PATENT DOCUMENT

Publication Number: US-7708604-B2
Application Number: US-11337708-A
Country: US
Kind Code: B2

Title: Mechanism for constraining the movement of an audio jack

Abstract:
A constraint mechanism for receiving an audio plug in an electronic device is provided. The constraint mechanism may include a conductive tube operative to receive the audio plug. In addition, the constraint mechanism may include several features operative to engage corresponding features of the electronic device to prevent the constraint mechanism from moving in any direction (e.g., which could cause damage in the electronic device if the audio jack was forced to move by an impact on the audio plug). For example, the constraint mechanism may include a center wall to prevent yawing, and rear tabs to prevent pitching. As another example, the constraint mechanism may include a side plate operative to be coupled to the electronic device to prevent rolling. In some embodiments, the constraint mechanism may include an asymmetrical tube entrance for ensuring the proper alignment of the constraint mechanism with an electronic device opening. The tube may include a conductive dimple extending through an aperture of the tube, where the aperture is substantially the same size and shape as the conductive dimple.

Claims:
1. A constraint mechanism for receiving an audio plug in an electronic device, comprising:
 a body comprising a tube operative to receive the audio plug; 
 a center wall extending from a first surface of the body, the center wall oriented in the same direction as the tube; and 
 a rear tab coupled to the center wall and offset from a second surface of the body, a top surface of the rear tab oriented substantially parallel to the second surface and defining at least one slot between the rear tab and the second surface. 
 
     
     
       2. The constraint mechanism of  claim 1 , wherein the first and second surfaces are the same. 
     
     
       3. The constraint mechanism of  claim 1 , wherein the rear tab further comprises a rear wall extending from the second surface, the rear wall substantially orthogonal to the center wall. 
     
     
       4. The constraint mechanism of  claim 1 , wherein the tube comprises an opening for receiving the plug, wherein a surface passing through the opening of the tube comprises a curved surface permitting only one proper orientation of the tube when the constraint mechanism is inserted in the electronic device. 
     
     
       5. The constraint mechanism of  claim 1 , wherein the length of the center wall is substantially equal to half of the length of the body. 
     
     
       6. The constraint mechanism of  claim 1 , wherein the at least one slot between the rear tab and the second surface is operative to receive at least one prong of the electronic device. 
     
     
       7. The constraint mechanism of  claim 1 , further comprising:
 a plate extending from a third surface of the body and operative to be coupled to the electronic device. 
 
     
     
       8. The constraint mechanism of  claim 7 , wherein the third surface of the body is substantially perpendicular to the first and second surfaces of the body. 
     
     
       9. The constraint mechanism of  claim 7 , wherein the plate comprises a hole through which a mechanical fastener may pass to engage the electronic device. 
     
     
       10. The constraint mechanism of  claim 1 , wherein the tube is operative to receive at least one conductive region an audio plug. 
     
     
       11. The constraint mechanism of  claim 10 , wherein the tube comprises at least one conductive portion for providing audio signals between the electronic device to an audio plug placed in the tube. 
     
     
       12. The constraint mechanism of  claim 11 , wherein:
 an inner surface of the tube is non-conductive; and 
 the at least one conductive portion comprises a conductive dimple extending through an aperture in the inner surface of the tube. 
 
     
     
       13. The constraint mechanism of  claim 12 , wherein the aperture is substantially the same shape and size as the dimple, such that substantially no free space exists between a periphery of the aperture and the dimple. 
     
     
       14. An electronic device for providing audio to a user, comprising:
 a constraint mechanism comprising a tube operative to receive an audio plug; 
 a slot operative to receive a center wall extending from a first surface of the constraint mechanism and a tab connected to the center wall and offset from the first surface, wherein the slot is delimited by at least one prong operative to extend between the tab and the first surface; 
 a threaded insert operative to be aligned with a hole in a plate extending from a second surface of the constraint mechanism; and 
 a mechanical fastener operative to pass through the hole in the plate and engage the insert. 
 
     
     
       15. The electronic device of  claim 14 , wherein the outer surface of the tab is substantially parallel to the top surface of the center wall. 
     
     
       16. The electronic device of  claim 14 , wherein the center wall is substantially in contact with an edge of the slot. 
     
     
       17. The electronic device of  claim 14 , wherein the slot comprises two prongs, the prongs delimiting opposite edges of the slot, wherein the tab is operative to engage each of the two prongs. 
     
     
       18. The electronic device of  claim 14 , wherein the tube further comprises at least one asymmetrical feature extending from a portion of the periphery of the opening of the tube. 
     
     
       19. The electronic device of  claim 18 , wherein the asymmetrical feature comprises an extension selectively increasing a wall thickness of the tube. 
     
     
       20. The electronic device of  claim 18 , further comprising a device opening through which the audio plug may pass, the device opening adjacent to at least one asymmetrical feature matching the at least one asymmetrical feature of the tube opening. 
     
     
       21. The electronic device of  claim 20 , wherein the threaded insert is aligned with the hole in the plate when the tube opening is positioned adjacent to the device opening. 
     
     
       22. The electronic device of  claim 14 , wherein:
 an inner surface of the tube is non-conductive; and 
 the constraint mechanism comprises at least one conductive dimple extending through an aperture in the tube. 
 
     
     
       23. The electronic device of  claim 22 , wherein the aperture is substantially the same shape and size as the dimple, such that substantially no free space exists between a periphery of the aperture and the dimple. 
     
     
       24. A method for constraining an audio plug in an electronic device, comprising:
 aligning a tube of a constraining mechanism with an opening in the electronic device; 
 sliding a center wall extending from a surface of the constraining mechanism in a slot of the electronic device, the slot comprising an open end and a closed end; 
 engaging a tab connected to the center wall and offset from the surface of the constraining mechanism with a prong adjacent to the open end of the slot; and 
 placing a plate extending from the constraining mechanism over a threaded insert of the electronic device. 
 
     
     
       25. The method of  claim 24 , further comprising inserting a mechanical fastener through a hole of the plate and into the threaded insert. 
     
     
       26. The method of  claim 24 , wherein aligning further comprises aligning an asymmetrical feature of the tube with a corresponding asymmetrical feature of the opening. 
     
     
       27. The method of  claim 24 , wherein engaging further comprises engaging the tab with at least one prong defining a sidewall of the slot, wherein the tab is restrained between the at least one prong and a surface of the electronic device.

Description:
BACKGROUND OF THE INVENTION 
     This invention is directed to a system for constraining an audio plug in an electronic device. 
     Media players, in particular portable media players, may provide audio to the user using a number of different approaches. For example, the media players may include speakers. As another example, the media players may include communications circuitry for wirelessly providing the audio to an audio output device (e.g., speakers or a headset). As yet another example, the media players may include a connector for receiving a wired audio output device (e.g., wired earbuds or earphones connected to the device using an audio jack). The connector may include several conductive portions (e.g., conductive dimples) extending through the surface of the conductor. 
     Although wired audio output devices are commonly used, they may be a source of fragility and damage for the audio connector. In particular, because the wired audio output device may include a plug having a first portion extending into the electronic device (e.g., inserted into the audio connector) and a second portion extending out of the electronic device (e.g., extending past the edge of the electronic device), brusque or abrupt movements of the second portion may cause the first portion to move also, thus causing the audio connector to move and perhaps even fail (e.g., by forcing the audio connector to bend inside the electronic device). In addition, if the plug is inserted in the audio connector at an extreme enough angle, the end of the plug may enter a cavity adjacent the conductive portion of the connector and damage the conductive portion. 
     SUMMARY OF THE INVENTION 
     A system for constraining an audio plug within an electronic device is provided. In addition, an audio jack with reduced size contacts is provided. 
     The audio connector may be incorporated in a constraint mechanism, which may include a body that surrounds a tube operative to receive an audio plug (e.g., an audio jack). The end of the tube may include one or more asymmetrical features (e.g., a straight portion or a curved portion) which may correspond to features of an aperture in the electronic device. By providing asymmetrical features, the constraint mechanism may have only one suitable orientation for insertion in the electronic device, thus ensuring other constraining features of the constraint mechanism are properly installed. 
     The constraint mechanism may include one or more features for preventing a plug inserted in the tube from causing the audio connector to move (e.g., from pitching, yawing, or rolling the audio connector). For example, to prevent yawing, the constraint mechanism may include a center wall extending orthogonally from one surface of the electronic device. The wall may be oriented in the same direction as the tube, and may extend at least half as long as the constraint mechanism body. The electronic device may include a corresponding slot operative to receive the center wall such that substantially all of both sides of the wall abut the edges of the slot. This may prevent the wall, and thus the constraint mechanism, from rotating within the slot (e.g., yawing). 
     To prevent pitching, the constraint mechanism may include a tab extending from a surface of the body, such that a portion of the tab is offset but parallel to the surface (e.g., creating a void between the constraint mechanism surface and the tab that an electronic device component may engage). If the tab extends from the same surface of the body as the center wall, one or more prongs or used to define the edges of the slot may be operative to engage the tab when the constraint mechanism is inserted in the electronic device. Because the tab is parallel but offset from the surface of the body, attempts to pitch the constraint mechanism will be prevented by the contact between the prongs of the electronic device and the lower surface of the tab and the surface of the body. 
     To prevent rolling, the electronic device may include a plate extending from a different surface of the body (e.g., a surface adjacent the surface of the center wall and tab). The plate may extend from a plane that includes the centerline of the tube, such that the resistance to the plate can prevent the tube from rolling. The plate may include a hole operative to be aligned with an insert (e.g., a threaded boss insert) of the electronic device when the constraint mechanism is properly positioned in the electronic device. In some embodiments, a mechanical fastener (e.g., a screw or bolt) may be passed through the hole to engage the insert. Then, the plate may abut either the insert or the mechanical fastener when the audio plug attempts to cause the constraint mechanism to roll, thus preventing the audio connector from rolling (e.g., and damaging electrical couplings between the tube and other electronic device components). 
     The audio connector may include several conductive portions within the tube. For example, the non-conductive tube may include several holes through which conductive dimples operative to contact conductive portions of an audio plug may extend. To prevent the tip of the audio plug from entering one of the several holes, and to prevent foreign particles from passing through one of the several holes and damaging components located behind the tube wall, the size of the holes may match the size of the conductive dimples. In addition, the shape of the holes may be match the shape of the dimples, thus eliminating excess space through which foreign particles may pass. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is a perspective view of an illustrative constraint mechanism for use in an electronic device in accordance with one embodiment of the invention; 
         FIG. 2  is a top view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention; 
         FIG. 3  is a front view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention; 
         FIG. 4  is a side view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention; 
         FIGS. 5 ,  6  and  7  are consecutive perspective views of a constraint mechanism as it is placed in the electronic device in accordance with one embodiment of the invention; 
         FIGS. 8 ,  9  and  10  are different consecutive perspective views of the constraint mechanism of  FIGS. 5-7  as it is placed in the electronic device in accordance with one embodiment of the invention; 
         FIG. 11  is a cross-sectional view of an audio connector in accordance with one embodiment of the invention; and 
         FIG. 12  is a cross-sectional view of another audio connector in accordance with one embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1  is a perspective view of an illustrative constraint mechanism for use in an electronic device in accordance with one embodiment of the invention.  FIG. 2  is a top view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention.  FIG. 3  is a front view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention.  FIG. 4  is a side view of the illustrative constraint mechanism of  FIG. 1  in accordance with one embodiment of the invention. An audio connector may be embedded in constraint mechanism  100 , which may include body  108  having tube  110  for receiving an audio plug (e.g., body  108  may be part of an audio jack for receiving an audio plug). Body  108  may have any suitable shape. For example, body  108  may in part follow the shape of tube  110  (e.g., to minimize the size of body  108 ). As another example, body  108  may be shaped substantially box-like. As still another example, body  108  may be shaped to support one or more attachment features for coupling body  108  to the electronic device (e.g., body  108  may include thicker portions near the attachment features of constraint mechanism  100 ). 
     In some embodiments, body  108  may include one or more electrically conductive portions for coupling electronic device circuitry (e.g. attached to the outer surface of body  108 ) to electrically conductive portions of tube  110 . For example, as discussed in more detail below, tube  110  may include one or more conductive portions (e.g., conductive dimples) extending through the surface of tube  110 . Tube  110  may include any suitable number of conductive portions (e.g., 5 portions: left channel, right channel, ground, microphone, and detect). The electrically conductive portions of body  108  may allow the electronic device to receive inputs from an audio output device coupled to the audio plug (e.g., inputs from an in-line switch or switches of an electronic device) and provide the inputs to control circuitry or processors of the electronic device. Similarly, the electrically conductive portions of body  108  may allow the electronic device provide audio signals to the audio output device coupled to the audio plug. 
     To enable constraint mechanism  100  to resist movements of the audio plug or impacts on the audio plug that are transferred to the tube  110 , constraint mechanism  100  may include several restraining features for preventing constraint mechanism  100  from yawing (e.g., in the direction shown by arrows  112 ), pitching (e.g., in the direction shown by arrows  113 ), or rolling (e.g., in the direction shown by arrows  114 ). 
     To resist yawing, body  108  may include center wall  120  extending from top surface  109  of body  108 . Center wall  120  may be oriented in any suitable direction, including for example in the direction of the centerline of tube  110  (e.g., center wall  120  runs along the length of tube  110 ). In some embodiments, center wall  120  may further be aligned with the centerline of tube  110 , or may instead be offset relative the centerline. Center wall  120  may extend from top surface  109  at any angle, including for example orthogonally (e.g., the plane of center wall  120  includes the centerline of tube  110 ). Leading edge  121  of center wall  120  may be shaped in any suitable manner, including for example have a rounded shape or an angled shape to help direct center wall  120  into a corresponding slot of the electronic device. Center wall  120  may have any suitable length, including for example more than half the length of top surface  109  or of body  108 , which may eliminate single contact points around which center wall  120  could rotate. Thus, when inserted in the electronic device, sides  122  and  123  of center wall  120  may abut the sides of the electronic device components defining the slot, thus preventing center wall  120  from rotating (and preventing constraint mechanism  100  from yawing). 
     To resist pitching, body  108  may include rear wall  130  extending from a surface of body  108  along back surface  111 . In the example shown in  FIGS. 1-4 , rear wall  130  extends in the same direction as center wall  120  (e.g., orthogonal to top surface  109 ), though it will be understood that rear wall  130  (and tab  132 ) may extend from any suitable surface of body  108 . Rear wall  130  may abut center wall  120  substantially orthogonally (e.g., forming a T-shape). A protrusion  131  may extend orthogonally from rear wall  130  to form tab  132 , such that a portion of tab  132  (e.g., protrusion  131 ) and top surface  109  are substantially parallel. Tab  132  may extend over only a small portion of top surface  109 , for example a section adjacent rear wall  130 , and may include more holes  133  (e.g., leaving only the frame or boundary of tab  132 ). Slots  134  and  135  may be small one or created between top surface  109  and tab  132 , and bounded by rear wall  130  and sides  122  and  123  of center wall  120 . When body  108  is inserted in the electronic device, prongs of the electronic device may extend into slots  134  and  135  such that the prongs are substantially in contact with both top surface  109  and the bottom surface of protrusion  311 . Then, if constraint mechanism  100  is pitched (e.g., along arrows  113 ), the prongs may abut the upper and lower walls of slots  134  and  135 , thus preventing constraint mechanism  100  from pitching (e.g., relative the opening of tube  110 , which is the point around which constraint mechanism  108  would pivot in response to a force on the audio plug). 
     To resist rolling, constraint mechanism  100  may include plate  140  extending orthogonally from the side of body  108  (e.g., a side other than top surface  109 ). Plate  140  may be oriented along the axis of the tube (e.g., and not in a plane of or substantially of the tube opening). Plate  140  may include hole  142  for receiving a mechanical fastener (e.g., a screw or bolt). When constraint mechanism  100  is inserted in the electronic device, plate  140  may rest on a corresponding feature of the device, and be coupled to the feature using the mechanical fastener (e.g., passing a screw through hole  142  and coupling it to the feature of the electronic device), such that attempts to roll body  108  will cause plate  140  to abut against the corresponding feature against the mechanical fastener, and prevent body  108  from rolling. In some embodiments, plate  140  or the constraining elements of plate  140  may be incorporated in center wall  120 , or any other suitable plate or wall protruding from the surface of body  108 . 
       FIGS. 5 ,  6  and  7  are consecutive perspective views of a constraint mechanism as it is placed in the electronic device in accordance with one embodiment of the invention.  FIGS. 8 ,  9  and  10  are different consecutive perspective views of the constraint mechanism of  FIGS. 5-7  as it is placed in the electronic device in accordance with one embodiment of the invention. Constraint mechanism  500  may include some or all of the features of constraint mechanism  100  ( FIG. 1 ). Constraint mechanism  500  may be inserted in electronic device  550  (e.g., in a housing of electronic device  550 ), which may include several features for receiving and constraining constraint mechanism  500 . For example, electronic device  550  may include opening  552  for receiving tip  515  of tube  510  (e.g., adjacent the entrance of the tube). The portion of opening  552  that is exposed (e.g., visible to a user) may include an aesthetically pleasing hole trim (e.g., a cosmetic finish adjacent opening  552 ). To ensure that constraint mechanism  500  is properly aligned in electronic device  550 , tip  515  may include one or more alignment features that limit the number of possible orientations of constraint mechanism  550  (e.g., asymmetrical features). For example, tip  515  may include straight portions  516  and  517  (connected at an angle), and round portion  518 . Opening  552  may include corresponding straight portions  556  and  557 , and round portion  558  for receiving tip  515 . Straight portion  516  and  517 , and round portion  518  may be distributed along tip  515  in any suitable manner to ensure that only one orientation of constraint mechanism  500  allows constraint mechanism  500  to extend into electronic device  550 . 
     Electronic device  550  may include prongs  560  and  562  for receiving a center wall of constraint mechanism  500  (e.g., center wall  120 ,  FIG. 2 ). Prongs  560  and  562  may extend from the surface of electronic device  500 , leaving slot  564  into which the center wall may fit. Prongs  560  and  562  may be spaced such that the sides of the center wall abut each of prongs  560  and  562 . As constraint mechanism  500  progressively engages electronic device  550 , the center wall advances in slot  564  until the leading edge of the center wall reaches the end of slot  564  and tip  515  is fully inserted in opening  552 . 
     In some embodiments, prongs  560  and  562  may not be solid walls, but may instead include free space  565  under top surfaces  561  and  563  of prongs  560  and  562 , respectively (thus forming tabs extending over the surface of electronic device  550 ). Prongs  560  and  562  may be sized such that free space  565  is operative to receive at least a portion of a tab coupled to the center wall (e.g., protrusion  131  of tab  132 ,  FIG. 1 ), and such that prongs  560  and  562  may be received in slots of constraint mechanism  500  (e.g., slots  134  and  135 ,  FIG. 1 ). Thus, prongs  560  and  562  may be used to prevent constraint mechanism from pitching or yawing. 
     Electronic device  500  may include any suitable mechanism for coupling plate  540  to the electronic device. For example, electronic device  500  may include a threaded boss insert (e.g., insert  570 ) that includes hole  572  to be aligned with hole  542  of coupling plate  540  when constraint mechanism  500  is fully inserted in electronic device  500  (e.g., as shown in  FIG. 7 ). A mechanical fastener may be used to couple plate  540  to insert  570  by passing the mechanical fastener through hole  542  and into hole  572 . For example, insert  570  may include threads for engaging a threaded mechanical fastener (e.g., a screw or a bolt). As another example, hole  572  may be smaller than the mechanical fastener to create an interference fit. As still another example, one of insert  570  and the mechanical fastener can be heated to create a heat-seal, or can include an adhesive or other coupling mechanism. Once plate  540  and insert  570  have been coupled, constraint mechanism  500  may be prevented from rolling, thus protecting electronic device  550  from damage that could otherwise be caused by moving an audio plug inserted in constraint mechanism  500 . 
       FIG. 11  is a cross-sectional view of an audio connector in accordance with one embodiment of the invention. Audio connector  1100  may be inserted in electronic device  1102 , such that opening  1104  in electronic device  1102  permits an audio plug to be placed in tube  1110 . Tube  1110  may be constructed from non-conductive material, but include apertures  1112  through which conductive material (e.g., conductive dimples  1120 ) may protrude and come into contact with an audio plug inserted in audio connector  1100 . For ease of manufacturing, apertures  1112  and dimples  1120  may have different shapes. For example, apertures  1112  may be substantially square, and dimples  1120  may be substantially round or spherical. In addition, apertures  1112  may be larger than dimples  1120 , leaving free space  1114  between the edges of aperture  1112  and dimples  1120 . Because at least one aperture  1112  may be located near opening  1104 , an audio plug inserted at an extreme angle may be forced into aperture  1112 , which may damage dimple  1120 . Also, foreign particles may pass between tube  1110  and dimple  1120  through free space  1114 , which may damage audio connector  1100 . 
       FIG. 12  is a cross-sectional view of another audio connector in accordance with one embodiment of the invention. Similar to audio connector  1100 , audio connector  1200  may be inserted in electronic device  1202 , such that opening  1204  in electronic device  1102  permits an audio plug to be placed in tube  1210 . Tube  1210  may be constructed from non-conductive material, but include apertures  1212  through which conductive dimples  1220  may protrude and come into contact with an audio plug inserted in audio connector  1200 . Different from audio connector  1100 , apertures  1212  and dimples  1220  may be designed and manufactured such that they have substantially the same shape and dimensions. For example, dimples  1220  may be substantially circular, and apertures  1212  may be circular holes having as diameter substantially the same diameter as dimples  1220 . By sizing apertures  1212  based on dimples  1220 , free space  1214  between the periphery of apertures  1212  and dimples  1220  may be minimized, or even eliminated. Then, even if foreign particles are inserted in tube  1210 , or even if an audio plug is inserted in tube  1210  at an extreme angle, the lack of free space  1214  may reduce or eliminate the risk of damage to dimples  1220  or any other portion of audio connector  1200 . 
     The above described embodiments of the present invention are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20080501
Publication Date: 20100504
Grant Date: 20100504
Priority Date: 20080501
Inventors: MYERS SCOTT
HAMEL BRADLEY
WANG ERIK
SLOEY JASON
HOWARTH RICHARD
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/73", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41257399