Robust audio device design

Embodiments of the disclosure provided herein are configured to desirably distribute and thus withstand forces that are applied to an audio device assembly during regular use. The configurations discussed herein can be used to prevent the various device related components from becoming damaged during use. The application of these forces can cause immediate failure of the electrical connections in extreme cases, or more typically cause eventual failure of the electrical connections and device due to repetitive application of the applied force. Therefore, it is desirable to minimize the stress applied to the various electrical connection points during use, such as the electrical connection points.

BACKGROUND

Field

Embodiments disclosed herein generally relate to a consumer electronic device that is configured to provide an audio output.

Description of the Related Art

Audio devices allow users to receive audio content or audio information from various media sources, such as internet, video players, gaming devices, music playing platforms or other types of devices. Typical portable audio devices may include wireless speakers, tethered headphones and wireless headphones. Wireless speakers and wireless headphones allow users to be un-tethered to a video, gaming or music playing platform. Wireless headphones are particularly popular among video game players, since a player cannot become entangled in an interconnecting cord while the player is playing the video game. In the case where the wireless headphones are wireless earbuds, it is common to string the part of the earbuds that is inserted into the user's ears together such that they are tethered to the user so that they will not be easily lost by the user. However, conventionally strung earbuds are typically not anchored to the user for comfort and complexity reasons, so it is not uncommon for users to handle these tethered designs by grabbing onto and/or pulling on the interconnecting cable. In conventional designs, the application of a force to the interconnecting cables and connection point(s) formed between the interconnecting cable and earbud/headphone components can cause the electrical connections to become disconnected or less reliable over time.

Conventional headphones that are used with various communication devices typically have buttons which are used to control the delivery of an audio signal to the user and/or remotely control the communication devices. These button initiated functions may include, for example, muting the delivery of audio input to the user or to initiate voice activated dialing. Typically a single press, or a long press, of a button within the headphone device can activate different functions. However, conventional headphone designs typically include structurally separate button assemblies that are attached to a portion of the interconnecting electrical transmission cable that connects the earbud/headphone components, and are not designed to be integrated into a rugged molded headphone assembly.

Therefore, there is a need for a more rugged audio device assembly that is able to support the stresses applied to its various components during normal use and operation. It is also desirable to provide a rugged audio device assembly that has an integrated multi-button control within the formed device.

SUMMARY

Embodiments of the present disclosure relate to an audio device assembly that contains audio components that are interconnected by use of a cable assembly that is configured to electrically interconnect the various audio components.

Embodiments of the present disclosure relate to an audio device, comprising an audio assembly, and electrical interface assembly and a cable assembly. The audio assembly may comprise a first device load support and a first electrical input connection that is in electrical communication with a first speaker, wherein the first device load support is configured to directly or indirectly support the first speaker. The electrical interface assembly may comprise an interface connection and an interface load support, wherein the interface connection is in electrical communication with interface control electronics. The cable assembly may comprise a wiring harness comprising a plurality of wires that electrically connect the first electrical input connection to the interface connection, and a first load supporting element that is coupled to the first device load support and the interface load support.

Embodiments of the present disclosure also relate to an audio device, comprising a first audio assembly, an electrical interface assembly and a first cable assembly. The first audio assembly comprises a first device load support, and a first electronic assembly comprising a first electrical input connection that is in electrical communication with a first speaker. The electrical interface assembly comprises a first interface connection and a second interface connection that are each coupled to an interface printed circuit board, and an interface load support. The first cable assembly comprises a wiring harness comprising a plurality of wires that electrically connect the first electrical input connection to the first interface connection, and a first load supporting element that is coupled to the first device load support and the interface load support.

Embodiments of the present disclosure may also relate to an audio device, comprising a first audio assembly and a first cable assembly comprising a flexible wall. The first audio assembly may include a first electrical input connection that is in electrical communication with a first speaker. The first cable assembly comprising a domed feature that has an inner surface, a supporting wall, a wiring harness comprising a plurality of wires that are electrically connected to the first electrical input connection, a switch and a sealed region. The switch and the wiring harness may be disposed between the flexible wall and the supporting wall. The switch is disposed on a support surface of a supporting element, which is disposed between the flexible wall and the supporting wall, and has a first connection point and a second connection point. The first and second connection points of the switch are each in electrical communication with one of the plurality of wires. The sealed region is at least partially defined by the inner surface and the support surface, wherein the switch is disposed within the sealed region.

Embodiments of the present disclosure may also relate to a method of forming an audio device, comprising forming a flexible wall that has a mounting surface, wherein the flexible wall further comprises a domed feature that has an inner surface, and positioning at least a portion of a wiring assembly over the mounting surface, and the wiring assembly includes a wiring harness that comprises a plurality of wires, a supporting element that has a supporting surface, and a switch that coupled to the supporting element and comprises a first connection point that is in electrical communication with a first wire of the plurality of wires and a second connection point that is electrical communication with a second wire of the plurality of wires. Then sealably bonding the supporting element to the mounting surface to form a sealed region that is at least partially defined by the inner surface and the supporting surface, wherein at least a portion of the switch is disposed within the sealed region.

DETAILED DESCRIPTION

FIG. 1Ais an isometric view of an audio device assembly100according to an embodiment of the present disclosure.FIG. 1Bis a bottom-side isometric view of a portion of the audio device assembly100that contains an interface assembly140that is included within a cable assembly110according to an embodiment of the present disclosure.FIG. 10is schematic view of the audio device assembly100that illustrates at least a portion of the electrical and structural interconnections found in the audio device assembly according to one embodiment of the present disclosure. In some embodiments of the disclosure, the audio device assembly100may include two audio output assemblies150and a cable assembly110that are adapted to deliver audio content to a user. When the audio device assembly100is in use a first audio output assembly150A and second audio output assembly150B may each be positioned on or inserted within the user's ear to deliver audio content to the user. In one example, the first audio output assembly150A and second audio output assembly150B are wireless earbuds, earphones, in-ear monitors, or other similar devices. While the audio device assembly100is primarily described herein as being a wireless headphone type system, this configuration is not intended to be limiting as to the scope of the disclosure provided herein since other electronic devices that include an interconnecting cable, such as non-wireless headphone or speaker configurations, may also benefit from the disclosure provided herein.

During normal operation of the audio device assembly100, a user may handle or grab onto the portion of the cable assembly110to remove or reposition the audio device assembly100. Handling or grabbing onto the cable assembly110can generate a force within a portion of the audio device assembly100that the user has grabbed onto. For example, a force can be generated between or within an audio output assembly150and a portion of cable assembly110, due to the user's handling of the cable assembly110. The applied force will cause a load to be placed within the various components found in the stressed portion of the cable assembly110, the audio output assembly150and the interface between the audio output assembly150and the cable assembly110. Various embodiments of the disclosure provided herein are configured to desirably distribute and thus withstand these applied forces to prevent the audio device assembly100from becoming damaged, which are a common occurrence in conventional headphone designs found in the market place today. In conventional headphone designs, these types of applied forces are typically transmitted from the user's hand to the shielding of an interconnecting signal transmitting wire in the headphone and then to the electrical connections formed between the signal transmitting wire and the various electronic components (e.g., headphone speakers, 3.5 mm jack, etc.) within the headphone. The application of these forces can cause immediate failure of the electrical connections in extreme cases, or more typically cause eventual failure of the electrical connections due to repetitive application of the applied force. Therefore, it is desirable to minimize the stress transferred to the various electrical connection points in the device, such as the electrical connection points191and192illustrated inFIG. 10, when a force is applied to the audio device assembly100during use.

In general, the audio device assembly100contains two or more audio output assemblies150that are coupled together by a cable assembly110. The cable assembly110may include an interconnection assembly120that is in electrical communication with the two or more audio output assemblies150through the cable assembly110. The cable assembly110may include a body210that includes a wiring harness220(FIG. 10) and one or more load supporting assembly225(FIG. 10). The body210may have a top surface210A and an opposing bottom surface210B. The body210will generally include a molded plastic, elastomer or other similar material that is configured to enclose and/or encapsulate the components within the wiring harness220and load supporting assembly225. In some embodiments, the body210may be formed from a flexible a thermoset type elastomer or a flexible thermoplastic type elastomer, such as a silicone rubber material.

The wiring harness220generally includes a plurality of electrical conductors that are adapted to supply power, provide a reference signal (e.g., ground) and/or transfer electrical signals between the various electrical components in the audio device assembly100. The wiring harness220may contain at least two electrically isolated wires222, such as about six to ten wires in some configurations. The wiring harness220is generally used to interconnect the various electrical components in the audio output assemblies150and/or electrically connect the audio output assemblies150to an interconnection assembly120. In one configuration, the wiring harness220includes a plurality of flexible stranded wires222, such as 22 to 38 gauge (AWG) stranded copper wires. The stranded wires222may be separately jacketed to prevent electrical shorts between adjacently positioned wires222. In some configurations, each strand of the stranded wire222may be separately jacketed to prevent electrical shorts between strands.

The interconnection of the audio output assemblies150and interconnection assembly120is made through the connection points191and192, which are also referred to herein as an input connection and an interface connection, respectively. The electrical connection points191and192are connecting elements that may each comprise an electrical connector, solder joints, bonding pads or other similar device or element that is configured to electrically connect the wires222to the electrical components in the audio output assemblies150and the interconnection assembly120.

The load supporting assembly225includes one or more load supporting elements230that couple the load supporting elements in the audio output assemblies150to the interconnection assembly120. The load supporting element230is a flexible filament, such as a cable, string, wire, thread or fiber, that is disposed within the cable assembly110. The one or more load supporting elements230are configured to support at least a portion of the forces applied to the cable assembly110, audio output assemblies150and/or interconnection assembly120during use. A load supporting element230may be a 0.01 mm to 3 mm diameter filament that is formed from a polymer material (e.g., ultra-high molecular weight polyethylene (UHMW-PE) material), nylon fiber, an aramid fiber (e.g., Kevlar™ fiber), stranded metal wire (e.g., stranded copper wire), or other useful material.

The interconnection assembly120, which is discussed further below, may include a device connector122that is adapted to electrically connect electrical components within the audio device assembly100to an external device, such as a computer, tablet, cell phone, audio delivery device or other useful electronic device. In one example, the device connector122is adapted to be coupled to a universal serial bus (USB) port of a computer. When the device connector122is connected to a computer it is adapted to deliver power to one or more batteries in the audio device assembly100and/or deliver information (e.g., digital audio data, digital media, etc.) to various components found within the audio device assembly100.

The audio device assembly100may also contain an interface assembly140that is used to control the delivery of information to the user through the two or more audio output assemblies150and/or provide input to a processor within the audio device assembly100so that one or more functions can be performed by one or more electronic components within the audio device assembly. The interface assembly140may contain one or more input assemblies that are adapted to provide input to the processor when actuated by the user. In one example, the interface assembly140includes a first input assembly142, a second input assembly144and third input assembly146. Each of the input assemblies may contain an input receiving feature141(FIG. 1B) that is adapted to receive the input from the user, such as by depressing a portion of the input receiving feature to cause a switch within the input assembly to be actuated, as is discussed further below. In one configuration, the interface assembly140includes first, second and third input assemblies that each contain an input receiving feature141A,141B,141C (FIG. 1B), respectively. Referring toFIG. 10, each of the input receiving features141include a switching device that is coupled to one or more components in the wiring harness220to provide a signal to the electrical components positioned in the audio output assemblies150and/or interconnection assembly120.

Each of the audio output assemblies150generally includes a connection assembly152, a component assembly154and a user interface element155. The user interface element155generally includes a molded or formed component that is adapted to be attached to or positioned on a user during operation. In one example, the interface element155is an earbud type of component that is adapted to be at least partially inserted within an ear canal of a user. The connection assembly152in each of the audio output assemblies150is generally used to join or couple the components in the cable assembly110to the various elements in the component assembly154, and will be discussed in further detail below.

A component assembly154includes various structural and electrical components used to provide the desired information to the user during operation. In some configurations, the component assembly154may include the connection assembly152, a body321(FIG. 3A), and an output electrical assembly107(FIG. 10). The output electrical assembly107may include a speaker111, speaker driver assembly106, a transceiver115, a memory unit108and a battery109.

In some embodiments, the component assembly154in at least one of the two or more audio output assemblies150includes a speaker driver assembly106, a transceiver115, a memory unit108and/or a battery109. Thus, in some configurations these electrical components are shared between the audio output assemblies150by use of the wiring harness220components. In other words, in some configurations, the audio device assembly100may only include one speaker driver assembly106, transceiver115, memory unit108and/or battery109, as an alternate configuration to the one illustrated inFIG. 10. Alternately, in some configurations, the electrical components illustrated in each of the audio output assemblies150inFIG. 10, such as the speaker driver assembly106, transceiver115, memory unit108and battery109, may instead be disposed in the interconnection assembly120. In this configuration, one or more of the electrical components may be coupled to the speakers111found in each of the two or more audio output assemblies150by use of the components in the wiring harness220.

The transceiver115is adapted to receive audio signals from an audio source195through a wireless communication link196, and thus can be used to generate an acoustic output by use of a speaker111without being physically connected to the audio source195. The audio source195may be any electronic device capable of transmitting an audio signal by wireless communication. The audio source195may be a video game console, a personal computer, a tablet computer, a laptop computer, a digital music player, a cell phone (e.g., a smart phone), an stereo system, a television, a video player (e.g., a DVD player, a Blu-ray player), a radio, or other similar device. The audio source195may include one or more transceivers configured to establish one or more different types of wireless communication links with the transceiver115, such as a Wi-Fi communication link, a Bluetooth® communication link, Avnera Audio Link (AAL) or near field communication (NFC) link. In some configurations, the audio source195is only required to communicate with a transceiver115in a first audio output assembly150, which then relays the received information to the electrical components in a second audio output assembly150using the one or more of the components in the wiring harness220.

The speaker driver assembly106may include a processing unit (not shown) that is configured to receive signals from the transceiver115and transfer the processed audio data (e.g., audio output information) to the speaker111. In one embodiment, the audio output assembly150is configured to primarily deliver the audio data to a user that is positioned adjacent to a front surface155A of the interface element155. The processing unit may be a hardware unit or combination of hardware units capable of executing software instructions and processing data. For example, the processing unit may be a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a combination of such units, and so forth. The speaker driver assembly106also contains one or more components that are configured to drive the speaker111so that the audio signal received from the transceiver115can be delivered to the user through the speaker111. The speaker driver assembly106may include a memory unit108that is coupled to the processing unit. The memory unit may include any technically feasible type of hardware unit configured to store data, such as a hard disk, a RAM module, a flash memory unit, or a combination of hardware units for storing data. The speaker driver assembly106may also further include a software application (not shown) that is stored within the memory unit108. The software application may include program codes that may be executed by the processing unit to perform various functionalities associated with the audio output assembly150. In one configuration, the software applications are configured to adjust one or more of the activities performed by the audio components based on information received by one or more sensors (e.g., switches) or the transceiver115. The activities may include, but are not limited to, turning on or off the audio component, putting the audio component in a “sleep” mode, adjusting the audio output parameters (e.g., volume, EQ settings, etc.) or other useful activities. The speakers111can include any conventional audio generating device, such as a device that includes a primary magnet (not shown) and a coil (not shown) that are configured to cooperatively drive a membrane (not shown) to generate an audio signal based on a signal sent from the speaker driver assembly106.

FIG. 2Ais a partial exploded view of the interconnection assembly120that includes the device connector122, and an interface electronic assembly250and a central structural element270that are each coupled to portions of the cable assembly110. The interface electronic assembly250may include a printed circuit board253, which includes the control electronics260that are in communication with the connector pins126of the device connector122and the plurality of electrical conductors, or wires222(FIG. 2B), of the wiring harness220. The control electronics260may include an I/O assembly125and various interface and supporting electronic components. Collectively the interface and supporting electronic components include one or more devices that enable the transmission of signals and power received through the device connector122and/or received by one or more of the electrical devices in the component assembly154in the one or more of the audio output assemblies150. In one configuration, the interface and supporting electronic components may include a processor128, a memory unit129and transceiver unit127that are in communication with the I/O assembly125. In this configuration, one or more of the output electrical assemblies107in one or more of the component assemblies154may not contain the same duplicative elements. The transceiver unit127may include one or more wireless transceivers that are configured to establish one or more different types of wireless communication links with transceivers residing within a computing device (e.g., audio source195). Alternately, the transceiver unit127may include one or more wired transceivers that are configured to establish a wired communication links with a transceiver residing within a computing device by use of the pins126in the device connector122. In some embodiments, the I/O assembly125may include various wiring elements and other useful signal transmission devices.

The interconnection assembly120may also include a molded feature280that includes a cable assembly section281and optionally an interface element section282. The molded feature280may include a moldable or castable material that is used to hold the electrical and structural components in the interconnection assembly120in a desired configuration during use. The molded material may include a silicone rubber, epoxy, thermoplastic materials, viscous adhesives or other useful non-conductive structurally supporting material.

The interconnection assembly120may further include a packaging assembly290that is configured to enclose at least portions of the interface electronic assembly250, central structural element270and portion of the cable assembly110. The packaging assembly290may include a top cover291and bottom cover292that are configured to enclose the molded feature280, the structural element270, the printed circuit board253and portions of the device connector122that do not include the pins126. The top cover291and bottom cover292may be formed from a coated metal, plastic or elastomeric material.

Structural Element Configuration Examples

In some embodiments, the audio device assembly100is configured to withstand the forces supplied to various portions of the audio device assembly by a user during operation. In general, the load bearing and/or structural designs disclosed herein can be used to reduce the stresses applied to the various electrical components and electrical connection points (e.g., connection points191and192illustrated inFIG. 10) within the audio device assembly100to avoid premature failure of the device. To facilitate the reduction in stress in the electrical connection points and electrical components, the audio device assembly100includes a central structural element270and one or more output assembly structural elements275(FIGS. 2B and 3B).FIG. 2Bis a partial isometric view of the cable assembly110that illustrates the major load bearing components in the central structural element270and output assembly structural element275. In some embodiments, the central structural element270includes a central load support271(e.g., interface load support) that is configured to engage with the load supporting element(s)230of the cable assembly110, and the output assembly structural element275includes a device load support276that is configured to engage with the opposing end of the load supporting element230. The output assembly structural element275will be discussed in conjunction withFIGS. 3A and 3Bin greater detail below.

When the audio device assembly100is fully assembled, the central structural element270and output assembly structural element275are coupled together via the load supporting element(s)230. In this configuration, when a tensile load is applied to the audio device assembly by a user, the applied loads are taken up by the load supporting element230, central structural element270and output assembly structural element275versus the electrical components found within the audio device assembly100. In one example, when a tensile load is applied by pulling on portions of the cable assembly110that are on opposite sides of the interconnection assembly120(e.g., −X and +X-directions inFIG. 1A), the applied tensile load will be substantially transmitted through the load supporting elements230in the cable assembly110and the central load support271versus the flexible stranded wires222of the wiring harness220and/or printed circuit board253.

In some embodiments, as illustrated inFIG. 2B, the cable assembly110includes two sections (e.g., sections110A and110B) that each extend from the interconnection assembly120to an audio output assembly150. In this configuration, the load supporting elements230in each section are coupled to one side of the central load support271and a portion of the device load support276. At the central load support271region of the audio device assembly100, the load supporting elements230in each section are intertwined with features of the central load support271to distribute any applied force and to connect the ends of the load supporting elements230. In one example, the load supporting elements230in each of the sections of the cable assembly110are wrapped around the support legs272and a support element232of a central leg273of the central load support271. In one embodiment, the ends of each of load supporting elements230in a section are tied together in a knot, clasped together using a clip, bonded together, or joined by any other desirable end joining method that can be used after intertwining the load supporting elements230around the features of the central load support271. In another embodiment, each of the ends of each of the load supporting elements230in a section are each intertwined with a retaining feature (not shown) in the central load support271that is adapted to hold or retain a portion of load supporting elements230by the compression and friction created between the load supporting elements230and the central load support271.

FIG. 2Cis a side cross-sectional view through the center of the interconnection assembly120and central portions of the cable assembly110illustrated inFIG. 2B. One will note that the load supporting elements230are partially obscured inFIG. 2Bby the wires222of the wiring harness220, since, in some embodiments, the load supporting elements230in the cable assembly110are positioned in the same plane (i.e., X-Y plane) as the wires222of the wiring harness220. In one configuration, one or more of the wires222in each section of the cable assembly110are electrically coupled (e.g., soldered, mounted in a connector, etc.) to the printed circuit board253at the connection point192. The wires222within the wiring harness220may also contain a one or more bends226,227that are used in conjunction with the load supporting elements230to reduce or prevent an applied force “F” from being transmitted to the connection point(s)192. The bends226,227may each be formed so that they have a radius of curvature that extends over an angle of between about 15 and about 135 degrees, such as 90 degrees as illustrated inFIG. 2C. As noted above, the transmission of the applied force “F” to the connection points192can lead to immediate or eventual failure of the device. However, by use of one or more of the configurations disclosed herein, the applied force “F” will only tend to straighten the flexible wires222at the bends226,227versus transmit the applied force “F” to the connection point192. Also, by positioning and coupling the ends of the load supporting elements230together so that they have no slack, or excess length, a substantial portion of the applied load will be taken up by the load supporting elements230and central load support271versus taken up by the electrical connection points192.

While not intending to be bound by theory, in some cases the material that is used to form the load supporting elements230is selected so that a significant portion of the applied load is taken up by the load supporting elements230versus the wires222. In some cases, the modulus of elasticity (E) and yield strength (σy) of the load supporting elements230is selected to assure that forces applied during normal operation are substantially taken up by the load supporting elements230versus the wires222. In one example, the tensile modulus of the material in the load supporting elements230is selected to be at least greater than 100,000 psi, or even at least 1,000,000 psi. Therefore, if it is assumed that the strain (∈) in two materials (e.g., wires222material and load supporting elements230material) that are loaded in parallel by a tensile force are equal, then by using Hooke's law (i.e., σ=E·∈), the percentage of the force taken up by each of the materials is proportional to the ratio of the modulus of elasticities of the materials. Therefore, by selecting a material, from which the load supporting elements230is made, that has a desirable modulus of elasticity (E) versus the modulus of elasticity (E) of the wires222, a desired proportional amount of an applied force can be taken-up by the load supporting elements230when a force is applied. It should be noted that this discussion fails to account for the added benefit of providing bends and slack in the wiring harness220components, which will tend to desirably increase the percentage of the load taken-up by the load supporting elements230. In one example, due to the structural configuration and material properties of the load supporting elements230, supports271,276and wires222, the load supporting elements230and supports271,276in each section of the audio device assembly100are adapted to bear or take-up at least 25% of the applied force, or even greater than 75% of the applied force, or even greater than 90% of the applied force.

In some embodiments, the printed circuit board253is mechanically coupled to, or engaged with, the central load support271to prevent significant relative motion between these components. In this case, any load applied to the device connector122, such as when it is inserted into a computer port, will be at least partially supported by the central load support271to minimize the amount of load that is applied to the connection points192. However, in some alternate embodiments, the printed circuit board253may not be mechanically coupled to, or engaged with, the central load support271, and thus may only be positioned adjacent to the central load support271. In this configuration, the printed circuit board253and wires222are at least allowed to “float” or freely move in at least one direction relative to the central load support271. In one configuration, the printed circuit board253and wires222are allowed to freely move in the plus and minus X and Y-directions, so that any bending moment or force generated by the application of an applied force to the cable assembly110will be transmitted to the central load support271via the load supporting elements230, and not to the connection points192. In some configurations, it may also be desirable to allow the printed circuit board253and wires222to also freely move in the plus and minus Z-direction.

FIG. 3Ais a side cross-sectional view of the audio output assembly150, which is coupled to portions of the cable assembly110. The audio output assembly150generally includes the output assembly structural element275, the output electrical assembly107and the body315. As discussed above, the output electrical assembly107includes various electrical components, such as the speaker111that are used to deliver an audio output to a user. Collectively the output electrical assembly107includes one or more electrical devices that enable the processing and transmission of an audio signal received from one or more the components in the output electrical assembly107and/or control electronics260(FIG. 1C) to a user. In some embodiments, the output electrical assembly107may include a printed circuit board353, which includes the control electronics360(FIG. 3B) that is in communication with the plurality of wires222of the wiring harness220through the connection point191. The control electronics360may also include I/O and other supporting electrical components that enable the processing and transmission of signals, and power received from the battery109, so that an audio output can be supplied to the user.

The audio output assembly150may also include a body315and a supporting structure325that is coupled to the device load support276. The supporting structure325can be a sheet metal piece that is used to support the output electrical assembly107components, such as the speaker111and the printed circuit board353, and provide support for the body315. In one configuration, the supporting structure325is attached to and/or supported by the device load support276, and thus in this case the electrical assembly107components are indirectly supported by the device load support276. The body315may include a plurality of walls314,317that are used to enclose at least a portion of the output assembly structural element275and the output electrical assembly107elements. The body315may also mate with the interface element155and cable assembly110to form a fully enclosed audio delivery assembly, such as an earbud. In some embodiments, the body315includes a molded polymer or plastic material that fully encloses the output assembly structural element275and the output electrical assembly107elements. In this configuration, the interface element155may be disposed over a portion of the body315, and engage with a feature formed in the body315so that the interface element155can be retained thereon.

As briefly discussed above, the output assembly structural element275includes the device load support276that is configured to directly and/or indirectly support the various output electrical assembly107elements and engage with a portion of the cable assembly110. The device load support276can be a molded plastic or a machined metal part that includes a load supporting feature305and cable guiding feature304that are adapted to engage with the load supporting elements230and wiring harness220elements, respectively. In this configuration, the load supporting elements230are coupled to the load supporting feature305of the device load support276. At the load supporting feature305, the load supporting elements230are intertwined with features formed in device load support276to distribute any applied force to the audio output assembly150and connect the ends of the load supporting elements230. In one example, the load supporting elements230are wrapped around the groove307and a support element306. In one embodiment, the ends of each of load supporting elements230are tied together in a knot, clasped together using a clip, bonded together, or joined by any other desirable end joining method that can be used after removing any slack and intertwining the load supporting elements230around the load supporting feature305. In another embodiment, each of the ends of each of load supporting elements230are intertwined with the groove307, which is further adapted to hold or retain a portion of load supporting elements230by compression and/or friction created between the load supporting elements230and the groove307.

Referring back toFIG. 3A, the one or more of the wires222are electrically coupled (e.g., soldered) to the printed circuit board353at the connection point191. The wires222within the wiring harness220may also contain one or more bends308,309that are used in conjunction with the load supporting elements230to reduce or prevent an applied force from being transmitted to the connection point191. The bends308,309may each include a radius of curvature that extends over an angle between about 15 and 135 degrees. In this configuration, an applied force will only tend to take up the provided slack, or provided excess length, in the flexible wires222at the bends308,309versus distribute the applied force to the connection point191. Also, by positioning and coupling the load supporting elements230together so that they have no slack, or excess length, a substantial portion of the applied load will be taken up by the load supporting elements230and the device load support276versus the electrical connection points191when a force is applied to the cable assembly110and audio output assembly150.

In some embodiments of the audio device assembly100, the wiring harness220and load supporting elements230in the cable assembly110are also configured to reduce or minimize the force supplied to the connection points191,192(FIG. 10) when a force is applied.FIGS. 4A-4Dare partial isometric cross-sectional views that illustrate various configurations of the wiring harness220and load supporting elements230in a portion of the cable assembly110.FIG. 4Aillustrates a configuration of the cable assembly110in which the wiring harness220includes a plurality of wires222that are arranged in a linear and planar orientation (X-Y plane). In this example, the load supporting elements230are positioned in an aligned relationship with the wires222, and are also substantially positioned within the same plane as the plane as the planar orientation of the plurality of wires222. In this example, the load supporting elements230are also positioned in a substantially parallel relationship with the wires222to allow the load supporting elements230to take up at least a portion of the load applied to the wires222. Also, while the stiffness of the cable assembly in the X-Y plane will be relatively high as compared to the stiffness of the cable assembly110in the Z-direction, this configuration allows the cable assembly110to be easily folded over itself in the X-Z plane to allow for easy storage of the audio device assembly100.

FIG. 4Billustrates a configuration of the cable assembly110in which the wiring harness220includes a bundle of wires222that may include a plurality of smaller stranded wires that are oriented in a straight or twisted manner. In this example, the load supporting elements230are aligned with the central axis of the bundle of wires222. In one example, two or more load supporting elements230are substantially aligned with a plane that also contains the central axis of the bundle of wires222. The stiffness of the cable assembly110in this configuration will tend to be more uniform in the Y and Z directions, but may lead to an unwanted rigidity in cable assembly110in the X-direction that can affect the ability of the load supporting elements230to take up an applied tensile load at the connection points.

FIG. 4Cillustrates a configuration of the cable assembly110in which the wiring harness220includes a bundle of wires222that are distributed in a non-straight or non-parallel orientation relative to the central axis (X-direction) of the cable assembly110. The wires222may also be oriented in a non-straight or non-parallel relationship to the load supporting elements230that extend between the central structural element270and output assembly structural element275. In this example, the load supporting elements230are aligned with the central axis of the cable assembly110(X-direction) that is aligned with a projection of a line, on the X-Y plane, that extends between the connection points of the wires222. In this configuration, the stiffness of the cable assembly110the rigidity of the bundle of wires222in the X, Y and Z-directions will be low, which will allow the load supporting elements230to more easily take up any applied tensile load and allow the cable assembly110to be easily folded up for easy storage of the audio device assembly100.

FIG. 4Dillustrates a configuration of the cable assembly110in which the wiring harness220includes an array of wires222that are distributed in a non-straight orientation relative to each other and to the axis of the cable assembly110. The array of wires222are also oriented in a non-straight or non-parallel orientation relative of the load supporting elements230that extend between the central structural element270and output assembly structural element275. In this example, the load supporting elements230are aligned with the central axis of the cable assembly (X-direction) that is aligned with a projection of a line, on the X-Y plane, that extends between the connection points of the wires222. In this configuration, the stiffness of the cable assembly110the rigidity of the bundle of wires222in the X, Y and Z-directions will be relatively low, which will allow the load supporting elements230to more easily take up any applied tensile load and allow the cable assembly110to be easily folded up for easy storage of the audio device assembly100.

FIG. 4Eillustrates an example of a conventional bundle401of shielded and twisted wires222that can be used in the wiring harnesses220illustrated inFIGS. 4B-4C. The wire bundle401generally include wires222that include a multiple stranded wire222A that has a shield222B that electrically isolates the wires222from each other. The wire bundle may also include an outer shield222C that is positioned to further shield the wires222. The wiring harness220design illustrated inFIG. 4Eis not intended to limit the scope of the disclosure provided herein, since other less complex wire and shielding configurations can be used.

It is believed that conventional wire strain relief designs that typically use a portion of a wire's shielding (e.g., shield222B or222C) to relieve or take up the force(s) applied to a conventional cable in a conventional audio device are ineffective in preventing premature failure of the conventional audio device since it is generally not possible to decouple the applied force taken up by the shielding from the bundled wire(s) due to bonding or friction created between the shielding and the wires. Therefore, since the embodiments of the disclosure provided herein decouple the load bearing elements from the electrical signal carrying components, the forces transmitted to the wiring harness220components can be significantly reduced or eliminated over the conventional audio device design. Also, by routing or arranging the decoupled wires222in the wiring harness220in desired orientations, such as adding bends226,227,308or309, the stresses applied to the connection points in the audio device assembly100can be further reduced. In some embodiments, it may be desirable to utilize the stress reducing features disclosed herein and additionally couple the wire shielding to a portion of the electrical component to which the electrical connection is made.

User Interface Controls

Referring back toFIG. 1A, the audio device assembly100may include an interface assembly140that is used to control the delivery of information to the user through the two or more audio output assemblies150. As noted above, the interface assembly140may contain one or more input assemblies142,144and146that are each adapted to provide the input to the processor when actuated by the user. However, it has been found that simply positioning an electro-mechanical switch or other similar signal generating components on or adjacent to a portion of the body210of the cable assembly110does not provide a desirable tactile response to a user when a switch in the input assembly is actuated by the user. Therefore, a novel input assembly configuration is described herein that will provide a reliable, electrically isolated and improved tactile response to the user, when user input is provided to the input assembly140.

FIG. 5is a side cross-sectional view of a representative input assembly, such as input assembly142, which is disposed within a central portion of one of the sections of the cable assembly110. The input assembly142includes an input receiving feature141A that is adapted to receive the input from the user, such as by depressing a portion of the input receiving feature to cause an electro-mechanical switch508disposed therein to be actuated. The electro-mechanical switch508is coupled to one or more components in the wiring harness220to provide a signal to the electrical components positioned in the audio output assemblies150and/or interconnection assembly120. In some embodiments, the input assembly142includes in input region504and a connection region514that are isolated from each other by a supporting element510and a gasket509.

The input region504is generally defined by the sealed region507that is defined by an inner surface505A of a domed feature503formed in the flexible wall505of the body210, a surface510A of the supporting element510and the gasket509. The domed feature503may have any desirable shape or configuration, and thus need not be hemispherically shaped as illustrated inFIGS. 1B and 5. In some embodiments, the supporting element510is printed circuit board that contains no through holes or features that allow a fluid to pass between the input region504and the connection region514. The gasket509may be a polymeric material and/or adhesive layer that is adapted to form a seal between the surface510A of the supporting element510and the inner surface505A of the flexible wall505to prevent a fluid from passing between the input region504and the connection region514. In this example, the gasket509may include a continuous polymeric layer and/or adhesive layer that is disposed around the domed feature503. It is believed that by providing user input by deforming a part of the domed feature503within the flexible wall505against the switch508that is disposed in the region507, an improved tactile response is provided to a user. In some configurations, a gap507A is formed between the switch508and the inner surface505A of the flexible wall505. In some cases, a plate506may be positioned so that the deformed flexible wall505does not contact the switch508when a force is applied by the user during the action of providing input to the input assembly142, so that the applied force does not damage the material in the flexible wall505. The plate506may include a thin plastic material, such as PET.

The connection region514generally includes a space512that is defined by the inner surface522A of the supporting wall522of the body210, a surface510B of the supporting element510and the gasket509. The connection region514generally includes a portion the wiring harnesses220that is electrically connected to switch508through one or more connection points (not shown) on the supporting element510. The connection points may be isolated from each other by a dielectric element511that is disposed between the wiring harnesses220and the supporting element510. To provide support to the supporting wall522a plastic backing material521may be used to bear some of the load supplied by the user to the input assembly142and provide electrical isolation for the components in the wiring harnesses220.

As briefly discussed above, in some configurations of the audio device assembly100the body210of the cable assembly110are formed by use of a single step or multiple step molding process. In this configuration, the walls505and522of the body210may be formed from a moldable elastomeric material, such as a 10 to 90 durometer (Shore A) silicone material.

In some cases, the cable assembly110formation process may include the following molding process sequence. First, the flexible wall505is formed by molding an elastomeric material into a desired shape. Then a wiring assembly is positioned on a mounting surface550A of the formed flexible wall505. The wiring assembly may include the wiring harness220, at least one supporting element510and the printed circuit board253, which are separately coupled to the wires222in the wiring harness220. During this step the supporting element510is bonded to the inner surface of the flexible walls505by the gasket509to form the sealed region507. During this step the load supporting elements230are also positioned and aligned relative to the wiring harness220and/or formed flexible wall505. Next, the backing material521is placed over the wiring harness220and the supporting wall522is formed on the flexible wall505, thus enclosing the components disposed on the flexible wall505within the walls505and522.

One example of an audio device formation process, may include forming the flexible wall550that has a mounting surface550A and a domed feature503formed therein. The domed feature503includes an inner surface505A that is adjacent to or a part of the mounting surface550A. Next, at least a portion of a wiring assembly is disposed on or over the mounting surface550A, wherein the wiring assembly includes the wiring harness220, a supporting element510, and the switch508that has a first connection point that is in electrical communication with a first wire within the wiring harness220and a second connection point that is electrical communication with a second wire within the wiring harness220. Next, sealably bonding and/or mounting the supporting element510to the mounting surface550A to form the sealed region507. The load supporting elements230can then be positioned and/or oriented in an aligned relationship with the wires222of the wiring harness220. In one example, at least a portion of the load supporting elements230are aligned in a parallel relationship with the wires222or with length of the wiring harness220(e.g., X-direction inFIG. 4A-4D) if the wires222are oriented in a non-straight configuration (e.g.,FIGS. 4C-4D). Then molding, casting or bonding the supporting wall522to the flexible wall550to enclose the supporting element510, the switch508and at least a portion of the wiring harness220and the load supporting elements230.

The disclosure has been described above with reference to specific embodiments. Various embodiments may be used in alone or in combination. Persons skilled in the art, however, will understand that various modifications and changes may be made thereto without departing from the broader spirit and scope of the disclosure as set forth in the appended claims. The foregoing description and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense.