Abstract: A low-profile power adapter is disclosed. In one embodiment, a low profile power adapter is facilitated by improved approaches to construct and assembly of a power adapter plug for the power adapter. According to one aspect, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug. According to another aspect, internal terminals used by a power adapter plug of a power adapter can be flexibly positioned on the power adapter plug, thereby facilitating interconnection with electrical components used by the power adapter. A molded base can be formed around the metal base leaving the blade and terminals exposed.

Abstract: This invention is directed to systems and methods for providing a port in an electronic device housing that is electrically isolated from a conductive portion of a connector inserted in the port. In some embodiments, the connector may include a non-conductive flange or ring operative to contact the housing and the portions of the housing within the port. In some embodiments, a thin layer of non-conductive material may be applied to the portions of the housing within the port to prevent conductive portions of the connector from coming into contact with the housing (e.g., and grounding the conductive portion). This invention may be of particular interest when the conductive portion that may come into contact with the housing is not used to ground the connector.

Abstract: A low profile connector system. In one set of embodiments, a low profile plug receptacle is provided that is thinner than a standard plug receptacle, thereby allowing the plug receptacle to be incorporated in small form factor (e.g., very thin) electronic devices while maintaining compatibility with standard plug connectors. In another set of embodiments, different types of custom plug connectors are provided that can improve the aesthetics of an electronic device housing the low profile plug receptacle when the custom plug connector is attached. In another set of embodiments, features are provided for preventing a plug connector from unintentionally falling out of, or coming loose from, the low profile plug receptacle and/or preventing a plug connector from rotating within the receptacle.

Abstract: Molded splitter structures and systems and methods for manufacturing molded splitter structures are disclosed.

Abstract: A headset can include a cable structure connecting non-cable components such as jacks and headphones. The cable structure can be constructed using a molding process. Different approaches can be used to ensure that a conductor bundle extending through the cable structure remains centered within the cable structure during the molding process. In some cases, a movable tube can be placed in the mold such that the conductor bundle is retained within the tube. As material is injected into the mold and reaches the tube, the tube can be displaced and progressively removed from the mold. Alternatively, the movable tube can be constructed such that the tube may combine with injected material to form a shell of the cable structure. In some cases, gates from which material is provided in the mold can be positioned and controlled to facilitate the injection of material in the mold while maintaining the centered position of the conductor bundle.

Abstract: A headset can include a cable structure connecting non-cable components such as jacks and headphones. The cable structure can include several legs connected at a bifurcation. An extrusion process can be used to manufacture legs of a multi-segment cable structure. As material is processed by an extruder, one or more system factors of the extruder can be dynamically adjusted to change a diameter of the resulting leg (e.g., to provide a smooth leg having a changing size). Once the leg is extruded, portions of the leg can be reformed to create undercuts used to connect the legs at a bifurcation region. In some cases, an extrusion process can be used to construct a jointly formed multi-leg cable structure having an integral bifurcation region and split.

Abstract: This is directed to a cable for use with an electronic device. The cable can be substantially flat, such that all of the conductive wires of the cable are substantially in the same plane. A spacer can be placed between the wires to ensure that wires conducting signals remain a minimum distance apart to avoid signal degradation. The spacer can also control the bending of the cables to favor bending in a preferred direction while reducing or limiting bending in a less preferred direction.

Abstract: This is directed to a cable structure for use with an electronic device. The cable structure can include one or more conductors around which a sheath is provided. To prevent the cable structure from tangling, the cable structure can include a core placed between the conductors and the sheath, where a stiffness of the core can be varied along different segments of the cable structure to facilitate or hinder bending of the cable structure in different areas. The size and distribution of the stiffer portions can be selected to prevent the cable from forming loops. The resistance of the core to bending can be varied using different approaches including, for example, by varying the materials used in the core, varying a cross-section of portions of the core, or combinations of these.

Abstract: Docking stations with a moveable connector that is more durable are provided. For example, when a portable electronic device, coupled with the connector, is pushed forward, the connector is designed to move (e.g. rotate), thereby reducing an impact of strain resulting from such a push. The rotatable connector may be biased to keep the portable electronic device in an upright position such that the electronic device is supported by a rear reference surface of the docking station, thereby preventing undue strain on the rotatable connector in the upright position and inhibiting movement forward. The rotatable connector may be partly below an outer shell of the docking station, and pivot at the outer shell, thereby reducing possible damage to parts below the outer shell. The rotatable connector may also retract when rotated, thereby removing a force that can break the connector at a position of full rotation forward.

Abstract: A compact power adapter is disclosed. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug.

Abstract: This is directed to a method for assembling components using a thermally activated adhesive. Two components of an electronic device housing can be coupled as part of the electronic device assembly. At least one of the two components can be thermally conductive. To use a thermally conductive adhesive to couple the components, the components can be placed in a fixture, and the adhesive between the components. The fixture can then be heated such that heat from the fixture is conducted through the thermally conductive component and into the adhesive. The adhesive can flow and propagate between the components. When the adhesive layer has flowed into an adequate layer, the fixture can be cooled such that heat can be removed from the adhesive through the thermally conductive component. The adhesive can harden and secure the components to each other.

Abstract: A compact power adapter is disclosed. In one embodiment, a compact power adapter is facilitated by improved approaches to construct and assemble the power adapter. According to one aspect, connectors can serve to electrically couple blades (or prongs) of a power adapter plug to a printed circuit board assembly internal to a housing for the power adapter. The connectors serve to couple AC power to the printed circuit board assembly where the AC power can be converted to DC power. The connectors also facilitate assembly of the power adapter in that reliable interconnections can be provided without wires, soldering or other custom assembly operations. In one embodiment, a base for a power adapter plug of a power adapter can include a metal base connected to a blade (or prong) of the power adapter plug. The metal base can provide mechanical support to the blade as well as electrical connectivity to an internal terminal for the power adapter plug.

Abstract: Connectors for cables such as a 30-pin connector are provided. The connectors may have thermal protection circuits and may carry a power supply voltage and a ground voltage. The thermal protection circuits may disable the power supply voltage when the temperature of the connector exceeds a threshold value. The connectors may have structures that encourage any dendritic failure to occur in a preferred location.

Abstract: An array of domes is constructed from a single sheet of constructed material. For example, several domes can be stamped at a preset distribution within a sheet of metal. The domes can be placed at any suitable position along the surface of the material, including for example at positions defined by the locations of contact pads on a circuit board. The conductive material can be electrically coupled to the circuit board at any suitable location, including for example along an edge of the piece of material. In some embodiments, the sheet of material can extend around the side walls of the circuit board, for example bent around the periphery of the circuit board. The sheet of material can be electrically coupled to the bottom of the circuit board, for example by soldering. This approach may provide a water resistant dome switch, whereby water can be prevented from leaking between the dome and the circuit board.

Abstract: This invention is directed to systems and methods for providing a port in an electronic device housing that is electrically isolated from a conductive portion of a connector inserted in the port without the use of a nonconductive trim in the port. In some embodiments, the connector may include a non-conductive flange or ring operative to contact the housing and the portions of the housing within the port. In some embodiments, a thin layer of non-conductive material may be applied to the portions of the housing within the port to prevent conductive portions of the connector from coming into contact with the housing (e.g., and grounding the conductive portion. This invention may be of particular interest when the conductive portion that may come into contact with the housing is not used to ground the connector.

Abstract: A removable component for use with an earphone is disclosed. As an example, the removable component can be an ear tip. According to one aspect, an improved ear tip can be provided for use with a headphone. The ear tip is suitable for in-ear operation and can have a cosmetic deformable outer member. The deformable outer member can enable the ear tip to readily conform to a user's ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. Methods for forming such ear tips are also disclosed.

Abstract: An adhesive having a light-activated distinctive appearance is disclosed. The adhesive in the presence of a certain type of light can project a distinctive color. In one embodiment, an adhesive can have a light-activated colorization. The light used to activate the colorization can be Ultraviolet (UV) light. The adhesive can be used in an assembly and/or review process for consumer products to facilitate assembly and/or review of consumer products assembled at least in part using adhesive.

Abstract: This invention is directed to systems and methods for providing a port in an electronic device housing that is electrically isolated from a conductive portion of a connector inserted in the port. In some embodiments, the connector may include a non-conductive flange or ring operative to contact the housing and the portions of the housing within the port. In some embodiments, a thin layer of non-conductive material may be applied to the portions of the housing within the port to prevent conductive portions of the connector from coming into contact with the housing (e.g., and grounding the conductive portion. This invention may be of particular interest when the conductive portion that may come into contact with the housing is not used to ground the connector.

Abstract: Integrated touch sensor and solar panel stack-up configurations that may be used on portable devices, particularly handheld portable devices such as a media player or phone are disclosed. The solar cell stack-up configurations may include one or more touch sensor layers and one or more solar cell layers. By integrating both the touch sensors and the solar cell layers into the same stack-up, surface area on the portable device may be conserved. The solar panel may be mounted face down or otherwise obstructed by a touch sensor or other component. In this configuration, the device may include light channels that allow light into the device and direct the light around the component and to the solar panel. A parabolic reflector may be used to direct the light.

Abstract: Integrated touch sensor and solar panel configurations that may be used on portable devices, particularly handheld portable devices such as a media player or phone are disclosed. The integrated touch sensor array and solar cell stack-ups may include electrodes that are used both for collecting solar energy and for sensing on a touch sensor array. By integrating both the touch sensors and the solar cell layers into the same stack-up, surface area on the portable device may be conserved. In addition to being used for capacitive sensing, the integrated touch sensor and solar panel configurations may also be used for optical sensing.