PATENT DOCUMENT

Publication Number: US-8292663-B2
Application Number: US-201113269825-A
Country: US
Kind Code: B2

Title: Audio plug with cosmetic hard shell

Abstract:
Apparatus, systems and methods for assembling an audio plug with a cosmetic hard shell are provided. A plug may be coupled to a cable. An inner member may be molded about an end portion of the plug and an end portion of the cable. A strain relief member may be molded about a portion of the cable such that the strain relief member is adjacent to and substantially flush with the inner member. The seam between the inner member and the strain relief member may be covered by coupling a hard, smooth outer shell over a portion of the inner member and a portion of the strain relief member. Each of the inner member, the strain relief member, and the outer shell may be formed by injection molding, be of a cylindrical shape, and be formed from the same or different materials.

Claims:
1. An audio plug comprising:
 a plug comprising a plurality of conductive regions separated by a plurality of isolating regions; 
 a cable comprising a plurality of wires, wherein each of the wires is electrically connected to a different one of the conductive regions; 
 a non-conductive inner member molded about the plug and the cable, wherein the inner member extends longitudinally along a portion of the plug and a portion of the cable; 
 a strain relief member surrounding the cable adjacent to the inner member that extends longitudinally along the cable, wherein the strain relief member is positioned substantially flush against the inner member to form a seam; and 
 an outer shell formed around the inner member and the strain relief such that the outer shell overlaps the seam formed between the inner member and the strain relief member. 
 
     
     
       2. The audio plug of  claim 1 , wherein the outer shell comprises one of a hard plastic, a metal, a ceramic, and a composite material. 
     
     
       3. The audio plug of  claim 1 , wherein the inner member comprises one of a plastic, a ceramic, and a composite material. 
     
     
       4. The audio plug of  claim 1 , wherein the outer shell is coupled to the inner member and the strain relief by an adhesive. 
     
     
       5. The audio plug of  claim 1 , wherein the outer shell is constructed from a material having a higher melting point than that of the inner member. 
     
     
       6. The audio plug of  claim 1 , wherein the outer shell is molded around the inner member and the strain relief member. 
     
     
       7. The audio plug of  claim 1 , wherein the plug is cylindrical in shape. 
     
     
       8. The audio plug of  claim 1 , wherein the outer shell is cylindrical in shape. 
     
     
       9. The audio plug of  claim 1 , wherein the outer shell comprises a smooth external surface. 
     
     
       10. The audio plug of  claim 1 , further comprising a coating applied to an external surface of the outer shell. 
     
     
       11. The audio plug of  claim 10 , wherein the coating gives the outer shell a glossy finish. 
     
     
       12. The audio plug of  claim 10 , wherein the coating gives the outer shell a matte finish.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of commonly-assigned U.S. patent application Ser. No. 12/900,144, filed Oct. 7, 2010, now U.S. Pat. No. 8,052,468, which is a continuation of commonly-assigned U.S. patent application Ser. No. 12/218,450, filed Jul. 14, 2008, now U.S. Pat. No. 7,833,055, each of which is fully incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention can relate to apparatus, systems and methods for assembling an audio plug with a cosmetic hard shell. 
     BACKGROUND OF THE DISCLOSURE 
     Electronic devices provide audio to headphones using different approaches, including using audio plugs inserted into a jack of the electronic device. Many existing audio plugs are encased in a soft plastic cover (e.g., between the plug portion and a cable). The soft plastic cover may be susceptible to damage or allow undesired access to the internal electrical connections of the plug. In addition, the soft plastic cover may not be cosmetically appealing if it is soiled through normal use by a user of the audio plug. 
     Therefore, it would be beneficial to provide an audio plug with a hard shell to better protect the components of the audio plug while maintaining the same outer diameter as an audio plug having a soft outer cover. In addition, it may be beneficial to provide an audio plug with a hard shell that has a smooth exterior for enhancing the cosmetic appearance of the plug. 
     SUMMARY OF THE DISCLOSURE 
     An audio plug with a hard outer shell is provided in accordance with some embodiments of the invention. 
     The outer shell may be formed from any suitable material, such as PCB ABS or Dow 5200 HF, and be of any suitable shape to protect the electrical connection between a plug and a cable while also providing a hard, smooth, and cosmetically appealing surface. The outer shell may be of any suitable diameter within the range of 1.0 millimeters to 8.0 millimeters, for example 4.95 millimeters. The audio plug assembled with the outer shell may be used with any suitable electronic device to transmit audio to a user of the electronic device. For example, the electronic device may include a media player, such as an iPod™ classic, an iPod™ nano, or an iPod™ touch available by Apple Inc. of Cupertino, Calif., a cellular telephone, such as an iPhone™ available by Apple Inc., a device capable of communicating wirelessly (with or without the aid of a wireless enabling accessory system) or via wired pathways (e.g., using traditional electrical wires), a pocket-sized personal computer such as an iPAQ Pocket PC available by Hewlett Packard Inc. of Palo Alto, Calif., a personal digital assistant (“PDA”), or a personal e-mail or messaging device with audio and/or video capabilities (e.g., a Blackberry® or a Sidekick®). 
     In some embodiments of the invention, the audio plug may be assembled with one or more intermediate components disposed underneath the outer shell. For example, a plug may be coupled (e.g., soldered) to a cable including any suitable number of wires. An inner member may be molded about an end portion of the plug and about an end of the wires adjacent to the plug to protect the joint (e.g., the solder joint). The inner member may extend longitudinally along the plug and the cable. A strain relief member may be molded about a portion of the wires such that the strain relief member is adjacent to and substantially flush with the inner member, thereby forming a seam. The strain relief member may also extend longitudinally along the cable and may have a similar thickness to the inner member. The seam between the inner member and the strain relief member may be covered by molding or coupling a hard outer shell in a longitudinal direction over a portion of the inner member and a portion of the strain relief member opposing end portions of each of the inner member and the strain relief member (e.g., the end portion of each of the inner member and the strain relief member furthest from the seam) may be exposed beyond the edges of the outer shell. In some embodiments of the invention, each of the inner member, the strain relief member, and the outer shell may be formed by a two-shot molding process. In some embodiments of the invention, each of the inner member, the strain relief member, and the outer shell may form a cylindrical shape and each may be formed from the same or different materials. 
     In some embodiments of the invention, the plug and the cable may be coupled together and carried by a fixture while the audio plug is being assembled with intermediate components and a cosmetic hard shell. The fixture may include an integral testing component that may provide testing to confirm the electrical connection between the plug and the cable during the assembly process. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and advantages of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  shows a perspective view of an audio plug with a cosmetic hard shell in accordance with some embodiments of the invention; 
         FIG. 2A  shows a side view of a plug coupled to a coated cable in accordance with some embodiments of the invention; 
         FIG. 2B  shows a side view of an inner member formed around the plug coupled to the coated cable of  FIG. 2A  in accordance with some embodiments of the invention; 
         FIG. 3  shows a side view of a strain relief member formed adjacent to the inner member of  FIG. 2B  in accordance with some embodiments of the invention; 
         FIG. 4A  shows a cross-sectional view of the cosmetic hard shell of  FIG. 1  in accordance with some embodiments of the invention; 
         FIG. 4B  shows a cross-sectional view of the audio plug of  FIG. 1  in accordance with some embodiments of the invention; and 
         FIG. 5  is a flowchart of an illustrative process for assembling an audio plug with a cosmetic hard shell in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Apparatus, systems and methods for assembling an audio plug with a cosmetic hard shell are provided and described with reference to  FIGS. 1-5 . 
       FIG. 1  shows a perspective view of an audio plug with a cosmetic hard shell in accordance with some embodiments of the invention. Outer shell  100  may be constructed from any suitable hard material, such as a hard plastic, metal, composite material, ceramic, or any other suitable hard material. For example, outer shell  100  may be constructed from PCB ABS or Dow 5200 HF, and be of any suitable shape to protect the electrical connection between plug  200  and cable  400  while also providing a user with a hard, smooth, cosmetically appealing surface. Outer shell  100  may cover (e.g., be placed around) a seam between inner member  250  and strain relief member  300  while permitting a portion of each of inner member  250  and strain relief member  300  to be exposed beyond the edges of outer shell  100 . Each of outer shell  100 , inner member  250 , and strain relief member  300  may include the same or different materials, be cylindrical in shape, and be formed by injection molding. In some embodiments, inner member  250  and strain relief member  300  may be located entirely within outer shell  100 . 
       FIG. 2A  shows a side view of a plug coupled to a coated cable in accordance with some embodiments of the invention. Plug  200  may be constructed from any suitable material and may be of any suitable shape to be coupled with an electronic device (not shown) to transmit audio media to a user of the electronic device. Plug  200  may include several conductive regions (e.g., constructed from a conduction material, such as metal) and several isolating regions separating the conductive regions (e.g., constructed from plastic). Plug  200  may be of any suitable diameter d within the range of 0.5 millimeters to 7.5 millimeters, for example diameter d may be equal to 3.5 millimeters. Plug  200  may be coupled to cable  400  using any suitable approach. For example, each conductive portion of plug  200  may be coupled to a distinct smaller wire  405  using any suitable approach that provides for electrical conductivity (e.g., soldering). Cable  400  may be coated with any suitable coating, such as a soft plastic coating to protect and electrically isolate smaller wires  405  while allowing cable  400  to bend in response to an external force. Cable  400  may be coupled to plug  200  to transport audio to the electronic device from a secondary device (e.g., a microphone) for use by a user of the secondary device. Alternatively, cable  400  may transport audio from the electronic device to a secondary device (e.g., headphones) for use by a user of the electronic device. 
       FIG. 2B  shows a side view of an inner member formed around the plug coupled to the coated cable of  FIG. 2A  in accordance with some embodiments of the invention. Inner member  250  may be constructed from any suitable material, such as, for example, plastic, ceramic, composite material, or any other suitable non-conductive material. For example, inner member  250  may be constructed from a plastic having a melting point lower than the melting point of the material used to form outer shell  100  ( FIG. 1 ). Inner member  250  may be of any suitable shape to protect the coupling of plug  200  to cable  400  and may extend longitudinally along a portion of plug  200  and a portion of cable  400 . For example, inner member  250  may be cylindrical with an external diameter  2   d ′ where inner member  250  is disposed over an end of plug  200  and the joint between plug  200  and cable  400 . External diameter  2   d ′ may be of any suitable diameter within the range of 0.6 millimeters to 7.6 millimeters, for example external diameter  2   d ′ may be equal to four millimeters. Between line B-B and line B′-B′, inner member  250  may be of any suitable second external diameter  2   d ″ within the range of 0.6 millimeters to 7.6 millimeters. In some embodiments, second external diameter  2   d ″ may be equal to external diameter  2   d ′. In some embodiments, inner member  250  may narrow in diameter where inner member  250  is disposed over cable  400  such that second external diameter  2   d ″ may be less than external diameter  2   d ′. By creating inner member  250  with a smaller diameter, the profile of outer shell  100  may be reduced. 
       FIG. 3  shows a side view of a strain relief member formed adjacent to the inner member of  FIG. 2B  in accordance with some embodiments of the invention. Strain relief member  300  may be constructed from any suitable material, such as, for example, plastic, ceramic, composite material, or any other suitable conductive or non-conductive material. For example, strain relief member  300  may be formed from the same material from which inner member  250  may be formed, or any other suitable flexible material operative to protect cable  400  from damage while permitting cable  400  to bend in response to an external force. Strain relief member  300  may be of any suitable shape and may extend longitudinally along cable  400 . For example, between line B′-B′ ( FIG. 2B ) and line C-C, strain relief member  300  may be cylindrical with any suitable external diameter  3   d  within the range of 0.6 millimeters to 7.6 millimeters. In some embodiments, external diameter  3   d  may be similar to second external diameter  2   d ″ of inner member  250 . In some embodiments, at line C-C, external diameter  3   d  may narrow such that external diameter  3   d  may be less than external diameter  2   d ′ and less than external diameter  2   d ″. Strain relief member  300  may be formed in the same manner as inner member  250 , such as by injection molding. Strain relief member  300  and inner member  250  may be positioned substantially flush against one another to form a seam at line B′-B′ and the seam between strain relief member  300  and inner member  250  may be disposed around cable  400 . In some embodiments, inner member  250  and strain relief member  300  may be combined into a single component that may be formed from a single mold to protect the electrical connection between plug  200  and cable  400  while permitting cable  400  to bend in response to an external force. 
       FIG. 4A  shows a cross-sectional view of outer shell  100  ( FIG. 1 ) in accordance with some embodiments of the invention. Outer shell  100  may be of a cylindrical shape with any suitable external diameter  4   d  within the range of 1.0 millimeters to 8.0 millimeters, for example 4.95 millimeters, and may have a hard, smooth external surface to present a cosmetically appealing appearance. Internal surface  110  of outer shell  100  may be formed to fit against the external surfaces of inner member  250  and strain relief member  300  to protect each of these components and the electrical connection between plug  200  and cable  400  from damage. Between line A-A and line B-B ( FIG. 2A ), outer shell  100  may be of any suitable thickness  4   t  within the range of 0.2 millimeters to 3.7 millimeters, for example thickness  4   t  may be equal to 0.5 millimeters. In some embodiments, thickness  4   t  may be less than 0.8 millimeters. Cavity  120  within outer shell  100  may have a diameter equal to ( 4   d −2* 4   t ). This diameter may be only slightly larger than external diameter  2   d ′ ( FIG. 2B ) of inner member  250  to ensure a tight fit between outer shell  100  and inner member  250 . In some embodiments, the end portion of inner member  250  disposed over plug  200  may extend beyond outer shell  100 , as shown in  FIG. 1 . 
     Between line B-B and line B′-B′ ( FIG. 2B ), cavity  120  may narrow to follow the dimensions of the external surface of inner member  250  to ensure a tight fit between outer shell  100  and inner member  250 . Between line B′-B′ and line C-C ( FIG. 3 ), outer shell  100  may be of any suitable thickness  4   t ′ within the range of 0.2 millimeters to 3.7 millimeters. In some embodiments, thickness  4   t ′ may be less than 0.8 millimeters. Cavity  120  may have a diameter equal to ( 4   d −2* 4   t ′) that may be only slightly larger than second external diameter  2   d ″ ( FIG. 2B ) to ensure a tight fit between outer shell  100  and each of inner member  250  and strain relief member  300 , respectively. From line C-C to the end portion of outer shell  100  that may be disposed over cable  400 , outer shell  100  may be of any suitable thickness  4   t ″ within the range of 0.2 millimeters to 3.7 millimeters. In some embodiments, thickness  4   t ″ may be less than 0.8 millimeters. Cavity  120  may have a diameter equal to ( 4   d −2* 4   t ″) that may be only slightly larger than external diameter  3   d  ( FIG. 3 ) to ensure a tight fit between outer shell  100  and strain relief member  300 . 
     In some embodiments, an adhesive may be disposed on a portion of the external surface of inner member  250  and/or a portion of the external surface of strain relief member  300  to bond outer shell  100  to inner member  250  and strain relief member  300 . For example, between line B-B and line B′-B′, glue, tape, or other adhesive may be disposed on inner member  250 . Between line B′-B′ and line C-C, glue, tape, or other adhesive may be disposed on strain member  300 . No adhesive may be disposed on inner member  250  between line A-A and line B-B so that at least a portion of the adhesive disposed between line B-B and line C-C may travel onto inner member  250  between line A-A and line B-B when outer shell  100  is coupled to inner member  250  and strain relief member  300 . The space between outer shell  100  and inner member  250  and strain relief member  300 , respectively, may be less than 0.1 millimeters thick when outer shell  100  is coupled to inner member  250  and strain relief member  300 . 
     In some embodiments, outer shell  100  may be disposed about inner member  250  and strain relief member  300  during manufacturing, for example using a two-shot molding process. For example, each of inner member  250  and strain relief member  300  first may be molded around the joint between plug  200  and cable  400 . The combined inner member  250  and strain relief member  300  coupled to plug  200  and cable  400  may be inserted into a second mold used to form outer shell  100 . Outer shell  100  may be constructed from a material having a higher melting point than that of the material or materials used to form inner member  250  and/or strain relief member  300 . Exposing inner member  250  and strain relief member  300  to the melted material used to form outer shell  100  may at least partially melt the external surfaces of inner member  250  and strain relief member  300 . The partially melted external surfaces may mix with the melted material used for outer shell  100 , causing inner member  250  and strain relief member  300  to bond to outer shell  100  as the materials cool. The molding process may be performed quickly to ensure proper bonding of outer shell  100  to the components of the audio plug. 
     The external appearance of outer shell  100  may be aesthetically enhanced after outer shell  100  has been formed using any suitable method. For example, the external surface of outer shell  100  may be polished or sanded to remove any surface imperfections and to improve the smoothness of outer shell  100 . Alternatively, a coating may be applied to the external surface of outer shell  100  to give outer shell  100  a glossy finish or a matte finish depending on the desired cosmetic appearance. 
       FIG. 4B  shows a cross-sectional view of the audio plug of  FIG. 1  in accordance with some embodiments of the invention. Audio plug  100  can include inner member  250  and strain relief member  300  positioned around cable  400 , wires  405  and plug  200 . Outer shell  100  is positioned around inner member  250  and strain relief member  300  such that the ends of sell  100  are contained within the edges of inner member  250  and strain relief member  300 .  FIG. 5  is a flowchart of an illustrative process for assembling an audio plug with a cosmetic hard shell in accordance with some embodiments of the invention. Process  500  may begin at step  502 . At step  504 , a plug may be coupled to a cable using any suitable process. For example, plug  200  may be soldered to cable  400  ( FIG. 2A ). At step  506 , a first member may be molded around the coupling of the plug to the cable using any suitable method. For example, inner member  250  ( FIG. 2B ) may be disposed around a portion of plug  200  and a portion of cable  400  using injection molding to protect the electrical connection between plug  200  and cable  400 . Process  500  may advance to step  508 , where a second member may be molded around a portion of the cable using any suitable method so as to form a seam with and be substantially flush with an end of the first member molded around the cable. For example, strain relief member  300  ( FIG. 3 ) may be disposed around a portion of cable  400  using injection molding to protect cable  400  from damage while permitting cable  400  to bend in response to an external force. Strain relief member  300  may be molded so as to be adjacent to and substantially flush with inner member  250 . At step  510 , a hard, smooth outer shell may be molded around the seam between the first member and the second member to protect the audio plug and to provide a cosmetically appealing appearance. For example, outer shell  100  ( FIG. 4A ) may be disposed around the seam between inner member  250  and strain relief member  300  using a two-shot molding process. As another example, outer shell  100  may be disposed around the seam between inner member  250  and strain relief member  300  using an adhesive disposed on at least a portion of the external surface of inner member  250  and disposed on at least a portion of the external surface of strain member  300 . Process  500  may then advance to step  512  and end. 
     While there have been described apparatus, systems and methods for assembling an audio plug with a cosmetic hard shell, it is to be understood that many changes may be made therein without departing from the spirit and scope of the invention. It will also be understood that various directional and orientational terms such as “up” and “down,” “left” and “right,” “top” and “bottom,” “side” and “edge” and “corner,” “height” and “width” and “depth,” “horizontal” and “vertical,” and the like are used herein only for convenience, and that no fixed or absolute directional or orientational limitations are intended by the use of these words. For example, the positioning of an inner member, a strain relief member, and an outer shell in this invention can have any desired orientation. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope of the invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20111010
Publication Date: 20121023
Grant Date: 20121023
Priority Date: 20080714
Inventors: CROOIJMANS WILHELMUS M. C.
STIEHL KURT
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49174", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R43/24", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R24/58", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49174", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R2107/00", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 41505550