PATENT DOCUMENT

Publication Number: US-9601882-B2
Application Number: US-201615079777-A
Country: US
Kind Code: B2

Title: Combined audio jack and mobile electronic device enclosure

Abstract:
Enclosures for electronic devices are provided. These enclosures can be integrally formed with a full or partial receptacle connector shell for receiving electrical connectors such as audio connectors or plugs. For example, an enclosure made from a polymer can be integrally formed with an audio jack shell in an injection molding process. As another example, an enclosure can be integrally formed with one or more full or partial walls of an audio jack shell to form a single piece of polymer or metal and the remaining walls of the audio jack shell can be overmolded or assembled to the polymer or metal walls of the audio jack and proximate portions of the enclosure to form a full or complete audio jack shell.

Claims:
What is claimed is: 
     
       1. An electronic device enclosure comprising:
 a unibody shell having a back portion including front and back surfaces, a bottom wall extending along a bottom edge of the back portion, and an opening formed within the bottom wall and arranged to be in communication with a cavity, the opening being sized and shaped to receive a plug connector such that the plug connector can be inserted through the opening and into the cavity; and 
 one or more connector shell walls integrally formed with the back portion and the bottom wall, wherein the cavity is at least partially defined by an inner surface of the one or more connector shell walls. 
 
     
     
       2. The electronic device enclosure of  claim 1  wherein the one or more connector shell walls include:
 the back portion that also forms the back portion of the unibody shell; 
 the bottom wall that also forms the bottom wall of the unibody shell; 
 a third wall opposite the bottom wall; 
 a top wall opposite the back portion; first and second opposing sidewalls having a length that extends from the bottom wall to the third wall and a width that extends from the back portion to the top wall. 
 
     
     
       3. The electronic device enclosure of  claim 2  further comprising a plurality of electrical contacts disposed within the top wall and configured to make electrical contact with the plug connector when it is received within the cavity. 
     
     
       4. The electronic device enclosure of  claim 1  wherein the bottom wall of the unibody shell is oriented perpendicular to the back portion. 
     
     
       5. The electronic device enclosure of  claim 1  wherein one or more electrical contacts are secured to a top wall of the unibody shell and form portions of electrical paths for mating with corresponding contacts on the plug connector. 
     
     
       6. The electronic device enclosure of  claim 1  wherein the cavity is configured to receive the plug connector. 
     
     
       7. The electronic device enclosure of  claim 1 , wherein the unibody shell is made from a polymer. 
     
     
       8. A unibody shell comprising:
 an electronic device housing for an electronic device and having a back portion including front and back surfaces and a bottom wall extending along a bottom edge of the back portion; 
 a receptacle connector shell integrally formed with the electronic device housing and the receptacle connector shell having an inner surface that at least partially defines a cavity configured to receive a plug connector, the receptacle connector shell formed by one or more connector shell walls integrally formed with the back portion and the bottom wall; and an opening formed within the bottom wall and arranged to be in communication with the cavity, the opening being sized and shaped to receive the plug connector such that the plug connector can be inserted through the opening and into the cavity. 
 
     
     
       9. The unibody shell of  claim 8  wherein the one or more connector shell walls include: the back portion that also forms the back portion of the electronic device housing; the bottom wall that also forms the bottom wall of the rear housing;
 a third wall opposite the bottom wall; a top wall opposite the back portion; and first and second opposing sidewalls having a length that extends from the bottom wall to the third wall and a width that extends from the back portion to the top wall. 
 
     
     
       10. The unibody shell of  claim 9  further comprising a plurality of electrical contacts secured to the to wall and forming portions of electrical paths for mating with corresponding contacts on the plug connector. 
     
     
       11. The unibody shell of  claim 8  wherein the plug connector is an audio plug connector. 
     
     
       12. The unibody shell of  claim 8  wherein the bottom wall is oriented perpendicular to the back portion. 
     
     
       13. The unibody shell of  claim 8  wherein the unibody shell is made from a polymer. 
     
     
       14. An audio jack shell formed as an integral portion of an electronic device enclosure, the audio jack shell comprising:
 a plurality of walls forming the audio jack shell including a to wall, a bottom wall, a back wall, a front wall and two side walls, each of the side walls, the front wall and the bottom wall extending from a back wall of the electronic device enclosure; a cavity at least partially defined by an inner surface of the audio jack shell and having an opening formed in the bottom wall for receiving an audio plug; and a plurality of electrical contacts disposed in the to wall of the audio jack shell for mating with corresponding contacts on the audio plug when the audio plug is inserted through the opening. 
 
     
     
       15. The audio jack shell of  claim 14  wherein the audio plug has a tip, a ring and a sleeve. 
     
     
       16. The audio jack shell of  claim 14  wherein the bottom wall is oriented perpendicular to the back wall. 
     
     
       17. The audio jack shell of  claim 14  wherein the electronic device enclosure is made from a polymer.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation of Ser. No. 13/969,378 filed on Aug. 16, 2013, now U.S. Pat. No. 9,326,391 for “Combined Audio Jack and Mobile Electronic Device Enclosure” that claims benefit under 35 U.S.C. §119(e), of U.S. Patent Application No. 61/696,111 filed Aug. 31, 2012 for “Combined Audio Jack and Mobile Electronic Device Enclosure.” The entire disclosure of the above mentioned applications are incorporated by reference for all purposes 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates generally to enclosures for electronic devices, and in particular enclosures including electrical connectors such as a receptacle connector for receiving an audio connector or plug. 
     Many electronic devices include electrical connectors that receive data and, in some cases, receive and provide power and data. These electrical connectors are typically receptacle connectors and are designed to receive a male plug connector. The male plug connector may be on the end of a cable. The plug connector may plug into the receptacle connector, thereby forming one or more conductive paths for signals and/or power. 
     Receptacle connectors often have a shell that surrounds and provides mechanical support for contacts of the receptacle connector. Receptacle connector shells are typically made from plastics. The contacts may be arranged to mate with corresponding contacts on the plug connector, e.g., an audio plug, to form portions of electrical paths between devices. 
     These receptacle connectors, e.g., audio jacks, are often manufactured separately from the enclosure and sometimes by a manufacturer different than the enclosure manufacturer. These off-the-shelf receptacle connectors may be attached with bolts or otherwise fixed to enclosures of electronic devices. Some receptacle connectors are customized for use within a specific electronic device or a group of electronic devices. These custom receptacle connectors may also be manufactured separately from the enclosure and inserted into the enclosure during the assembly process of the electronic device. 
     As electronic devices continue to become smaller, these enclosures have increasingly limited internal space while still including a large number of internal components. Limited space within the enclosures of devices creates a number of challenges. For example, the limited internal space of these enclosures drives the demand for smaller internal components such as smaller receptacle connector shells. However, smaller receptacle connector shells that are compatible with industry standard connectors such as the 3.5 mm audio plug may not be available. Proprietary plug connectors or 2.5 mm audio plugs that include smaller receptacle connectors shells could be implemented in some situations but that would require consumers to purchase new devices and/or related accessories. 
     Many devices suffer from all or some of these deficiencies or from similar deficiencies. Accordingly, it is desirable to provide enclosures having smaller internal components such as audio jacks. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention relates generally to enclosures for electronic devices, and in particular enclosures integrally formed with a full or partial receptacle connector shell for receiving electrical connectors such as audio connectors or plugs. For example, an enclosure made from a polymer may be integrally formed with an audio jack shell in an injection molding process. As another example, an enclosure may be integrally formed with one or more full or partial walls of an audio jack shell to form a single piece of polymer or metal and the remaining walls of the audio jack shell may be overmolded to the polymer or metal walls of the audio jack and proximate portions of the enclosure to form a full or complete audio jack shell. Accordingly, a receptacle connector shell may be integrated with an enclosure of an electronic device to reduce the overall space requirements of the receptacle connector within the enclosure and/or potentially reduce the size of the enclosure required to contain the receptacle connector. This enclosure design may also be desirable because it may provide sealing between the receptacle connector shell and the enclosure to protect against liquid ingress, a structurally robust receptacle connector shell, and reduced material requirements and manual assembly time. 
     According to one embodiment, an electronic device enclosure is provided. The electronic device enclosure can include a back portion that includes front and back surfaces, left and right opposing walls, and top and bottom opposing walls. The bottom wall can include an opening that communicates with a cavity. The electronic device enclosure can also include inner surfaces of a connector shell that define the cavity. The connector shell can be integrally formed with the back portion and the bottom wall and can be defined at least in part by: a top connector shell portion extending from the bottom wall towards the top wall, first and second opposing sidewalls extending from the bottom wall towards the top wall, and a third sidewall opposite the bottom wall extending between the first and second sidewalls. The first, second and third sidewalls can also extend from the top connector shell portion to the back portion. The enclosure can form a unified body that is formed from a single piece of material. 
     According to another embodiment, an electronic device enclosure is provided. The electronic device enclosure can include a back portion that includes front and back surfaces, left and right opposing walls, and top and bottom opposing walls. The bottom wall can include including an opening. The front surface of the back portion can include first and second ridges disposed adjacent to and on opposite sides of the opening and extending towards the top wall. The first and second ridges can include a depth. The enclosure can form a unified body that is formed from a single piece of material. 
     According to yet another embodiment, an electronic device enclosure is provided. The electronic device enclosure can include left and right opposing walls and top and bottom opposing walls extending between the left and right opposing walls. The bottom wall can include an opening. The electronic device enclosure can also include at least a portion of a connector shell integrally formed with the bottom wall. The enclosure can form a unified body that is formed from a single piece of material. 
     Although aspects of the invention are described in relation to enclosures integrally formed with reduced size audio jacks, it is appreciated that these features, aspects and methods can be used in a variety of different environments, regardless of receptacle connector size or type. 
     The enclosures described herein may be integrally formed with a variety of different electrical connector shells, which may use a variety of different connector technologies. The invention may apply to many commonly used connectors, including standard Universal Serial Bus (USB), a High-Definition Multimedia Interface (HDMI), Digital Visual Interface (DVI), DisplayPort, Thunderbolt, FireWire, power, Ethernet connectors, as well as many of the proprietary connectors, e.g., Apple&#39;s proprietary 30-pin connector, used with common electronics. The invention may also apply to internal connectors or other connections between components within the enclosure of an electronic device. Additionally, the invention may apply to devices such as tablets, laptops, netbooks, desktops, and all-in-one computers; cell, smart, and media phones; storage devices, portable media players, navigation systems, monitors, and others. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a simplified illustrative block diagram representing an electronic media device that includes an audio receptacle connector according to embodiments of the present invention; 
         FIG. 2  illustrates a rendering of one particular electronic media device; 
         FIGS. 3A-B  illustrate examples of audio plugs having three and four conductive portions, respectfully; 
         FIG. 4A  illustrates a sectional perspective view of a traditional electronic device enclosure having an audio jack mounted thereon; 
         FIG. 4B  illustrates a cross-sectional view of a section of a traditional enclosure having an audio jack mounted thereon and having a cover glass frame and a cover glass assembled therewith; 
         FIGS. 5A-B  illustrate perspective and sectional perspective views, respectively, of an electronic device enclosure integrally formed with an audio jack shell; 
         FIG. 5C  illustrates a cross-sectional view of a section of a unibody enclosure integrally formed with audio jack shell and having a cover glass frame and a cover glass assembled therewith; 
         FIG. 6A  illustrates a section of an electronic device enclosure integrally formed with a partial audio jack shell; 
         FIGS. 6B and 6C  illustrate two perspective views of a section of an electronic device enclosure for an electronic device integrally formed with a first partial audio jack shell and overmolded with a second partial audio jack shell; and 
         FIG. 7  illustrates a perspective view of an electronic device enclosure that does not include a back portion and is integrally formed with an audio jack shell. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described in detail with reference to certain embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known details have not been described in detail in order not to unnecessarily obscure the present invention. 
     Before describing the present invention, electronic devices in which the invention may be implemented and audio connectors or plugs corresponding to receptacle connectors of the invention are first described in the following two sections. 
     I. Electronic Devices in which the Invention May be Implemented 
       FIG. 1  is a simplified illustrative block diagram representing an electronic media device  100  that includes an audio receptacle connector  105  according to embodiments of the present invention. Electronic media device  100  may also include, among other components, connector receptacle  110 , one or more user input components  120 , one or more output components  125 , control circuitry  130 , graphics circuitry  135 , a bus  140 , a memory  145 , a storage device  150 , communications circuitry  155  and POM (position, orientation or movement sensor) sensors  160 . Control circuitry  130  may communicate with the other components of electronic media device  100  (e.g., via bus  140 ) to control the operation of electronic media device  100 . In some embodiments, control circuitry  130  may execute instructions stored in a memory  145 . Control circuitry  130  may also be operative to control the performance of electronic media device  100 . Control circuitry  130  may include, for example, a processor, a microcontroller and a bus (e.g., for sending instructions to the other components of electronic media device  100 ). In some embodiments, control circuitry  130  may also drive the display and process inputs received from input component  120 . 
     Memory  145  may include one or more different types of memory that may be used to perform device functions. For example, memory  145  may include cache, flash memory, ROM, RAM and hybrid types of memory. Memory  145  may also store firmware for the device and its applications (e.g., operating system, user interface functions and processor functions). Storage device  150  may include one or more suitable storage mediums or mechanisms, such as a magnetic hard drive, flash drive, tape drive, optical drive, permanent memory (such as ROM), semi-permanent memory (such as RAM) or cache. Storage device  150  may be used for storing media (e.g., audio and video files), text, pictures, graphics, advertising or any suitable user-specific or global information that may be used by electronic media device  100 . Storage device  150  may also store programs or applications that may run on control circuitry  130 , may maintain files formatted to be read and edited by one or more of the applications and may store any additional files that may aid the operation of one or more applications (e.g., files with metadata). It should be understood that any of the information stored on storage device  150  may instead be stored in memory  145 . 
     Electronic media device  100  may also include input component  120  and output component  125  for providing a user with the ability to interact with electronic media device  100 . For example, input component  120  and output component  125  may provide an interface for a user to interact with an application running on control circuitry  130 . Input component  120  may take a variety of forms, such as a keyboard/keypad, trackpad, mouse, click wheel, button, stylus or touch screen. Input component  120  may also include one or more devices for user authentication (e.g., a smart card reader, a fingerprint reader or an iris scanner) as well as an audio input device (e.g., a microphone) or a video input device (e.g., a camera or a web cam) for recording video or still frames. Output component  125  may include any suitable display, such as a liquid crystal display (LCD) or a touch screen display, a projection device, a speaker or any other suitable system for presenting information or media to a user. Output component  125  may be controlled by graphics circuitry  135 . Graphics circuitry  135  may include a video card, such as a video card with 2D, 3D or vector graphics capabilities. In some embodiments, output component  125  may also include an audio component that is remotely coupled to electronic media device  100 . For example, output component  125  may include a headset, headphones or ear buds that may be coupled to electronic media device  100  with a wire or wirelessly (e.g., Bluetooth headphones or a Bluetooth headset). 
     Electronic media device  100  may have one or more applications (e.g., software applications) stored on storage device  150  or in memory  145 . Control circuitry  130  may be configured to execute instructions of the applications from memory  145 . For example, control circuitry  130  may be configured to execute a media player application that causes full-motion video or audio to be presented or displayed on output component  125 . Other applications resident on electronic media device  100  may include, for example, a telephony application, a GPS navigator application, a web browser application and a calendar or organizer application. Electronic media device  100  may also execute any suitable operating system, such as Mac OS, Apple iOS, Linux or Windows and can include a set of applications stored on storage device  150  or memory  145 , which applications may be compatible with the operating system running on the device. 
     In some embodiments, electronic media device  100  may also include communications circuitry  155  to connect to one or more communications networks. Communications circuitry  155  may be any suitable communications circuitry operative to connect to a communications network and to transmit communications (e.g., voice or data) from electronic media device  100  to other devices within the communications network. Communications circuitry  155  may be operative to interface with the communications network using any suitable communications protocol such as, for example, Wi-Fi (e.g., a 802.11 protocol), Bluetooth, high frequency systems (e.g., 900 MHz, 2.4 GHz and 5.6 GHz communication systems), infrared, GSM, GSM plus EDGE, CDMA, quadband and other cellular protocols, VOIP or any other suitable protocol. 
     In some embodiments, communications circuitry  155  may be operative to create a communications network using any suitable communications protocol. Communications circuitry  155  may create a short-range communications network using a short-range communications protocol to connect to other devices. For example, communications circuitry  155  may be operative to create a local communications network using the Bluetooth protocol to couple with a Bluetooth headset (or any other Bluetooth device). Communications circuitry  155  may also include a wired or wireless network interface card (NIC) configured to connect to the Internet or any other public or private network. For example, electronic media device  100  may be configured to connect to the Internet via a wireless network, such as a packet radio network, an RF network, a cellular network or any other suitable type of network. Communication circuitry  145  may be used to initiate and conduct communications with other communications devices or media devices within a communications network. 
     Electronic media device  100  may also include any other component suitable for performing a communications operation. For example, electronic media device  100  may include a power supply, an antenna, ports or interfaces for coupling to a host device, a secondary input mechanism (e.g., an ON/OFF switch) or any other suitable component. 
     Electronic media device  100  may also include POM sensors  160 . POM sensors  160  may be used to determine the approximate geographical or physical location of electronic media device  100 . As described in more detail below, the location of electronic media device  100  may be derived from any suitable trilateration or triangulation technique, in which case POM sensors  160  may include an RF triangulation detector or sensor or any other location circuitry configured to determine the location of electronic media device  100 . 
     POM sensors  160  may also include one or more sensors or circuitry for detecting the position orientation or movement of electronic media device  100 . Such sensors and circuitry may include, for example, single-axis or multi-axis accelerometers, angular rate or inertial sensors (e.g., optical gyroscopes, vibrating gyroscopes, gas rate gyroscopes or ring gyroscopes), magnetometers (e.g., scalar or vector magnetometers), ambient light sensors, proximity sensors, motion sensors (e.g., a passive infrared (PIR) sensor, active ultrasonic sensor or active microwave sensor) and linear velocity sensors. For example, control circuitry  130  may be configured to read data from one or more of POM sensors  160  in order to determine the location orientation or velocity of electronic media device  100 . One or more of POM sensors  160  may be positioned near output component  125  (e.g., above, below or on either side of the display screen of electronic media device  100 ). 
       FIG. 2  depicts an illustrative rendering of one particular electronic media device  200 . Device  200  includes a multipurpose button  205  as an input component, a touch screen display  210  as both an input and output component, and a speaker  215  as an output component, all of which are housed within a device housing  220 . Device  200  also includes a primary receptacle connector  230  and an audio receptacle connector  235  or audio jack within device housing  220 . Each of the receptacle connectors  230  and  235  can be positioned within housing  220  such that an opening of the receptacle connectors  230 ,  235  into which a corresponding plug connector is inserted is located at an exterior surface of the device housing. In some embodiments, these openings may be located at an exterior side surface of device  200 . For simplicity, various internal components, such as the control circuitry, graphics circuitry, bus, memory, storage device and other components are not shown in  FIG. 2 . 
     Electronic media device  200  may be a portable computing device; a tablet; a smart or media phone; or a portable media player. However, as discussed earlier, embodiments of the present invention may be implemented in laptops, desktops; all-in-one computers; cell phones, storage devices; navigation systems; monitors or other electronic devices. 
     Embodiments of the invention disclosed herein pertain to an enclosure portion (not shown in  FIG. 2 ) of housing  220  that is integrally formed with audio receptacle connector  235 , but in other embodiments the enclosure may be integrally formed with receptacle connector  230 . Additionally, in some embodiments, housing  220  may only include a single receptacle connector  230  (as opposed to the two receptacle connectors shown in  FIG. 2 ) that is used to connect to other electronic devices. In these embodiments, the enclosure may be integrally formed with receptacle connector  230 . 
     II. Audio Connectors or Plugs Corresponding to Receptacle Connectors of the Invention 
     Embodiments of the present invention may include a receptacle connector for receiving an audio connector or plug, e.g., a standard audio connector or plug. Standard audio plugs are available in three sizes according to the outside diameter of the plug: a 6.35 mm (¼″) plug, a 3.5 mm (⅛″) miniature plug and a 2.5 mm ( 3/32″) subminiature plug. The plugs include multiple conductive regions that extend along the length of the connectors in distinct portions of the plug such as the tip, sleeve and one or more middle portions between the tip and sleeve resulting in the connectors often being referred to as TRS (tip, ring and sleeve) connectors. 
       FIGS. 3A and 3B  illustrate examples of audio plugs  310  and  320  having three and four conductive portions, respectfully. As shown in  FIG. 3A , plug  310  includes a conductive tip  312 , a conductive sleeve  316  and a conductive ring  314  electrically isolated from the tip  312  and the sleeve  316  by insulating rings  317  and  318 . The three conductive portions  312 ,  314 ,  316  are for left and right audio channels and a ground connection, respectively. Plug  320 , shown in  FIG. 3B , includes four conductive portions: a conductive tip  322 , a conductive sleeve  326  and two conductive rings  324 ,  325  and is thus sometime referred to as a TRRS (tip, ring, ring, sleeve) connector. The four conductive portions  322 ,  324 ,  325  and  326  are electrically isolated by insulating rings  327 ,  328  and  329  and are typically used for left and right audio, ground and microphone signals, respectively. 
     When plugs  310  and  320  are 3.5 mm miniature connectors, the outer diameter of conductive sleeve  316 ,  326  and conductive rings  314 ,  324 ,  325  is 3.5 mm and the insertion length of the connector is 14 mm. For 2.5 mm subminiature connectors, the outer diameter of the conductive sleeve is 2.5 mm and the insertion length of the connector is 11 mm long. Such TRS and TRRS connectors are used in many commercially available MP3 players and smart phones as well as other electronic devices. Electronic devices such as MP3 players and smart phones are continuously being designed to be thinner and smaller and/or to include video displays with screens that are pushed out as close to the outer edge of the devices as possible. The diameter and length of current 3.5 mm and even 2.5 mm audio connectors are limiting factors in making such devices smaller and thinner and in allowing the displays to be larger for a given form factor. 
     The sizes of corresponding receptacle connectors or audio jacks for the standard audio plugs connectors described above are also limiting factors in making portable electronic devices smaller. An example of traditional audio jacks mounted within an enclosure of an electronic device is shown in the following figures. 
     III. Prior Art 
       FIG. 4A  illustrates a perspective view of a section of a traditional electronic device enclosure  400  having an audio jack  405  mounted thereon. Enclosure  400  includes a back portion  410  having bottom and left walls  415 ,  420  as well as top and right walls (not shown in  FIG. 4A ). Bottom wall  415  includes an opening (opening  465  shown in  FIG. 4B ) for access to audio jack  405 . 
     Audio jack  405  is assembled on back portion  410 , adjacent to an opening (opening  465  in  FIG. 4B ) on bottom wall  415 . Audio jack  405  is mounted to back portion  410  via a screw (not shown in  FIG. 4B ) that is threaded through audio jack bracket  425  and threaded opening  430 . Audio jack  405  also includes contacts  435 - 439  for mating with corresponding contacts on a standard audio plug. 
       FIG. 4B  illustrates a cross-sectional view of a section of traditional electronic device enclosure  400  having audio jack  405  mounted thereon and having a cover glass frame  440  and a cover glass  445  assembled therewith. Cover glass frame  440  and cover glass  445  are held in position by shelf  450  and other interlocking features (not shown in  FIG. 4B ). As shown in  FIG. 4B , an opening  470  of audio jack  405  is registered with opening  465  of bottom wall  415 . Trim gasket  455  surrounds opening  470  and is intended to seal gaps between enclosure  400  and audio jack  405  in order to limit liquid ingress. A trim  460  may be included that surrounds opening  465 . A standard audio plug may be inserted through opening  465  and into opening  470  in order for its contacts to mate with corresponding contacts  435 - 439  (not shown in  FIG. 4B ) of audio jack  405 . 
     Embodiments of unified bodies including an enclosure and a full or partial audio jack shell are discussed in the next section and potentially may require less internal space, parts, cost and manual assembly time than traditional embodiments described above. 
     IV. Full and Partial Unibody Designs 
     Enclosures may be integrally formed with a full or partial receptacle connector shell for receiving electrical connectors such as audio connectors or plugs. In this manner, the enclosure may form a unified body or unibody with a full or partial receptacle connector where the unibody is formed from a single piece of material. Examples of these unibodies formed from a single piece of polymer or metal are discussed below. 
     A. Full Unibody Design 
       FIGS. 5A and 5B  illustrate perspective and sectional perspective views, respectively, of an electronic device enclosure  500  integrally formed with an audio jack shell  505 . Enclosure  500  includes a back portion  510  having top and bottom opposing walls  515 ,  520  and left and right opposing walls  525 ,  530 . Bottom wall may include an opening  535  (only shown in  FIG. 5A ), for receiving plug connectors, e.g., standard audio plugs. Back portion  510  and bottom wall  520  may be integrally formed with audio jack shell  505  so as to form unibody enclosure  500  that is formed from a single piece of polymer or metal. Audio jack shell  505  includes a front portion  501 , a right sidewall  502  and an opposing left side wall (not shown in  FIGS. 5A-B ), and a top wall  503 . In some embodiments, contacts  540 - 544 , for mating with corresponding contacts on a standard audio plug, may not be integrally formed with enclosure  500 , but rather assembled separately. 
     This single piece enclosure  500  including audio jack shell  505  may be formed by injecting molten polymer, e.g., thermoplastics, or glass filled resin, e.g., glass reinforced nylon, into a mold, i.e., injection molding, so as to form a single piece of polymer. Alternatively, enclosure  500  may be formed by molding Liquidmetal or a metal injection molding process (MIM) to form a single piece of metal, e.g., stainless steel. 
       FIG. 5C  illustrates a cross-sectional view of a section of unibody enclosure  500  integrally formed with audio jack shell  505  and having a cover glass frame  545  and a cover glass  550  assembled therewith. Cover glass frame  545  and cover glass  550  are supported by shelf  551  (shown in  FIGS. 5A-B ) and other interlocking features (not shown in  FIG. 5C ). As shown in  FIG. 5C , opening  535  serves as the opening for enclosure  500  and audio jack  505  because these elements are formed from a single piece of material. Opening  535  may be configured to receive standard audio plugs. As compared to traditional enclosure  400  (as shown in  FIGS. 4A-B  and discussed above), the overall depth in which audio jack shell  505  extends towards top wall  515  may be reduced by not including a trim (e.g., trim  460  as shown in  FIG. 4B ) or a trim gasket (e.g., gasket  455  as shown in  FIG. 4B ). Not including a trim eliminates cosmetic gaps between an enclosure and the trim. However, the potential for liquid ingress at the interface of the enclosure  500  and the audio jack  505  is also eliminated by virtue of the elimination of the cosmetic gaps. Hence, trim gaskets may not be needed for enclosure  500  to fill gaps at seams between parts to prevent liquid ingress. 
     Although not shown in  FIGS. 5A-5C , in some embodiments, enclosure  500  may also include one or more additional openings (in addition to opening  535 ) for providing access to more than one receptacle connector. For example, enclosure  500  may include openings for two receptacle connectors such as receptacle connectors  230  and  235  (as shown in  FIG. 2 ). Furthermore, one or more of the additional receptacle connectors may be integrated with embodiments of enclosure  500  in addition to or instead of audio jack  505 . 
     B. Partial Unibody Design 
       FIG. 6A  illustrates a section of an electronic device enclosure  600  integrally formed with a partial audio jack shell  605 . Enclosure  600  includes back portion  610  having a top wall (not shown in  FIG. 6A ) opposite a bottom wall  620  as well as left wall  625  opposite a right wall (not shown in  FIG. 6A ). Bottom wall  620  may include an opening  630  for receiving plug connectors, e.g., audio plugs. Back portion  610  and bottom wall  620  may be integrally formed with partial audio jack shell  605  so at to form a unibody enclosure  600  from a single piece of polymer or metal. Partial audio jack shell  605  may include first and second ridges  635 ,  640  having interlocking pockets  645 - 647  and  648 - 650 , respectively. Interlocking pockets  645 - 650  may be used for interlocking with an overmolded part, as discussed below. 
     This single piece enclosure  600  including audio jack shell  605  may be formed by injecting molten polymer, e.g., thermoplastics, or glass filled resin, e.g., glass reinforced nylon, into a mold, i.e., injection molding, so as to form a single piece of polymer. Alternatively, enclosure  600  may be formed by molding Liquidmetal or a metal injection molding process (MIM) to form a single piece of metal, e.g., stainless steel. In other embodiments, single piece enclosure  600  may be formed by computer numerical control (CNC) of a machining tool. 
     In some embodiments, enclosure  600  may include more or fewer ridges, e.g., ridges  635  and  640 , than shown in  FIG. 6A . For example, enclosure  600  may include one ridge or three ridges. In other embodiments, other portions of an audio jack shell may be integrally formed with enclosure  600 . 
       FIGS. 6B and 6C  illustrate two perspective views of a section of an electronic device enclosure  600  for an electronic device integrally formed with a first partial audio jack shell  605  and overmolded with a second partial audio jack shell  606   a . Second partial audio jack shell  606   a  may be formed over first partial audio jack shell  605  via overmolding molten polymer over bottom wall  620 , back portion  610  and first partial audio jack shell  605  to form a full audio jack shell, as shown in  FIG. 6B . Second partial audio jack shell  606   b  provides a view of what second partial audio jack shell  606   a  would look like if it was separated from enclosure  600  after the overmolding process. Second partial audio jack shell  606   a  includes interlocking pegs  661 - 663  (shown on second partial audio jack shell  606   b ) that correspond to pockets  645 - 647  (shown in  FIG. 6A ) for locking second partial audio jack shell  606   a  to first partial audio jack shell  605 . Second partial audio jack shell  606   a  also includes additional interlocking pegs  671 - 673  (shown on second partial audio jack shell  606   b ) corresponding to interlocking pockets  648 - 650  (shown in  FIG. 6A ). Second partial audio jack shell  606   a  may be implemented in embodiments where enclosure  600  includes partial audio jack shell  605  and may be formed from a single piece of polymer or metal. 
     In some embodiments, first partial audio jack shell  605  and/or second partial audio jack shell  606   a  may include contacts (e.g., contacts  540 - 544  shown in  FIG. 5B ) for mating with corresponding contacts on a standard audio plug. The contacts may be integrally formed with enclosure  600  or may be assembled with first partial audio jack shell  605  and/or second partial audio jack shell  606   a  separately, as discussed below. As shown in  FIG. 6B , an opening  675  of residual audio jack shell  606   a  is registered with opening  630  of bottom wall  620 . A standard audio plug may be inserted through opening  630  and into opening  675  in order for its contacts to mate with corresponding contacts that may be implemented on first partial audio jack shell  605  and/or second partial audio jack shell  606   a.    
     Gaps occurring at seams—interfacing surfaces between two discrete parts—between enclosure  600  and second partial audio jack shell  606   a  may be eliminated by virtue of the overmolding process which typically does not leave gaps at the seams. In this manner, liquid ingress may also be prevented in these embodiments as well. However, in some embodiments, second partial audio jack shell  606   a  may not be formed by overmolding, but rather by injection molding. Thereafter, the injection molded second partial audio jack shell  606   a  may be assembled, e.g., via press fitting, with enclosure  600 . In these embodiments, assembling second partial audio jack shell  606   a  with enclosure  600  may result in seams with gaps; gaskets or sealants may be used at the gap locations to prevent liquid ingress. 
     In some embodiments, second partial audio jack shell  606   a  may be formed by a multiple-shot overmolding process wherein each overmolding process forms a different part of second partial audio jack shell  606   a . Each overmolding process may use different types of polymers. 
     Embodiments of enclosure  600  may achieve similar benefits to that of enclosure  500  discussed above. In addition, enclosure  600  may be suitable with metal enclosures and/or allow for the use of more than one material implemented for an audio jack shell. For example, in some situations, it may be desirable to use glass filled resin for part of an audio jack for its structural properties and a cosmetic non-glass filled resin, e.g., polycarbonate, for parts of the audio jack exposed to the users of electronic devices. 
     Although not shown in  FIGS. 6A-6C , in some embodiments, enclosure  600  may also include one or more additional openings (in addition to opening  630 ) for providing access to more than one receptacle connector. For example, enclosure  600  may include openings for two receptacle connectors such as receptacle connectors  230  and  235  (as shown in  FIG. 2 ). Furthermore, one or more of the additional receptacle connectors may be integrated with embodiments of enclosure  600  in addition to or instead of audio jack  605 . 
     C. Metal Trim 
     In some embodiments, it may be desirable to include a trim, as discussed with regards to the prior art, in the enclosure embodiments described above. The trim, which may be made from a metallic material, may be assembled with the enclosure and surround a receptacle connector opening of a bottom wall of an enclosure. Cosmetic gaps between the enclosure and the metal trim are removed by virtue of the insert molding process that may fill in potential gaps at the seams between the enclosure and the metal trim. It may be desirable for enclosures according to the present invention to include a metal trim in order to prevent wear caused by inserting and extracting plug connectors, e.g., TRS or TRRS audio plugs, into and from the opening of the enclosure, 
     D. Assembly of Contacts for Audio Jacks 
     Contacts implemented on enclosures of the present invention may be manually assembled using a press fit connection or insert molded in an overmolding process applied to a full or partial audio jack integrally formed with an enclosure. Similarly, contacts may be manually assembled using a press fit connection or insert molded in an overmolding process applied to a residual audio jack overmold. 
     V. Alternative Unibody Designs 
     Although embodiments disclosed herein relate to receptacle connector shells (e.g., audio jack shells) integrally formed with a back portion and bottom wall of an enclosure, enclosures according to the present invention may include receptacle connector shells integrally formed with any walls or portions of the enclosure. For example, a receptacle connector shell could be integrally formed with the back portion and the top wall. As another example, a receptacle connector shell could be integrally formed with the back portion and the top and left walls. As yet another example, the receptacle connector shell may not be integrally formed with a back portion of an enclosure, but rather with one or more two walls of the enclosure, e.g., bottom and right walls. The following figure illustrates an example of a unibody enclosure that does not include a back portion. 
       FIG. 7  illustrates a perspective view of an electronic device enclosure  700  that does not include a back portion and is integrally formed with an audio jack shell  705 . Enclosure  700  includes top and bottom opposing walls  715 ,  720  and left and right opposing walls  725 ,  730 . Bottom wall may include an opening  735 , for receiving plug connectors, e.g., standard audio plugs. Bottom wall  720  may be integrally formed with audio jack shell  705  so as to form unibody enclosure  700  that is formed from a single piece of polymer or metal. Audio jack shell  705  includes a front portion  701 , a right sidewall  702  and an opposing left side wall (not shown in  FIG. 7 ), and a top wall  703 . In some embodiments, contacts  740 - 744  for mating with corresponding contacts on a standard audio plug may not be integrally formed with enclosure  700  but rather assembled separately. 
     As with other embodiments discussed herein, single piece enclosure  700 , including audio jack shell  705 , may be formed by injecting molten polymer, e.g., thermoplastics, or glass filled resin, e.g., glass reinforced nylon, into a mold, i.e., injection molding, so as to form a single piece of polymer. Alternatively, enclosure  700  may be formed by molding Liquidmetal or a metal injection molding process (MIM) to form a single piece of metal, e.g., stainless steel. 
     Although not shown in  FIG. 7 , in some embodiments, enclosure  700  may also include one or more additional openings (in addition to opening  735 ) for providing access to more than one receptacle connector. For example, enclosure  700  may include openings for two receptacle connectors such as receptacle connectors  230  and  235  (as shown in  FIG. 2 ). Furthermore, one or more of the additional receptacle connectors may be integrated with embodiments of enclosure  700  in addition to or instead of audio jack  705 . 
     Other components described herein may be integrally formed with an audio jack shell that is integrally formed with an enclosure, according to embodiments of the present invention. That is, components adjacent to audio jack shells could share one or more walls with the audio jack shell. Other components could also be formed integrally within the enclosure regardless of their proximity to the audio jack housing. For example, components could be integrated with walls of the enclosure or just the back portion of the enclosure. 
     Also, while a number of specific embodiments were disclosed with specific features, a person of skill in the art will recognize instances where the features of one embodiment can be combined with the features of another embodiment. For example, some specific embodiments of the invention set forth above were illustrated with audio jacks. A person of skill in the art will readily appreciate that any of the types of receptacle connectors described herein may be integrally formed with an enclosure, as well as other internal components specifically mentioned herein and not specifically mentioned herein. Also, those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the inventions described herein. Such equivalents are intended to be encompassed by the following claims.

Metadata:
Filing Date: 20160324
Publication Date: 20170321
Grant Date: 20170321
Priority Date: 20120831
Inventors: WOODHULL CHARLES B.
SLOEY JASON S.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2105/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0004", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K5/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2105/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0274", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 49123888