that the material does not have to be removed later (e.g., pin  170  may be formed as an asymmetrical cylinder that includes flange  170   a ). Such a pin  170  may permit plug  100  to include four pins soldered to the inside of plug  100  within a diameter d (e.g., a diameter of 3.5 millimeters), and also may permit both flanges  150   a  and  170   a  to be exposed at end A so as to be coupled to any other suitable device without obstructing one another. For example, flange  170   a  may extend or be provided beyond end  110   a  and beyond flanges  130   a  and  150   a  towards end A without obstructing any of end  110   a , flange  130   a , or flange  150   a  from being coupled to any suitable device. Although pin  170  may include a solder contact on the inside of plug  100  and pin  150  may be at least partially inserted within the hollow of pin  170 , the maximum solder height of plug  100  (which may be equal to diameter d) may be determined by pin  150  because face  170   b  may have a thickness  170   t  that may be thinner than the thickness  150   t  of face  150   b  where pins  150  and  170  may be exposed to a user of plug  100 . In some embodiments, thickness  170   t  also may be thinner than thickness  130   t  of face  130   b.    
     In some embodiments, plug  100  may be coupled to any suitable device, such as a cable extending from headphones, to form an electrical connection in any suitable manner. End  110   a  of pin  110  may be soldered to a wire within a cable that may in turn be coupled to headphones. Pins  130  and  150  may be soldered at flanges  130   a  and  150   a  to two additional wires within the cable. Pin  170  may be soldered to a fourth wire within the cable at flange  170   a . Flange  170   a  may extend beyond end  110   a  and flanges  130   a  and  150   a  towards end A (e.g., along axis L 1  away from flange  170   b  at end B of plug  100 ). For example, flange  170   a  may extend a distance e 1  beyond end  110   a , in the direction of arrow a along longitudinal axis L 1  toward end A of plug  100 . Flange  170   a  also may extend a distance e 2  beyond flange  130   a , in the direction of arrow a along longitudinal axis L 1  toward end A of plug  100 . Flange  170   a  also may extend a distance e 3  beyond flange  150   a , in the direction of arrow a along longitudinal axis L 1  toward end A of plug  100 . 
     Plug  100  may include any suitable number of nonconductive or isolating regions to separate conductive pins  110 ,  130 ,  150 , and  170 . Regions  120 ,  140 , and  160  may include any suitable nonconductive material, including, for example, polypropylene or another plastic. Regions  120 ,  140 , and  160  may be formed in any suitable manner, including, for example, by being poured around a nested arrangement of pins  110 ,  130 , and  150  and, in some embodiments, around pin  170  during the assembly of plug  100 . Plug  100  also may include any suitable nonconductive region  180  that may be disposed around portions of end  110   a  and flanges  130   a ,  150   a , and  170   a  to protect the coupling of the pins to any suitable device at end A. Region  180  may include the same material as regions  120 ,  140 , and  160  and, when disposed around plug  100 , may increase the diameter of plug  100  from diameter d to diameter d′. The assembly of plug  100  is described further below with respect to  FIG. 5 . Plug  100  may include any suitable dimensions. In some embodiments, plug  100  may include any suitable diameter d, including, for example, a diameter d equal to 3.5 millimeters. In some embodiments, plug  100  may also include any suitable second diameter d′, including, for example, a diameter d′ equal to 4.0 millimeters. In some embodiments, plug  100  may include any suitable length N 1 , including, for example, a length of 20 millimeters. In some embodiments, each of pins  110 ,  130 ,  150 , and  170  may be centered about longitudinal axis L 1 . 
     When end B of plug  100  is inserted into any suitable jack (e.g., any suitable 3-pole or 4-pole audio jack of an electronic device), each of pins  110 ,  130 ,  150 , and  170  may contact a conductive region or pole of the jack to create an electrical connection. The jack (not shown) may include any suitable design to accept plug  100 . In some embodiments, the electronic device may include a trimless port into which plug  100  may be inserted, as described more fully in Lynch et al., U.S. patent application Ser. No. 12/188,735, filed on Aug. 8, 2008 (now U.S. Pat. No. 7,771,240, issued on Aug. 10, 2010), which is incorporated by reference herein in its entirety. 
     The electrical connection between plug  100  and the jack may be used to transmit audio signals or other data between the electronic device and any device that may be coupled to plug  100  (e.g., headphones). In some embodiments, pin  110  may be used to provide audio to a left headphone driver, pin  130  may be used to provide audio to a right headphone driver, pin  150  may serve to ground plug  100  with respect to the jack, and pin  170  may provide a microphone capability to a user of the headphones. Pin  170  also may be used in conjunction with controlling the volume of the audio emitted from the headphones. For example, the volume may be controlled through a device that may be coupled to a headphones cable, the cable may be coupled to plug  100 , and a wire in the cable that may be associated with controlling the device may be coupled to pin  170 . In some embodiments, plug  100  may be used as a USB connector. For example, pins  110  and  130  may be used to transfer data between any suitable electronic device (e.g., an iPod Shuffle™ available by Apple Inc. of Cupertino, Calif.) and any suitable device coupled to plug  100  (e.g., a computer). In such embodiments, pin  150  may be used to ground plug  100  to the electronic device, and pin  170  may be used to provide power to the device coupled to plug  100 . 
       FIG. 2  is a perspective view of plug  100  in accordance with some embodiments of the invention. At least faces  130   b ,  150   b , and  170   b  may be uniform around the circumference and along the length of plug  100  and they may be separated by nonconductive regions  120 ,  140 , and  160 . Region  180  is shown in  FIGS. 1 and 2  as being cut away from end  110   a  and flanges  130   a ,  150   a , and  170   a  at end A to show the contact portions of plug  100  at end A, but it is to be understood that region  180  may include a uniform cylinder that may be disposed, or molded, over end  110   a  and flanges  130   a ,  150   a , and  170   a  to protect any physical and/or electrical connections with any suitable device. In some embodiments, any other suitable member, such as a strain relief member or a hard plastic member may also be molded over plug  100  and/or region  180 , as more fully described in Stiehl et al., U.S. patent application Ser. No. 12/218,450, filed on Jul. 14, 2008 (now U.S. Pat. No. 7,833,055, issued Nov. 16, 2010), which is incorporated by reference herein in its entirety. 
     The location of flange  170   a  may extend beyond end  110   a  and flanges  130   a  and  150   a  toward end A of plug  100 . To accommodate pin  170  within the same diameter d that may be needed to accommodate pins  110 ,  130 , and  150 , at least a portion of pin  170  at end A may be removed (e.g., a portion of pin  170  adjacent flange  170   a  about longitudinal axis L 1 ) or pin  170  may be formed as an asymmetrical cylinder, thereby permitting flanges  130   a  and  150   a  to also be exposed at end A. Although face  170   b  may include thickness  170   t  ( FIG. 1 ) that may be thinner than thickness  150   t  ( FIG. 1 ) of face  150   b  and thickness  130   t  ( FIG. 1 ) of face  130   b , pin  170  may have the same outward appearance as pins  130  and  150  to a user of plug  100  (e.g., at end B). 
     In some embodiments, a plug may be assembled with two or more pins arranged in any suitable alternative fashion.  FIG. 3  is a cross-sectional view of a diving contact plug in accordance with some embodiments of the invention. Plug  300  may include any suitable number of conductive contacts or pins. For example, plug  300  may include four pins  310 ,  330 ,  350 , and  370 , each of which may include any suitable conductive material (e.g., metal) and may be of any suitable length from end C to end D of plug  300 . Pin  310  may be solid or hollow (not shown), whereas pins  330 ,  350 , and  370  may be hollow. In some embodiments, pins  310 ,  330 ,  350 , and  370  may extend along and about longitudinal axis L 3  and may be nested within one another. For example, as shown in  FIGS. 3 and 4 , pin  310  (e.g., an innermost pin) may extend along and about axis L 3  at least partially within the hollow of pin  330 , pin  330  (e.g., a mid-inner pin or an inner pin) may extend along and about axis L 3  at least partially within the hollow of pin  350 , and pin  350  (e.g., an inner pin or an outer pin) may extend along and about axis L 3  at least partially within the hollow of pin  370  (e.g., an outer pin or an outermost pin). At one end C of plug  300 , a conductive portion of each one of pins  310 ,  330 ,  350 , and  370 , respectively, may be exposed, such as, for example, end  310   c , and flanges  330   c ,  350   c , and  370   c , which may be coupled to respective portions of any other suitable device to form an electrical connection. 
     Each one of pins  310 ,  330 ,  350 , and  370  may also present face  310   d ,  330   d ,  350   d , and  370   d,  respectively, to a user of plug  300  that may be inserted in the direction of arrow d within a jack of an electronic device. Face  370   d  may have a thickness  370   t  that may be thinner than the thickness  350   t  of face  350   d  where pins  350  and  370  may be exposed to a user of plug  300 . In some embodiments, thickness  370   t  also may be thinner than thickness  330   t  of face  330   d.    
     In some embodiments, pin  370  may be coupled to other portions of plug  300  such that at least a portion of pin  370  (e.g., flange  370   c  that may be exposed at end C for being coupled to any suitable device) may be at the same depth  3   t  from longitudinal axis L 3  within plug  300  as a portion of pin  350  (e.g., portion  350   c ′). In other embodiments, portions of pin  370  may be even closer to axis L 3  than portions of pin  350  (e.g., flange  370   c  may be at a depth  3   t  from axis L 3  that is less than or equal to a depth  3   t ′ between flange  350   c  and axis L 3 ). In some embodiments, pin  370  may be soldered to other portions of plug  300  such that flange  370   c  and flange  350   c  may be at least partially exposed at the same distance C 1  from end C (e.g., from end  310   c  of pin  310 ) for being coupled to any suitable device. That is, in some embodiments, a plane perpendicular to axis L 3  at a distance C 1  from end C may intersect both flange  350   c  and flange  370   c  (e.g., a plane that includes the line P 3  and that is perpendicular to axis L 3 ). In some embodiments, a plane that includes the line P 3  at a distance C 1  from end C and that is perpendicular to axis L 3  may intersect ends  310   c  and  330   c  and flanges  350   c  and  370   c.    
     Before a portion of pin  370  may be soldered at the same depth  3   t  as pin  350 , for example, any suitable portion of the conductive material that creates pin  350  may be removed. In other embodiments, pin  350  may be formed such that the material does not have to be removed later (e.g., pin  350  may be formed as an asymmetrical cylinder that includes flange  350   c ). Such embodiments of pin  350  may permit plug  300  to include four pins soldered within a diameter  3   d  (e.g., a diameter of 3.5 millimeters), and also may permit both flanges  350   c  and  370   c  to be coupled to any other suitable device. Because at least a portion of pin  350  may be shaped to permit pin  370  to be soldered at the same depth  3   t  from longitudinal axis L 3  as pin  350 , the portion of pin  370  that may be exposed at end C (e.g., flange  370   c ) may be spaced about axis L 3  from the exposed portion of pin  350  (e.g., flange  350   c ) so as not to obstruct that portion of pin  350 . In some embodiments, flange  370   c  and flange  350   c  may be exposed at the same distance C 1  along axis L 3  of plug  300  from end C. 
     In some embodiments, plug  300  may be coupled to any suitable device, such as a headphone cable, to form an electrical connection in any suitable manner. Ends  310   c  and  330   c  may be soldered to two different wires within a cable that may in turn be coupled to drivers of the headphones. Pins  350  and  370  may be soldered at flanges  350   c  and  370   c , respectively, to two further wires within the cable (e.g., ground and a microphone). In some embodiments, pins  310  and  330  may be used to transfer data between any suitable electronic device and any suitable device coupled to plug  300 . In such embodiments, pin  350  may be used to ground plug  300  to the electronic device, and pin  370  may be used to provide power to the device coupled to plug  300 , such that plug  300  may be used as a USB cable connector, for example. 
     Plug  300  also may include any suitable number of nonconductive or isolating regions to separate conductive pins  310 ,  330 ,  350 , and  370 . Regions  320 ,  340 ,  360 , and  380  may be the same as, and may include some or all of the features of, regions  120 ,  140 ,  160 , and  180  ( FIGS. 1 and 2 ), respectively. Regions  320 ,  340 ,  360 , and  380  also may be formed in any suitable manner, including, for example, in the same manner as regions  120 ,  140 ,  160 , and  180 . When disposed around plug  300 , region  380  may increase the diameter of plug  300  from diameter  3   d  to diameter  3   d ′. The assembly of plug  300  is also described further below with respect to  FIG. 5 . 
     Plug  300  may include any suitable dimensions. In some embodiments, plug  300  may include any suitable diameter  3   d , including, for example, a diameter  3   d  equal to diameter d (e.g., 3.5 millimeters). In some embodiments, plug  300  may include any suitable second diameter  3   d ′, including, for example, a diameter  3   d ′ equal to diameter d′ (e.g., 4.0 millimeters). In some embodiments, each of pins  310 ,  330 ,  350 , and  370  may be centered about longitudinal axis L 3 . 
     In some embodiments, plug  300  also may include any suitable length N 2 , including, for example, a length of 19 meters. Length N 2  may be the same as, or shorter than, length N 1  of plug  100 . For example, length N 2  may be shorter than length N 1  if flange  370   c  is at the same depth  3   t  (or in some embodiments, a greater depth) from axis L 3  as portion  350   c ′ because both flange  370   c  and flange  350   c  may be exposed for coupling to any suitable electronic device without having to extend flange  370   c , and plug  300 , beyond flange  350   c.    
     Alternatively, length N 2  may be shorter than length N 1  if flange  370   c  and flange  350   c  are at least partially exposed at the same distance C 1  from end C (e.g., at end  310   c  of pin  310 ) because both flange  370   c  and flange  350   c  may be exposed for coupling to any suitable electronic device without having to extend flange  370   c , and plug  300 , beyond flange  350   c . Length N 2  may be shortened further if at least a portion of the other pins of plug  300  are located at the same depth with respect to axis L 3  (not shown). For example, length N 2  may be shortened further if flange  370   c  is at the same or greater depth from longitudinal axis L 3  as portion  350   c ′ and if at least a portion of pin  330  is at the same depth (or, in some embodiments, a greater depth) from axis L 3  as at least a portion of pin  310 . Any combination of shared depths between at least two pins of plug  300  may be used to shorten length N 2 . In some embodiments, length N 2  also may be shortened further if ends  310   c  and  330   c , and flanges  350   c  and  370   c  are all at least partially exposed at the same distance C 1  from end C (not shown). Any combination of exposure distances between at least two pins of plug  300  may be used to shorten length N 2 . 
     When inserted into any suitable jack (e.g., any suitable 3-pole or 4-pole audio jack of an electronic device), plug  300  may interact with the jack in the same manner as plug  100 . For example, plug  300  may be used to transmit audio signals or other data between the electronic device and any device that may be coupled to plug  300  (e.g., headphones). 
       FIG. 4  is a perspective view of plug  300  in accordance with some embodiments of the invention. At least faces  330   d ,  350   d , and  370   d  may be uniform around the circumference and/or along the length of plug  300  at end D, and they may be separated by nonconductive regions  320 ,  340 , and  360 . Portions of region  380  are shown in  FIGS. 3 and 4  as being cut away from ends  310   c  and  330   c  and notched between flange  350   c  and portion  371  at end C, but it is to be understood that region  380  may include a uniform cylinder molded over ends  310   c  and  330   c , flanges  350   c  and  370   c , and portion  371  to protect any physical and electrical connection between plug  300  and any suitable device. In some embodiments, any other suitable member, such as a strain relief member or a hard plastic member, may also be molded over plug  300  and/or region  380 . 
     The location of flange  370   c  may be at the same depth  3   t  from longitudinal axis L 3  as flange  350   c  and/or may be exposed at the same distance C 1  along axis L 3  of plug  300  from end C (e.g., from end  310   c  of pin  310 ). To accommodate pin  370  within the same diameter  3   d  that may be needed to accommodate pins  310 ,  330 , and  350 , at least a portion of pin  350  towards end C may be removed (e.g., a portion of pin  350  adjacent flange  350   c  about longitudinal axis L 3 ) or pin  350  may be formed as an asymmetrical cylinder, thereby permitting both of flanges  350   c  and  370   c  to be exposed at end C. Although face  370   d  may include a thickness  370   t  ( FIG. 3 ) that may be thinner than thickness  330   t  ( FIG. 3 ) of face  330   d  and thickness  350   t  ( FIG. 3 ) of face  350   d , pins  330 ,  350 , and  370  all may have the same outward appearance to a user of plug  300 . 
     While 4-pin plugs have been shown in each of  FIGS. 1-4 , it is to be understood that a plug that includes any suitable number of pins may be configured according to the invention. For example, plug  100  and/or plug  300  may include two pins or three pins, where at least one of the pins may be partially asymmetrical and may be soldered within the plug, or may be soldered to dive down to the depth of at least one of the other pins, or may be exposed at a certain distance along the plug as another pin. For example, a 3-pin plug may include a third pin that may dive down to the depth of at least a second pin and the second pin may dive down to the depth of a first pin. Alternatively, the third pin may be exposed at a particular distance along the plug as the second pin and/or the second pin may be exposed at the same distance along the plug as the first pin. Any suitable combination of shared depths and/or exposure distances may be used with at least two pins. 
       FIG. 5  is a flowchart of an illustrative process for assembling a plug and coupling the plug to a cable in accordance with some embodiments of the invention. In some embodiments, plug  100  and plug  300  may be assembled in the same manner. Process  500  may begin at step  502 . At step  504 , at least one conductive contact or pin may be arranged within a tool. For example, pin  150  or pin  350  may be inserted at least partially into a tool. In some embodiments, any suitable number of pins, including, for example, pins  110 ,  130 , and  150  and/or pin  170 , may be inserted into the tool in any suitable arrangement (e.g., a nested arrangement). The pin or pins may include any suitable material, such as metal, and may be of any suitable dimensions. In some embodiments, at least a portion of the conductive material that creates pin  350  may be removed before pin  350  may be arranged within the tool. In some embodiments, pin  350  may be pre-formed as an asymmetrical cylinder (e.g., a cylinder with a portion of conductive material already missing about one end portion). In some embodiments, the pin arranged within the tool at step  504  may include any suitable cross-section, such as a square, rectangular, or elliptical cross-section, or any other suitable cross-section. 
     At step  506 , a layer of nonconductive material may be provided around the at least one pin placed in the tool. For example, the nonconductive material may include polypropylene that may be poured into the tool around at least a portion of the pin, but at least a portion of one or both ends of the pin may remain exposed beyond the nonconductive material. In some embodiments, the nonconductive material may be formed so as to extend beyond both ends of the pin and thereafter at least a portion of the nonconductive material may be removed from one or both ends of the pin. The one or more exposed ends may be used to couple the plug to a cable or to a jack of an electronic device. In some embodiments, the nonconductive material may be poured around and between any suitable number of pins (e.g., pins  310 ,  330 , and  350 ) to stabilize the pins within the plug and to electrically isolate the pins from one another. Each pin may be at least partially exposed, however, at one or both ends beyond the nonconductive material. 
     At step  508 , a portion of the pin may be coupled to a cable in any suitable fashion. For example, flange  150   a  or flange  350   c  may be coupled (e.g., soldered) to a wire within the cable. The cable, in turn, may be coupled to any suitable device, including, for example, headphones. Soldering the pin to the wire may create an electrical connection between the plug and the device that may be used to transmit audio or other data between the device and a user of the device. 
     Process  500  may advance to step  510 , where at least one other pin may be coupled to the plug. For example, pin  170  may be coupled to plug  100  such that at least a portion of pin  170  (e.g., flange  170   a ) may be exposed on the internal surface of plug  100  and also may be exposed beyond the nonconductive material provided at step  506 . In some embodiments, at least a portion of the conductive material that creates pin  170  may be removed before pin  170  may be coupled to plug  100 , or pin  170  may be pre-formed as an asymmetrical cylinder (e.g., a cylinder with a portion of conductive material already missing about one end portion), to permit flange  170   a  to extend toward end A of plug  100  without also obstructing end  110   a  and flanges  130   a  and  150   a  from extending toward end A and from being coupled to any suitable device. As with the pin arranged in the tool at step  504 , the other pin also may include any suitable cross-section, such as a square, rectangular, or elliptical cross-section, or any other suitable cross-section. Alternatively, pin  370  may be soldered to the nonconductive material and flange  370   c  and portion  371  may be exposed beyond a portion of pin  350  and beyond the nonconductive material provided at step  506 . 
     In some embodiments, step  510  may be performed prior to performing step  508 . For example, all of the pins may be coupled to form the plug before at least one of the pins may be coupled to a cable (e.g., a headphones cable). In some embodiments, step  510  also may be performed prior to performing step  506 . For example, all of the pins of the plug may be arranged within the tool before the nonconductive material is provided around the pins. Alternatively, the at least one other pin may be coupled to the plug at step  510  as described and another layer of nonconductive material may be disposed around at least a portion of the other pin before any of the pins of the plug may be coupled to a cable. 
     At step  512 , the other pin may be coupled to the cable. For example, flange  170   a  or flange  370   c  may be soldered to a wire within the cable. Process  500  may advance to step  514 , where another layer of nonconductive material may be provided around the coupling of the pins to the cable. For example, an additional layer of polypropylene (e.g., region  180 ) may be poured around the location at end A where pins  150  and  170  may be coupled to the wires (e.g., at flanges  150   a  and  170   a ) to protect the electrical connection between the plug and the cable. In some embodiments, the additional layer of nonconductive material may be provided around the plug before any of the pins of the plug may be coupled to the cable. Alternatively, in some embodiments, the nonconductive material provided at step  506  may be provided at the same time that an additional layer of nonconductive material may be provided around the at least one other pin of step  510  or at the same time that the additional layer of nonconductive material at step  514  may be provided. Process  500  may then advance to step  516  and end. 
     It will be understood that process  500  may be modified in any suitable way and that the steps may be performed in any suitable order. For example, in some embodiments, all of the pins of the plug may be arranged in the tool and a layer of nonconductive material may be disposed about at least a portion of all of the pins before the pins may be coupled to any suitable device. Alternatively, in some embodiments, some of the pins of the plug (e.g., 3 pins) may be arranged in the tool and a layer of nonconductive material may be disposed about at least a portion of each of those pins. Another pin (e.g., a fourth pin) may be coupled to the plug, an additional layer of nonconductive material may be disposed about at least a portion of the other pin, and then all of the pins may be coupled to any suitable device. 
     While there have been described apparatus, systems and methods for assembling a plug with a low profile, it is to be understood that many changes may be made therein without departing from the spirit and scope of the invention. It will also be understood that various directional and orientational terms such as “up” and “down,” “left” and “right,” “top” and “bottom,” “side” and “edge” and “corner,” “height” and “width” and “depth,” “horizontal” and “vertical,” and the like are used herein only for convenience, and that no fixed or absolute directional or orientational limitations are intended by the use of these words. For example, each of the pins can have any desired orientation within the plug. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope of the invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20110422
Publication Date: 20120807
Grant Date: 20120807
Priority Date: 20080118
Inventors: STIEHL KURT
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49208", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/4922", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/28", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40380519