Abstract: A plug assembly having a core structural member and methods for manufacturing such plug assemblies are provided. A plug assembly can include a core structural member defining an elongated component having a bore therethrough. Several conductors can be inserted through the bore to be coupled to conductive regions used to transfer data and/or power. The conductive regions can include a ring or band that is provided axially over the structural member such that an external surface of the band can transfer signals. Each conductive region can include an arm extending from an internal surface of the band along the axis of the structural member. The arm may extend to a tip of the structural member so that a connector passing through the bore of the structural member can be connected to the arm (e.g., soldered to a tip of the arm). The structural member can include slots for receiving each arm.

Abstract: Thin plug assemblies and methods for constructing the same are disclosed. The plug assembly can include a plug portion, a cable portion, and an interfacing portion between the plug portion and the cable portion. The plug portion can include several conductive regions each connected to a conductor of the cable portion to form conductor/plug member coupling(s), for example via a plug extension member associated with each conductive region. The plug assembly is constructed such that a diameter of the plug portion, interface portion, and at least part of the cable portion have substantially the same diameter. Ring structures enhance one or more of the conductor/plug member couplings by providing a press or interference fit directly to the coupling(s). Ring structures are constructed to slide axially over at least one conductor and at least one plug member.

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 such as, for example, a main leg splitting into left and right legs. To prevent tangling of the cable structure, one or more rods constructed from a super-elastic material can be embedded in each of the legs. For example, a first set of superelastic rods can extend from the main leg to the left leg, a second set of superelastic rods can extend from the main leg to the right leg, and a third set of superelastic rods can extend from the left leg to the right leg. In some cases, the super-elastic rods can be incorporated in a conductor bundle used to transfer signals through the cable structure.

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: Compression molded cable structures and systems and methods for manufacturing molded cable structures are disclosed.

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: Compression molded cable structures and systems and methods for manufacturing molded cable structures are disclosed.

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 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: 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: 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: 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.