iPod Mini Design Flaw?

terradyn writes "Over at iPodlounge they've discovered that the iPod mini's have a major issue with their headphone jacks. It looks like the jacks connection to the main system board is extremely poorly engineered and so normal use will wear it out and cause lots of static after around 35-40 days... If any pressure on your iPod Mini results in crackling and static, you should return your iPod immediately to an Apple store for a free replacement. They're also theorizing over in the forums that the iPod Mini shortage may be a cover for this problem..." Update: 04/12 01:08 GMT by T : billybob writes "Someone in the forum thread originally linked to has posted pictures of the iPod taken apart, demonstrating the problem."

Comments

Apple is not unique in this problem.

[maeka]

I can't think of a single portable music player that I have owned in the last 20 years that did not suffer from this problem. Indeed, it is the fear of such a problem that has kept me from buying any MP3 player.

Everything from an original Sony Walkman, to discount store AM/FM radios, to expensive Sony and Phillips CD players have suffered from this annoying loose headphone jack disease. Some may suffer earlier than others, but none have survived without a little home soldering work more than a year.

iPod engineering

[Anonymous Coward]

My impression is that the engineers at Apple that work on the iPod are rarely stopped on the street and mistaken for Steve Wozniak.

The battery-life meters on the 3rd-generation iPods are nothing short of random, and now this. For what they're charging for these things, why doesn't the battery indicator work as well as the one on my two-year-old $49 cell phone?

Usage problem with 1st Gen iPod

[sithkhan]

I have this EXACT problem with my 1st generation iPod. There is a hard plastic collar around the jack, and after three months of pocket-related stress, the jack began to hiss and the left channel began to fade in and out. I KNOW Apple did not forsee this design flaw in the first gereation. I have not had the pleasure of usiong the second or third generations to compare. I simply mess with the plug until the music returns. Too bad there is not a Firewire headphone. That would be kick ass!

Mechanical Problems

[ajs318]

It sounds as though the jack socket is prone to dry joints where it solders to the board. Either that, or the contacts are losing their springiness after a few insertion cycles.

Dry joints can be repaired "while-U-wait" in any suitably-equipped workshop -- or at home, but it's fiddly and I'd be reluctant to open up such an expensive precision instrument {and anyway, 30-40 days is well within the 12 month statutory guarantee period}.

I'm guessing that the PCB would be double-side surface mounted, reflow soldering both sides. The long-term solution is going to require a PCB redesign and new solder paste masks -- either too much solder or too little solder can cause poor joints; and maybe they should spec a socket with a plastic lug on the underside passing through a hole in the board, which would give it a bit more stability. Using a traditional socket with through-hole pins would be even more secure, especially if dummy pins were added for mechanical support, but would require an additional operation to hand-solder it in place.

It's understandable that Apple is using delaying tactics, as it will probably require a long round of accelerated testing to determine exactly what the problem is and how best to fix it. {I used to work in the R&D department of a company which designed and made electronic control modules, by the way}.

Re:now it makes sense

[kd5ujz]

Im guessing they use it for space saving. You would need two rca plugs to replace one 1/8 plug. a better idea would be a modified banana plug, with some sort of grounding mechanisim from the plug to the frame of what you are using, then use the plugs for +R and +L audio.