Abstract: Devices and methods of manufacture for improved connector plugs are provided herein. In one aspect, an exemplary connector plug comprises a shield shell having a proximal stepped-down portion and a boot member that fittingly receives the stepped-down proximal portion so that an outer surface of the distal shield shell and the boot member is about flush with a minimal or negligible space therebetween. In some embodiments, the shield shell comprises a separate front shield shell and a reduced profile rear shield shell welded together so as to provide the advantageous reduced profile and improved aesthetic appearance, while maintaining the structural integrity of the connector. In many embodiments, weld strength of the shield shells is improved by providing line-to-line contact between shield shells by using deflectable tabs and/or utilizing thermal expansion properties of one or both shield shells.

Abstract: Devices and methods of manufacture for improved connector plugs are provided herein. In one aspect, an exemplary connector plug comprises a shield shell having a proximal stepped-down portion and a boot member that fittingly receives the stepped-down proximal portion so that an outer surface of the distal shield shell and the boot member is about flush with a minimal or negligible space therebetween. In some embodiments, the shield shell comprises a separate front shield shell and a reduced profile rear shield shell welded together so as to provide the advantageous reduced profile and improved aesthetic appearance, while maintaining the structural integrity of the connector. In many embodiments, weld strength of the shield shells is improved by providing line-to-line contact between shield shells by using deflectable tabs and/or utilizing thermal expansion properties of one or both shield shells.

Abstract: Improved techniques are disclosed for housing electronic components. A first housing member can be made to have an exterior surface that covers a majority of the housing. The first housing member can be of unitary construction. The first housing member can be seamlessly constructed. The first housing member can be formed in one injection molding. An electrical power conduction pin can extend through an aperture in a cover plate, and can be arranged for mechanically coupling the cover plate with a major interior surface of the first housing member, so as to secure the cover plate to the first housing member.

Abstract: A corrosion-resistant electrical connector is disclosed. A multi-layer nickel underplating is applied to the substrate material of the connector contacts. The three layers of nickel include a leveling nickel layer, a sulfumate nickel layer, and a high-phosphorous nickel layer. A layer of gold is applied to the nickel underplating in an embodiment.

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: 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: Cables with braided shields constructed from metal-doped fibers and methods for making the same are disclosed. This braided shield maintains the electrical conductivity of a conventional all-metal braided shield, but is less stiff. This allows for a much more flexible cable and increased cable flex life because the metal-doped fibers are not as sensitive to bending fatigue as their all metal counterparts.

Abstract: Electronic devices may be provided that contain wireless communications circuitry. The wireless communications circuitry may include antenna structures that are formed from an internal ground plane and a peripheral conductive housing member. A conductive path may be formed that connects the peripheral conductive housing member and the internal ground plane. The conductive path may include a flex circuit. The flex circuit can include a solder flow barrier to constrain flow of solder. A metal structure may be welded to the peripheral conductive housing member. A solder pad and other traces in the flex circuit may be soldered to the metal structure at one end of the conductive path. At the other end of the conductive path, the flex circuit may be attached to the ground plane using a bracket, screw, and screw boss.

Abstract: This is directed to connector assemblies for electric cables, and methods of manufacturing the same, that may include a body molded about one or more connections made between one or more conductive leads of the electric cable and one or more electrical contacts of the connector assembly. The molded body may provide support to the connections and may maintain the relative positions of the traces for functionally aligning exposed portions of the traces with other connector assemblies.

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: 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 integrated solar roofing tile connection system for installing on a roof surface for converting solar energy into electrical energy includes a plurality of battens that each have a length and are mounted to the roof surface. The plurality of battens are generally parallel to and spaced from one another. A plurality of electrically connected female connectors mounted to each batten and spaced along the length of each batten. A plurality of photovoltaic roofing tiles are mounted to each batten. Each photovoltaic roofing tile has a tile base that has a first side surface, a second side surface and a top edge and a photovoltaic circuit. The photovoltaic circuit includes a plurality of electrically interconnected photovoltaic cells and first and second terminal ends. Each photovoltaic roofing tile includes a male connector that extends from the tile base. Each male connector at least partially exposes the first and second terminal ends.

Abstract: A photovoltaic roofing tile for installing on a roof surface and converting solar energy into electrical energy includes a tile base that has a first side surface, a second side surface and a top edge. A rigid contact support extends outwardly from the top edge of the tile base and is generally parallel with the first side surface of the tile base. A plurality of electrically interconnected photovoltaic cells are arranged on the first side surface of the tile base and forming of a photovoltaic circuit that has first and second terminal ends. A contact tab extends from the top edge of the tile base and along the contact support to form a male connector. The contact tab includes the first and second terminal ends, the first and second terminal ends being at least partially exposed on an outer surface of the male connector.

Abstract: A method of manufacturing a photovoltaic roofing tile for installing on a roof surface and converting solar energy into electrical energy includes the steps of forming a generally flexible photovoltaic laminate, the laminate including a photovoltaic layer including plurality of electrically interconnected photovoltaic cells and a photovoltaic circuit electrically connecting the photovoltaic cells, inserting the laminate into a tile mold and injecting a molten thermoplastic material into the tile mold to form and fixedly attached a tile base to the laminate.