PATENT DOCUMENT

Publication Number: US-9704663-B2
Application Number: US-201213476945-A
Country: US
Kind Code: B2

Title: Accessory button controller assembly

Abstract:
An accessory may be provided with a button controller having a microphone and switches. Plastic structures for the accessory may be formed by injection molding. Plastic structures may be molded around a printed circuit and wiring. The wiring may have a plastic jacket. The molded plastic structures may bond with the plastic jacket to retain the wiring. The molded plastic structures may be molded directly to the printed circuit board. Protrusions on the molded plastic structures may mate with openings in a metal clip. Housing structures may be mounted to the metal clip. The metal clip may be provided with a spring to short the metal clip to a trace on the printed circuit. The metal clip may also have a portion that receives electrostatic charge during electrostatic discharge events and that discharges the charge through the spring to the trace on the printed circuit.

Claims:
What is claimed is: 
     
       1. An accessory button controller, comprising:
 wiring having a plastic jacket; 
 a printed circuit board comprising at least one switch coupled to the wiring; 
 a plastic structure overmolded over the printed circuit board; 
 a strain relief structure overmolded over:
 an end region of the plastic structure; and 
 a portion of the plastic jacket; and 
 
 a first outer housing member forming a first portion of an external surface of the accessory button controller; and 
 a second outer housing member forming a second portion of the external surface of the accessory button controller, the first and second portions aligned on symmetrically opposite sides of the printed circuit board, wherein: 
 the first and second outer housing members enclose the printed circuit board and the plastic structure; 
 the first and second outer housing members are configured to move toward one another in response to an applied force; and 
 the movement of the first and second outer housing members toward one another causes an actuation of the at least one switch. 
 
     
     
       2. The accessory button controller of  claim 1 , wherein the first and second housing members partially enclose the strain relief structure. 
     
     
       3. The accessory button controller of  claim 1 , further comprising a metal clip interposed between one of the first or second housing members and the plastic structure. 
     
     
       4. The accessory button controller of  claim 3 , wherein the printed circuit board comprises at least one trace; and the metal clip comprises a portion that is shorted to the trace. 
     
     
       5. The accessory button controller of  claim 4 , wherein
 the first outer housing member and the second outer housing member are separated by a gap. 
 
     
     
       6. The accessory button controller of  claim 1  further comprising:
 a microphone on the printed circuit; 
 a conductive mesh covering the microphone; and 
 conductive adhesive configured to attach the conductive mesh to the printed circuit over the microphone. 
 
     
     
       7. An accessory, comprising:
 an earbud comprising:
 a speaker driver enclosure portion; and 
 a hollow neck portion; 
 
 wires coupled to the earbud, the wires comprising a knot to retain the wires in the hollow neck portion; 
 a bead threaded onto the wires to prevent compression of the knot; and 
 an accessory button controller coupled to the wires, wherein the accessory button controller comprises:
 a printed circuit comprising at least one switch mounted to the printed circuit; 
 a plastic structure that is overmolded over the printed circuit; and 
 a housing assembly comprising first and second outer housing members positioned on opposite sides of the printed circuit board; and 
 
 an overmolded strain relief structure that is coupled to the plastic structure at an end region and surrounds the wires, wherein: 
 at least one of the first or second outer housing members is configured to translate toward the printed circuit board; 
 the at least one switch is configured to generate an electrical response in response to the translation of the at least one of the first or second outer housing members; and 
 the knot of the wires is tied to the bead. 
 
     
     
       8. The accessory of  claim 7  wherein:
 the wires comprise a plastic jacket; and 
 a portion of the plastic structure is overmolded over the wires and bonds to the plastic jacket to retain the wires within the accessory button controller. 
 
     
     
       9. The accessory of  claim 7 , wherein
 the first outer housing member and 
 the second outer housing member are separated by a gap. 
 
     
     
       10. The accessory of  claim 9 , further comprising:
 at least one trace on the printed circuit; 
 a metal structure comprising:
 an opening that engages a protrusion in the plastic structure; 
 at least one spring that shorts the metal structure to the trace; and 
 a portion that receives electrostatic charge through the gap formed between the first outer housing member and the second outer housing member. 
 
 
     
     
       11. An accessory button controller, comprising:
 a printed circuit having a least one conductive trace; 
 a switch on the printed circuit; 
 a housing having a first portion positioned along a top surface of the printed circuit board and a second portion positioned along a bottom surface of the printed circuit board, thereby enclosing the printed circuit within the housing; 
 a plastic structure that is overmolded over the printed circuit, the plastic structure includes at least one protrusion and defines an end region; 
 a strain relief structure coupled to, and overlapping the end region of, the plastic structure and extending beyond a perimeter of the housing; and 
 a clip coupled to the housing, the clip comprising an opening that mates with the protrusion of the plastic structure; wherein: 
 the housing surrounds the plastic structure and a portion of the strain relief structure: 
 at least one of the first or second portions is configured to move toward the plastic structure and the portion of the strain relief structure in response to a user input; and 
 the switch is configured to detect the user input using the movement of the first or second portions. 
 
     
     
       12. The accessory button controller of  claim 11 , wherein:
 the accessory button controller further comprises a wiring that is coupled to the printed circuit; 
 the wiring comprises a plastic jacket; 
 the plastic structure is configured to bond with the plastic jacket to retain the wiring within the housing; and 
 the strain relief structure surrounds the wiring. 
 
     
     
       13. The accessory button controller of  claim 11 , wherein
 the first portion of the housing is coupled to the clip; and 
 the second portion of the housing is coupled to the plastic structure, the first and second portions are separated by a gap and the clip has a protrusion that is configured to receive electrostatic charge through the gap. 
 
     
     
       14. The accessory button controller of  claim 13 , wherein the clip comprises a spring portion that is shorted to the conductive trace on the printed circuit board to discharge electrostatic charge. 
     
     
       15. A method, comprising:
 forming metal traces on a printed circuit board; 
 placing the printed circuit board in a molding tool having a set of injection molding shutoff structures with a recess that accommodates the metal traces by holding the printed circuit board while the recess overlaps the metal traces without crushing the metal traces; 
 injection molding a first plastic into a first cavity formed by the molding tool and one of the set of injection molding shutoff structures, the injection molded first plastic forming a plastic structure that covers the printed circuit board; and 
 injection molding a second plastic into a second cavity formed by the molding tool and another of the set of injection molding shutoff structures, the injection molded second plastic forming a strain-relief structure surrounding a portion of the plastic structure at an end region, 
 positioning a first outer housing member along a first surface of the printed circuit board, the injection molded plastic, and the portion of the strain relief structure; 
 positioning a second outer housing member along a second surface of the printed circuit board, the injection molded plastic, and the portion of the strain relief structure, opposite the first surface; 
 coupling the first and second outer housing members such that the first and second outer housing members are configured to move toward one another in response to an applied force, 
 wherein the movement of the first and second outer housing members toward one another is configured to cause an actuation of at least one switch positioned on the printed circuit board. 
 
     
     
       16. The method of  claim 15 , wherein the printed circuit board comprises a button controller printed circuit board having metal traces covered with polymer film. 
     
     
       17. The accessory button controller in  claim 4 , wherein the metal clip comprises a portion that is configured to gather electrostatic charge that is discharged through the metal clip to the trace of the printed circuit board. 
     
     
       18. The accessory button controller in  claim 5 , wherein the metal clip comprises:
 a protrusion that receives electrostatic charge through the gap; and 
 a spring portion that is shorted to the trace. 
 
     
     
       19. The accessory of  claim 10 , wherein the metal structure discharges the electrostatic charge through the spring to the trace on the printed circuit. 
     
     
       20. The method of  claim 16 , wherein:
 placing the printed circuit board in the molding tool comprises placing the button controller printed circuit board in the molding tool; and 
 injection molding the plastic comprises injection molding the plastic without peeling off the polymer film.

Description:
BACKGROUND 
     This relates to electronic devices, and more particularly, to accessories for electronic devices. 
     Electronic devices such as computers, media players, and cellular telephones typically contain user interface components that allow these devices to be controlled by a user. It is sometimes desirable to add accessories to electronic devices. For example, a user may desire to plug a headset or adapter accessory into an electronic device to allow the user to listen to audio. 
     Headsets are sometimes provided with buttons and microphones. A headset microphone may be used to pick up a user&#39;s voice during a telephone call. Buttons may be used to control media file playback, to make volume level adjustments during a telephone call, and to issue other commands for the electronic device. Buttons and a microphone may be mounted within a button controller assembly. Microphone signals and button signals may be routed from the button controller assembly to an electronic device using wires in the headset. 
     The designers of accessories and other electronic equipment are challenged with designing parts that are not overly complex or costly and that exhibit satisfactory reliability and performance 
     It would therefore be desirable to provide improved electronic device accessories such as accessories with button controller assemblies. 
     SUMMARY 
     An accessory may be provided with ear buds, a cable, and a button controller coupled to the cable. 
     The ear buds may have a hollow neck portion. A wire in the ear buds may be knotted to prevent removal of the wire from the hollow neck portion. To prevent the knot from over-tightening, a bead may be placed over the wire in the knot. 
     The button controller may have a printed circuit that contains conductive traces, a microphone, switches, and other circuitry. Plastic structures for the button controller may be formed by injection molding within an injection molding tool. The injection molding tool may have shutoff structures. Each shutoff structure may have a protrusion that forms a recess. The recess may accommodate traces on the printed circuit board by allowing the shutoff structure to hold the printed circuit board during injection molding operations without crushing traces that are overlapped by the recess. 
     Plastic structures may be molded around a printed circuit and wiring. The wiring may have a plastic jacket. The molded plastic structures may bond with the plastic jacket to retain the wiring. The molded plastic structures may be molded directly to the printed circuit board. Protrusions on the molded plastic structures may mate with openings in a metal clip. Housing structures may be mounted to the metal clip. 
     The metal clip may be provided with a spring that shorts the metal clip to a trace on the printed circuit. The metal clip may also have a portion such as a protrusion that receives electrostatic charge during electrostatic discharge events and that discharges the charge through the spring to the trace on the printed circuit. 
     The microphone hole on the printed circuit may be covered with a conductive mesh that is attached to the printed circuit with conductive adhesive to provide additional electrostatic discharge protection. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of a system including an electronic device and associated accessory in accordance with an embodiment of the present invention. 
         FIG. 2  is a wiring diagram for an illustrative accessory such as a pair of headphones with a button controller that has switches and a microphone in accordance with an embodiment of the present invention. 
         FIG. 3  is perspective view of an illustrative button controller in accordance with an embodiment of the present invention. 
         FIG. 4  is an exploded perspective view of the button controller of  FIG. 3  in accordance with an embodiment of the present invention. 
         FIG. 5  is an exploded perspective view of button controller assembly components such as a button cover member and clip structure in accordance with an embodiment of the present invention. 
         FIG. 6  is a cross-sectional end view of an illustrative button controller in accordance with an embodiment of the present invention. 
         FIG. 7  is a cross-sectional end view of a substrate with traces in accordance with an embodiment of the present invention. 
         FIG. 8  is a cross-sectional end view of the substrate of  FIG. 7  following application of a flexible layer of polymer in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross-sectional end view of the substrate and polymer layer of  FIG. 8  after installation in an injection molding tool in accordance with an embodiment of the present invention. 
         FIG. 10  is a cross-sectional end view of the substrate of  FIG. 8  following injection molding of a plastic structure using the injection molding tool of  FIG. 9  in accordance with an embodiment of the present invention. 
         FIG. 11  is a perspective view of a substrate with an injection molding tool shut-off structure in accordance with an embodiment of the present invention. 
         FIG. 12  is a cross-sectional end view of the substrate of  FIG. 8  following injection molding of a plastic structure in accordance with an embodiment of the present invention. 
         FIG. 13  is a perspective view of a shut-off structure in an injection molding tool that has a recess that is configured to bridge overlapped traces on a substrate during molding operations in accordance with an embodiment of the present invention. 
         FIG. 14  is top view of a portion of a button controller structure showing shut-off regions that may be contacted by shut-off structures in an injection molding tool during injection molding operations in accordance with an embodiment of the present invention. 
         FIG. 15  is a perspective view of a portion of a button controller showing how a cable may be routed through an overmolded structure to help retain the cable within the button controller in accordance with an embodiment of the present invention. 
         FIG. 16  is a perspective view of a portion of a button controller showing how engagement features such as snaps may be molded into an overmold structure in accordance with an embodiment of the present invention. 
         FIG. 17  is a perspective view of an earbud in accordance with an embodiment of the present invention. 
         FIG. 18  is a perspective view of a bead structure that may be used in a cable knot to help retain a cable in an earbud of the type shown in  FIG. 17  in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic components such as microphones and buttons may be used in a wide range of applications. For example, microphones and buttons may be used to form a button controller for a headset or other accessory. Button structures and microphone structures may, in general, be used in any suitable system. Button controller assemblies that are suitable for use in accessories such as electronic device headsets are sometimes described herein as an example. 
     An illustrative system in which an accessory may be used with an electronic device is shown in  FIG. 1 . As shown in  FIG. 1 , electronic device  10  may be coupled to an accessory such as headset  12  by plugging plug  16  of accessory  12  into jack  14  of electronic device  10 . 
     Electronic device  10  may be a computer such as a desktop computer, tablet computer, or laptop computer. Device  10  may also be a handheld electronic device such as a cellular telephone or media player, a tablet device, other portable electronic devices, or any other electronic equipment. Headset  12  may have speakers  18  and controller  22 . Controller  22  may have buttons and may therefore sometimes be referred to as a button controller or button controller assembly. Button controller  22  and speakers  18  may be coupled to device  10  using cable  20 . Cable  20  may contain multiple wires. Button controller  22  may, if desired, include a microphone. The microphone may be used by a user of device  10  and headset  12  during a telephone call (e.g., to pick up the user&#39;s voice). 
     Button controller  22  may include buttons such as buttons  24 ,  26 , and  28 . There may, in general, be any suitable number of buttons in button controller  22  (e.g., one or more buttons, two or more buttons, three or more buttons, etc.). With one suitable arrangement, which is sometimes described herein as an example, button controller  22  may include three buttons. These buttons may be used to issue commands for device  10 . Examples of commands that may be issued for device  10  using the buttons of button controller assembly  22  include stop, forward, and reverse commands, volume up and down commands, telephone call control commands, etc. 
     A wiring diagram of an illustrative accessory such as headset  12  of  FIG. 1  is shown in  FIG. 2 . As shown in  FIG. 2 , headset  12  may have wires in cables  20  that interconnect left speaker  18  (LS), right speaker  18  (RS), plug  16 , and button controller  22 . Two ground lines (G and G 2 ) may be coupled to a ground terminal in plug  16 . A microphone line (M), left speaker line (L), and right speaker line (R) may be coupled to a microphone terminal, left speaker terminal, and right speaker terminal in plug  16 , respectively. Ground line G 2  and microphone line M may terminate on terminals in button controller  22 . Ground line G and speaker line L may pass through the housing of button controller  22  to couple to speaker terminals in left speaker LS. Right speaker RS may have terminals that are coupled between right speaker line R and ground speaker line G. 
       FIG. 3  is a perspective view of an illustrative button controller for an accessory. As shown in  FIG. 3 , button controller  22  may have a housing formed from lower housing member  30  and upper housing member  32 . Button labels for buttons such as buttons  28 ,  26 , and  24  may be formed from portions of member  32  that overlap corresponding switches in the interior of button controller  22 . During operation, upper housing member  32  and/or lower housing member  30  may flex where squeezed by a user. When flexed in this way, the flexing housing member structures in button controller  22  may press inwardly against a corresponding switch on a printed circuit board in the interior of button controller  22 . As an example, a printed circuit in controller  22  may be provided with an array of three switches. When a user squeezes button controller  22  between the user&#39;s finger to actuate a particular one of buttons  24 ,  26 , and  28 , a portion of member  30  that overlaps a corresponding switch may flex and actuate that switch. Other types of switch actuation schemes may be used in button controller  22 , if desired. The use of flexing housing members to operate corresponding internal switches is merely illustrative. 
     Strain relief structures such as strain relief structures  34  may help guide cables  20  into and out of button controller assembly  22 . 
       FIG. 4  is an exploded rear perspective view of button controller  22 . As shown in  FIG. 4 , controller  22  may include rear housing member  30  (e.g., a flexible plastic structure). Rear housing member  30  may have an opening such as opening  62  that may or may not permit sound to pass from the exterior of button controller  22  to a microphone in the interior of button controller  22 . Opening  62  may be covered with a mesh such as a metal mesh  42  or other structure that allows sound to pass. 
     In the interior of button controller  22 , printed circuit board microphone hole  47  in may be covered with a mesh such as mesh  44  or other material that may or may not allow sound to pass. Mesh  44  may be formed form a conductive material such as metal or metal-coated plastic and may be attached to traces such as ground traces  46  on printed circuit board  56  and/or other conductive structures such as using conductive adhesive  64 . The use of conductive adhesive  64  to attach mesh  44  to ground traces on printed circuit board  56  may help to discharge static charge, thereby helping to provide button controller  22  with immunity to electrostatic discharge (ESD) events. 
     Plastic structures  38  may be overmolded over printed circuit  56 . As shown in  FIG. 4 , plastic structures  38  have engagement features such as snaps  60  that are configured to mate with corresponding engagement features in clip member  36 . Clip member  36  may, for example, be formed from a sheet of patterned metal having prongs  50  with holes  52  that are configured to mate with snaps  60 . Clip member  36  may be attached to housing member  30  using adhesive, heat stakes, or other attachment mechanisms. Because structures  38  may be overmolded directly to printed circuit  56  and because snaps  60  may be formed as integral parts of structures  38 , mechanical tolerances associated with attaching clip  36  and housing member  30  relative to printed circuit  56  may be well controlled. Switches  40  may be accurately located relative to printed circuit  56  by soldering switches  40  to printed circuit  56 , so the arrangement of  FIG. 4  may be used to accurately locate housing member  30  relative to switches  40  to enhance performance. 
     Printed circuit board  56  may be supported using overmolded plastic structures  38 . Components may be mounted on printed circuit board  56  such as a microphone, discrete electrical components, integrated circuits for audio and communications functions, and other circuitry. Switches  40  may be soldered to printed circuit board  56  in alignment with printed labels for buttons in button regions  28 ,  26 , and  24  on upper housing member  32 . Traces on printed circuit board  56  and other circuitry may be used to interconnect switches  40  with wires in cable  20 . Housing structures such as housings  30  and  32  may be formed from materials such as plastic. Heat stakes such as heat stakes  58  on housing member  32  may be used to attach housing member  32  to plastic structure  38 . Heat stakes on housing member  30  may engage with heat stake openings  49  on clip  36 . 
     When a user actuates a desired button by squeezing members  30  and  32  inwardly towards each other, a corresponding portion of housing member  30  may deflect and press against a respective one of switches  40 . If desired, button member  32  may be configured to deflect to compress switches such as switches  40  (e.g., in addition to or as an alternative to a configuration in which housing member  30  deflects). The configuration of  FIG. 4  in which deflection of flexible housing member  30  is used to actuate switches  40  is merely illustrative. Switch  40  may be tact switches (e.g., switches based on dome switch members mounted in individual plastic switch housings) or may be switches of other suitable types. 
     Ground traces such as grounding pad structures  46  may be formed on printed circuit  56 . Metal clip  36  may have features such as protruding tab structure  54  that serve to gather electrostatic charge from a user&#39;s fingers during an electrostatic discharge event. To provide a grounding path that helps discharge the electrostatic charge, clip  36  may have a portion such as spring portion  48  that is configured to contact grounding pad structures  46  or other conductive traces on printed circuit  56 . 
     Plastic structures  38  may be formed by injection molding plastic into a mold structure on printed circuit  56 . This type of injection molding process may sometimes be referred to as overmolding and plastic structures  38  may sometimes be referred to as overmold structures or an overmold. As shown in  FIG. 4 , strain relief structures such as strain relief structures  34  may be overmolded on structures  38 . Strain relief structures  34  may, as an example, be formed from a soft elastomeric plastic material that is configured to flex as cable  20  flexes. Strain relief structures  34  may enclose and surround cable  20  and the wires within cable  20 . 
       FIG. 5  is an exploded perspective view of lower housing member  30 , microphone mesh  42 , and clip  36 . 
       FIG. 6  is a cross-sectional end view of button controller  22  of  FIG. 3  taken in the vicinity of protruding tab  54 . As shown in  FIG. 6 , the presence of protruding tab  54  or other suitable portions of clip  36  that are located in the vicinity of gap  66  between upper housing  32  and lower housing  30  may help to gather static charge from external objects such as finger  68 . Clip  36  may be shorted to ground using ground traces  46 , thereby discharging charge buildup during an electrostatic discharge event. 
     Injection molded plastic structure  38  ( FIG. 4 ) may be injection molded over electronic components and conductive traces on a printed circuit board such as printed circuit  56 . Printed circuit  56  may be a rigid printed circuit board such as a fiberglass-filled epoxy printed circuit board (e.g., an FR4 board), may be a flexible printed circuit (“flex circuit”) such as a flexible sheet of polyimide or other flexible polymer layer, may be an injection molded plastic substrate or other dielectric support structure, or may be formed from two or more of these structures. 
     Initially, as shown in  FIG. 7 , a printed circuit substrate such as substrate  70  may be covered with patterned metal traces  72  to form printed circuit structures  56 . Substrate  70  may be, for example, a rigid printed circuit board substrate or a flex circuit substrate. Traces  72  may be formed using screen printing, pad printing, ink-jet printing, physical vapor deposition, chemical vapor deposition, photolithography, or other suitable fabrication techniques. Traces  72  may be formed from metals such as aluminum, copper, gold, etc. 
     As shown in  FIG. 8 , traces  72  in printed circuit  56  may be covered with a thin protective polymer layer such as polymer layer  74 . During subsequent injection molding operations, printed circuit  56  of  FIG. 8  may be held in place by support structures within an injection molding tool cavity. Some of the injection molding support structures may be used to block the flow of injection molded plastic into particular portions of printed circuit  56  and may therefore sometimes be referred to as shutoff structures. 
     A portion of an illustrative injection molding tool in which printed circuit structures  56  of  FIG. 8  have been mounted is shown in  FIG. 9 . Injection molding tool  76  may include mold structures such as mold structures  78  and may include mold structures such as shutoff structures  80 . As shown in  FIG. 9 , some shutoff structures  80  may have a protruding portion such as protrusion  82 . Protrusion  82  may create a recess such as recess  84 . When mounted on printed circuit  56  as shown in  FIG. 9 , protrusion  82  may be used to bear against the upper surface of printed circuit  56  while recess  84  accommodates traces  72  by overlapping traces  72  without exerting excessive pressure on traces  72 . By using shutoff structures such as shutoff structure  80  of  FIG. 9  that have a protrusion such as protrusion  82  and a corresponding recess such as recess  84 , injection molding support structures such as structures  78  and  80  may hold printed circuit  56  firmly without crushing surface features such as metal traces  72 . While printed circuit  56  is held securely in place in this way, plastic may be injected into mold cavities such as cavity  86  without causing polymer layer  74  to peel off of substrate  70  due to injected plastic between substrate  70  and layer  74 . 
     A cross-sectional end view of printed circuit structures  56  following formation of a plastic structure such as structure  38  following injection molding of plastic into cavity  86  of  FIG. 9  while using shutoff structure  80  and mold structures  78  is shown in  FIG. 10 .  FIG. 11  is a perspective view of printed circuit  56  showing how shutoff structures such as shutoff structure  80  of  FIG. 9  may be located a particular points along the length of an elongated printed circuit such as printed circuit  56 . Only one shutoff structure  80  is shown in the example of  FIG. 11 , but in general, two or more, three or more, five or more, or ten or more shutoff structures may be used in holding printed circuit  56  during molding operations. 
     The cross-sectional end view of  FIG. 10  was taken along line  88  of  FIG. 11  and viewed in direction  90  of  FIG. 11  (following removal of shutoff structure  80  from printed circuit  56 ). In regions of printed circuit  56  without shutoff structures, injected plastic may cover more of printed circuit  56 . As an example, plastic structures such as plastic structures  38  of  FIG. 12  may be formed by injection molding plastic into molding tool  78  in portions of printed circuit without a shutoff structure. The cross-sectional end view of  FIG. 12  has been taken along line  92  of  FIG. 11  and viewed in direction  92  and shows how printed circuit  56  of  FIG. 11  may appear following molding operations. 
     If desired, shutoff structures may be provided with multiple protrusions. As an example, illustrative shutoff structure  80  of  FIG. 13  has been configured to have two protrusions  82 , so that recess  84  forms a notch that bridges traces  72 . 
     A top view of plastic structures  38  showing regions where shutoff structures  80  may contact printed circuit  56  during injection molding operations is shown in  FIG. 14 . As shown in  FIG. 14 , a shutoff structure placed along the upper edge of printed circuit  56  may contact printed circuit  56  at locations such as locations  80 - 1  and  80 - 2 , whereas a shutoff structure placed along an opposing lower edge of printed circuit  56  may contact printed circuit  56  at location  80 - 3 . The upper shutoff structure (in this example) may have protrusions that form a recess such as recess  84  that bridges printed circuit traces such as trace  72 , thereby preventing traces  72  from being crushed during molding operations. 
       FIG. 15  is a rear perspective view of internal structures that may be formed in illustrative button controller  22 . As shown in  FIG. 15 , plastic structures  38  may be molded to form portions  38 ′ that surround cable  20 . Cable  20  may contain wiring surrounded by a plastic jacket. Following injection molding of injection molded plastic material  38 , portions  38 ′ of plastic structures  38  may form a bond with the plastic coating (jacket) material on cable  20 . The bond between injection molded plastic support structures  38  and the plastic jacket of cable  20  may form a retention mechanism for holding cable  20  in place within button controller  22 . 
     Recesses, protrusions, and other interlocking shapes may be formed in end regions  100  of structures  38 . Strain relief structures  34  may then be overmolded on top of structures  38 . Once overmolded, strain relief structures  34  may engage with the interlocking shapes of structures  38  and may surround cable  20 , thereby helping to retain cable  20  to button controller  22 . 
     Wires  102  of cable  20  such as wires M and G 2  of  FIG. 2  may be soldered to pads  104  on printed circuit  56 . Wires  106  such as wires L and G of  FIG. 2  may be routed along the length of printed circuit  56 . Adhesive such as glue  108  may help hold wires  106  in place along printed circuit  56 . Illustrative locations where molding tool structures (shutoff structures) may contact printed circuit board  56  during molding are shown by areas  110  in  FIG. 15 . 
       FIG. 16  is a front perspective view of internal structures that may be formed in illustrative button controller  22 . As shown in  FIG. 16 , structures  38  may have openings  110  corresponding to the locations of shutoff structures  80  during injection molding operations. Snaps  60  may be used to engage openings  52  in clip tabs  50  ( FIG. 4 ). Snaps  60  may be formed as integral portions of structures  38 . By overmolding structures  38  over printed circuit  56 , tight tolerances on the position of snaps  60  relative to switches  40  (soldered to printed circuit  56 ) may be achieved. 
       FIG. 17  is a diagram of an illustrative earbud. As shown in  FIG. 17 , earbud  18  may have a portion such as speaker enclosure structure  120  that contains a speaker driver for emitting sound when earbud  18  is located in a user&#39;s ear. Earbud  18  may also have a neck portion such as neck structure  124  that couples speaker enclosure structure  120  to cable  20 . Neck structure  124  may be hollow to accommodate wires in cable  20 . To prevent cable dislodgement during use of accessory  12 , the wires of cable  20  such as wires  126  of  FIG. 18  (e.g., a positive signal line and a ground signal line encased in a common jacket) may be provided with a knot such as knot  128 . Knot  128  may be placed in region  122  of neck structure  124  ( FIG. 17 ) to prevent cable  20  from being pulled out of earbud  18  during use. 
     To prevent knot  128  from becoming compressed during use of accessory  12 , a knot retention structure such as bead  130  may be threaded onto wires  126  prior to knot formation. Bead  130  may have the shape of a ring with a circular opening. Wires  126  may be routed through the circular opening before tying wires  126  to form knot  128 . In the absence of ring  130 , tension on wires  126  during use has the potential to compress knot  128 , leading to a possibility that knot  128  will become too small to be securely retained within the hollow core of neck structure  124 . In the presence of ring  130 , knot  128  is tied to ring  130  and will remain sufficiently large to prevent cable  20  and wire  126  from being pulled through neck structure  124 . 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20120521
Publication Date: 20170711
Grant Date: 20170711
Priority Date: 20120521
Inventors: STANLEY CRAIG M.
STIEHL KURT R.
WEBB MICHAEL J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2203/1327", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0214", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0228", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/10053", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2239/008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1327", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0214", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0228", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2239/008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2201/10053", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K2203/1327", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0214", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2239/008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0228", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K2201/10053", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 48537025