Device charging system

A charging stand is provided including a body having a first surface, and a bump having a top region and one or more sides. The one or more sides extend between the first surface and the top region. The charging stand further includes one or more base contact pins that are coupled to the body. Each base contact pin has an exposed end disposed at a first distance in a first direction from the first surface. The charging stand further includes a bump contact pin extending from the top region of the bump. The bump contact pin has an exposed end disposed a second distance in the first direction from the first surface, the second distance is greater than the first distance, and the first direction is perpendicular to the first surface.

BACKGROUND

Field

Embodiments of the present disclosure generally relate to a charging system for an electronic device.

Description of the Related Art

Portable electronic devices are often powered by a rechargeable power source, such as a rechargeable battery. There are numerous ways to recharge portable electrical and electronic devices including one of the most common methods of inserting a plug into a charging port of the portable electronic device. While inserting a plug into a charging port of a portable electronic device is not very difficult, the process can still be inconvenient and often requires the user to use two hands to complete the process.

Another method for recharging a portable electronic device is to use a charging stand in which the portable electronic device is placed on the charging stand, so that electrical contacts on the portable electronic device make a connection with electrical contacts on the charging stand in order to recharge the portable electronic device. While using a charging stand can simplify the recharging process for the user, the user still has to align the electrical contacts of the portable electronic device with the electrical contacts of the charging stand. Furthermore, a slight misalignment between the electrical contacts of the portable electronic device and the electrical contacts of the charging stand can prevent recharging from occurring, which can cause the portable electronic device to be uncharged when the user attempts to use the portable electronic device.

Therefore, there is a need for a charging system that overcomes the deficiencies of existing charging systems described above.

SUMMARY

Embodiments of the present disclosure generally relate to a charging system for an electronic device and components of the charging system, such as a charging stand and an electrical connector for connecting an electronic device to the charging stand.

In one embodiment, a charging stand is provided including a body having a first surface, and a bump having a top region and one or more sides. The one or more sides extend between the first surface and the top region. The charging stand further includes one or more base contact pins that are coupled to the body. Each base contact pin has an exposed end disposed at a first distance in a first direction from the first surface. The charging stand further includes a bump contact pin extending from the top region of the bump. The bump contact pin has an exposed end disposed a second distance in the first direction from the first surface, the second distance is greater than the first distance, and the first direction is perpendicular to the first surface.

In another embodiment, an electronic device is provided including a housing enclosing an interior region. The housing includes an opening. The electronic device further includes an onboard power source. The electronic device further includes an electrical connector disposed in the opening. The electrical connector includes a first portion extending outward through the opening. The first portion includes a core; an outer body disposed around the core, the outer body having a base; an inner recess wherein the outer body is disposed around the inner recess; and an electrical contact disposed in the inner recess. The electronic device further includes a second portion extending into the interior region of the housing. The first portion is removably connected to the second portion, and the second portion electrically connects the first portion to the onboard power source.

In another embodiment, an electrical charging system is provided including and electronic device and a charging stand. The electronic device includes a housing enclosing an interior region. The housing includes an opening. The electronic device further includes an onboard power source; and an electrical connector disposed in the opening. The electrical connector includes: a core; an outer body disposed around the core, and the outer body having a base; an inner recess wherein the outer body is disposed around the inner recess; and an electrical contact disposed in the inner recess, wherein the electrical contact is electrically isolated from the outer body. The charging stand includes a body having a first surface; a bump having a top region and one or more sides, wherein the one or more sides extend between the first surface and the top region. The charging stand further includes one or more base contact pins that are coupled to the body, each base contact pin having an exposed end disposed at a first distance in a first direction from the first surface. The charging stand further includes a bump contact pin extending from the top region of the bump. The bump contact pin has an exposed end disposed a second distance in the first direction from the first surface. The second distance is greater than the first direction. The first direction is perpendicular to the first surface. The bump contact pin contacts the electrical contact disposed in the inner recess when the outer body is disposed over the bump.

In another embodiment, an electrical charging system is provided. The electrical charging system includes an electronic device and a charging stand. The electronic device includes a housing enclosing an interior region, the housing including an opening. The electronic device further includes an onboard power source and an electrical connector disposed in the opening. The electrical connector includes a first portion extending outward through the opening. The first portion includes a core; an outer body disposed around the core, the outer body having a base; an inner recess wherein the outer body is disposed around the inner recess; and an electrical contact disposed in the inner recess. The electrical connector further includes a second portion extending into the interior region of the housing, the first portion removably connected to second portion, wherein second portion electrically connects the first portion to the onboard power source. The charging stand includes a body having a first surface; a bump having a top region and one or more sides, the one or more sides extending between the first surface and the top region; one or more base contact pins that are coupled to the body, each base contact pin having an exposed end disposed at a first distance in a first direction from the first surface; a bump contact pin extending from the top region of the bump, wherein the bump contact pin has an exposed end disposed a second distance in the first direction from the first surface, the second distance is greater than the first direction, the first direction is perpendicular to the first surface, and the bump contact pin contacts the electrical contact disposed in the inner recess.

DETAILED DESCRIPTION

Embodiments of the present disclosure generally relate to a charging system for an electronic device. The embodiments disclosed improve the process of charging an electronic device by simplifying the user's experience to recharge the electronic device while providing a mechanically and electrically stable and reliable charging system.

FIG. 1Ais a side cross-sectional view of an electrical charging system100, according to one embodiment. The electrical charging system100includes a charging stand300and an audio speaker101(electronic device) including an electrical connector200.FIG. 1Bis a close-up side cross-sectional view of portions of the charging stand300and the audio speaker101enclosed in dashed box1B ofFIG. 1A, where the electrical connection is made between the charging stand300and the electrical connector200of the audio speaker101, according to one embodiment.FIG. 1Cis a close-up side cross-sectional view of the portions of the charging stand300and the audio speaker101shown inFIG. 1Bafter the audio speaker101has been placed on the charging stand300, according to one embodiment.FIG. 1Dis a perspective view of the charging stand300and the audio speaker101, according to one embodiment. Although an audio speaker101is used as an exemplary electronic device for the embodiments disclosed herein, one skilled in the art would understand that numerous other rechargeable electrical and electronic devices may be designed to incorporate the beneficial features of this disclosure.

The Charging Stand

Referring toFIGS. 1A-1D, the charging stand300is described. The charging stand300can be used to provide electrical power to the audio speaker101through the electrical connector200in order to recharge an onboard power source135(e.g., a battery) of the audio speaker101. The charging stand300can receive external power from an external power source30, such as an electrical outlet. For example, in one embodiment the charging stand300receives an AC voltage from the external power source30and converts the AC voltage to a DC voltage that is provided to the audio speaker101to recharge the onboard power source135of the audio speaker101.

The charging stand300includes a body305having a first surface301and an opposing second surface302. The second surface302can be a flat surface that can be placed on a corresponding external flat surface, such as a floor or a top surface of a table, desk, countertop, or shelf. However, in some embodiments, the second surface302of the charging stand300may also be placed on surfaces that have other orientations, such as a vertical surface (e.g., a wall). For example, in one embodiment the charging stand300can include an additional support (not shown) extending from the first surface301to provide support for the audio speaker101when the charging stand300is mounted on a vertical surface. For example, the additional support (not shown) may be a full or partial sleeve that has an opening that is slightly larger than the external surface of the audio speaker101.

The charging stand300further includes a power supply circuit330. The power supply circuit330can receive external power (e.g., 120 VAC power) from the external power source30. The power supply circuit330can convert the received AC voltage into one or more DC voltages, which can be used to power the electronics of the charging stand300as well as supply power to the audio speaker101. For example, the charging stand300can supply a first voltage V1(e.g., 3 V) to the electronics of the charging stand, and either a second voltage V2(e.g., 5 V) or a third voltage V3(e.g., 12 V) to the audio speaker101. In some embodiments, the third voltage V3is higher than the second voltage V2, and the charging stand300can switch the voltage supplied to the audio speaker101to the higher voltage V3in order to more rapidly recharge the onboard power source135of the audio speaker101.

The electronics of the charging stand300can include a processor370, a memory unit371, one or more transceivers375, one or more sensors380, and a switching device335each of which can be connected to the power supply circuit330. The memory unit371may include one or more software applications372. The processor370may be a hardware unit or combination of hardware units capable of executing software applications and processing data. In some configurations, the processor370includes a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), and/or a combination of such units. The processor370is generally configured to execute the one or more software applications372included within memory unit371.

The memory unit371may be any technically feasible type of hardware unit configured to store data. For example, the memory unit371could be a hard disk, a random access memory (RAM) module, a flash memory unit, or a combination of different hardware units configured to store data. The software application372, which is stored within the memory unit371, includes program code that may be executed by processor370in order to perform various functionalities associated with the charging stand300, such as software for communicating to the audio speaker101and software for controlling the power supplied by the power supply circuit330to the audio speaker101.

The one or more transceivers375may include one or more transceivers configured to establish one or more different types of wireless communication links, such as a Bluetooth, NFC or Wi-Fi type of communication link, with other transceivers residing within other computing devices found within the external region60, such as audio speaker101. However, in some embodiments the one or more transceivers375can also be configured to establish one or more different types of wired communication links.

The switching device335can be used to control the power provided to the audio speaker101. The switching device335can be, for example, a relay or a solid state switch. The switching device335receives two input voltages V2, V3and provides one output voltage Vout to be supplied to the audio speaker101. Furthermore, during some times the switching device335may also electrically disconnect from both input voltages V2, V3, so that no voltage is supplied to the output of the switching device335. For example, in one embodiment the one or more sensors380in the charging stand300may include one or more physical position sensors (not shown), such as a pressure or proximity sensor to determine when the audio speaker101is placed on the charging stand300, and Vout can be maintained at 0 V until the audio speaker101is sensed by the charging stand300. Furthermore, the one or more sensors380may include one or more sensors to determine when the charging stand300is actively charging the audio speaker101. For example, in one embodiment, the one or more sensors380may include one or more current measuring sensors (e.g., a current sensing amplifier or ammeter) to detect the current flowing from the switching device335to the bump contact pin323(described below). Thus, althoughFIG. 1Ashows a single box for the one or more sensors380, the one or more sensors may be disposed at various locations in the charging stand300. Furthermore, in some embodiments, one or more of the one or more sensors380or additional sensors may be placed in the audio speaker101and the audio speaker101can provide the sensor status and/or data to the charging stand300.

The processor370or I/O connected to the processor370can send a signal to the switching device335causing the output voltage Vout to switch between the second voltage V2, the third voltage V3, or no voltage based on execution of the software application372in the memory unit371. In one embodiment, through execution of the software application372, the charging stand300can initially provide 0 V, then provide the second voltage V2when the audio speaker101is physically sensed by one of the one or more sensors, and then after receiving confirmation from the audio speaker101(e.g., confirmation received over a wireless connection) that the audio speaker101is actively recharging or that the current detected by one of the one or more sensors380is within an expected range, the charging stand300can then provide the third voltage V3as the output voltage Vout to more rapidly recharge the power source135in the audio speaker101.

The charging stand300further includes a protruding region, or raised region, that includes a bump310that has a base311, one or more sides312, and a top region313. The one or more sides312extend between the first surface301and the top region313. In some embodiments, the outer surface of the bump310is formed of a dielectric material that electrically isolates the various electrically conductive components disposed within the charging stand300, such as one or more charging related electrical connection points from each other. In one example, the bump310, and outer surface of the charging stand300, is formed from a plastic material, such as ABS, polycarbonate, acrylic, polyethylene or other similar polymer containing material. The bump310extends from the base311at the first surface301to the top region313. In some embodiments, the bump310can have a shape of a cone, a truncated cone, a hemisphere, a truncated hemisphere, a polygon, or a truncated polygon. For example, inFIG. 1B, the one or more sides312of the bump310between the first surface301and the top region313of the bump310form a truncated cone. The one or more electrical connection points in the charging stand300may include one or more base contact pins, such as a first contact pin321and a second contact pin322that are each coupled to the body305, as shown inFIG. 1B. In some embodiments, the one or more base contact pins extend through first surface301and are spaced apart from the base311of the bump310. In other embodiments, the one or more base contact pins are disposed through a portion of the base311of the bump310or partially through the first surface301and partially through the base311of the bump310. The first contact pin321and the second contact pin322each have a corresponding exposed end321A,322A disposed at a first distance341in the Z-direction from the first surface301. The Z-direction can be perpendicular to the first surface301. Furthermore, the exposed ends321A,322A of the one or more base contact pins321,322can be disposed on a plane that is substantially parallel to the first surface301. The one or more base contact pins may each be connected to an electrical ground, such as the electrical ground of the power supply circuit330. In some embodiments, the one or more base contact pins (e.g., contact pins321,322) may extend from a lower portion of the bump310proximate to the first surface301.

The one or more electrical connection points in the charging stand300further includes a bump contact pin, such as the third contact pin323extending from the top region313of the bump310. The third contact pin323has an exposed end323A disposed at a second distance342in the Z-direction from the first surface301. The second distance342is greater than the first distance341. The third contact pin323may be electrically connected to the output voltage Vout of the switching device335. The first contact pin321can be electrically connected to the second contact pin322. The third contact pin323is electrically isolated from the first contact pin321and the second contact pin322. In some embodiments, one or more of the contact pins321-323may each be spring loaded in the Z-direction (FIG. 1A) to ensure sufficient contact is reliably achieved between the pins321-323and their respective mating surfaces formed in the electrical connector200due to positional tolerance stack-up issues. Each of the spring loaded contact pins321-323may be similarly configured as the spring loaded portions (e.g., first portion conductor216and spring216A) of the electrical contact214, which are further described below. In some electrical configurations, the third contact pin323can be used to supply a charging voltage to the audio speaker101relative to the one or more base contact pins, such as the pins321and/or322. One or more of the first contact pin321and the second contact pin322can be used to connect the electrical connector200to the ground of the power supply circuit330for charging of the audio speaker101.

In some embodiments, such as the charging stand400described below, the one or more sides312of the bump310can have a convex surface, such as an embodiment in which the bump310has the shape of a hemisphere or truncated hemisphere. In such embodiments, the convex surface can position the third contact pin323, so that the third contact pin323is not within a direct line of sight with the first contact pin321and the second contact pin322. Positioning the third contact pin323out of the line of sight of the first contact pin321and the second contact pin322can be useful for preventing an inadvertent electrical short from being created between the third contact pin323and one or more of the first contact pin321and the second contact pin322when a foreign conductive object (e.g., a set of keys) is placed on the charging stand300.

The Audio Speaker

Referring toFIG. 1A, the audio speaker101is described. The audio speaker101includes a housing105, a circuit board160, a speaker assembly102, and the electrical connector200, which was introduced above. The audio speaker101can be placed on or against the charging stand300, so that electrical power can be provided by the charging stand300to the electrical connector200to recharge the power source135that is coupled to the electrical connector200.

The housing105of the audio speaker101encloses an interior region107of the audio speaker101separating the interior region107of the housing105from an external region60outside the housing105. The housing105includes an opening106for connecting external electrical power to the audio speaker101. The electrical connector200can be positioned within the opening106to provide the conductive path between the external electrical power provided by the charging stand300and the power source135disposed in the audio speaker101. The electrical connector200can also form part of a seal formed between the opening106and the electrical connector200within the housing105. For example, the electrical connector200can be used to create a water-tight or air-tight seal with the opening106. The housing105can be formed of, for example, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), PC-ABS, nylon, styrene, acrylic, methyl methacrylate ABS or other similar structural material. In some embodiments, the electrical connector200may include one or more elastomeric seals (e.g., a gasket or a seal overmolded onto the electrical connector) to help form the seal between the electrical connector200and a surface of the opening106formed in the housing105.

In some embodiments, the circuit board160can be a printed circuit board (PCB). In some embodiments, the circuit board160includes electronics and/or wiring for handling the signals between the audio speaker101and any external I/O (not shown) attached to the audio speaker101. The circuit board160is also used to transfer signals to and from the speaker assembly102.

In one embodiment, as shown inFIG. 1A, the circuit board160can further include electronics for operating the audio speaker101. For example, the circuit board160can include a processor170, a memory unit171, one or more input/output (I/O) components174, one or more transceivers175, the onboard power source135, and a charging circuit130for charging the onboard power source135. The processor170, the memory unit171, the one or more I/O components174, the one or more transceivers175, and the charging circuit130may each be coupled to the onboard power source135. Furthermore, at least the memory unit171, the one or more I/O components174, and the one or more transceivers175may each be coupled to the processor170.

The memory unit171may include one or more software applications172and stored media data173. Processor170may be a hardware unit or combination of hardware units capable of executing software applications and processing data, which may, for example, including the delivery of audio information from the audio speaker101. In some configurations, the processor170includes a central processing unit (CPU), a digital signal processor (DSP), an application-specific integrated circuit (ASIC), and/or a combination of such units. The processor170is generally configured to execute the one or more software applications172and process the stored media data173, which are each included within memory unit171.

The memory unit171may be any technically feasible type of hardware unit configured to store data. For example, the memory unit171may include any type of non-volatile type memory device, such as a hard disk, a random access memory (RAM) module, a flash memory unit, or a combination of different hardware units configured to store data. The software application172, which is stored within the memory unit171, includes program code that may be executed by processor170in order to perform various functionalities associated with the audio speaker101, such as communicating with the charging stand300and controlling the audio signals sent to the speaker assembly102.

The I/O components174are coupled to processor170and may include components capable of receiving input and/or components capable of providing output. For example, the I/O components174are coupled to the speaker assembly102, which is configured to generate an acoustic output. The one or more transceivers175can be configured to establish one or more different types of wireless communication links, such as a Bluetooth, NFC or Wi-Fi type of communication link, with other transceivers residing within other computing devices found within the external region60, such as the one or more transceivers375within the charging stand300. For example,FIG. 1Ashows that the charging stand300and the audio speaker101can communicate over a wireless communication link50. However, in some embodiments the one or more transceivers175may also include one or more transceivers configured to establish one or more different types of wired communication links with the charging stand300or other devices.

The speaker assembly102can include an active speaker assembly110and a passive speaker assembly120that can both be sealably mounted to the housing105. The active speaker assembly110can be coupled to the circuit board160. For example, the active speaker assembly110can receive audio signals from the I/O components174of the circuit board160. The active speaker assembly110generally includes a sealed diaphragm112, a frame114, a sealed surround116, a voice coil115, a pole piece118, a permanent magnet117, a dust cover113and a spider119. During operation, the I/O components174deliver a signal to the active speaker assembly110, which causes the voice coil115to move the diaphragm112relative to the enclosure housing105(i.e., +/−X-direction) due to the varying magnetic field generated by the voice coil115reacting against the magnetic field provided by the permanent magnet117. In some embodiments, the sealed diaphragm112includes a diaphragm layer and a coating layer that are configured to sealably enclose a portion of the interior region107. The diaphragm layer may include a paper, polymer, metal or other material that is light weight and has a desired stiffness for the size of the audio speaker101. The coating layer can includes a material (e.g., polymer) that is used to coat a surface of the sealed diaphragm112to assure that air or a liquid will not pass through the sealed diaphragm112.

The passive speaker assembly120can be, for example, a passive radiator. Typically, the passive speaker assembly120is similar to the active speaker assembly110but does not include the active components, such as the voice coil, permanent magnet, and pole piece. The passive speaker assembly120generally includes a sealed diaphragm122, a frame124, a sealed surround126, a dust cover123and a spider129. The passive speaker assembly120moves in response to the changes in air pressure of the interior region107caused by the movements of the active speaker assembly110.

The sound quality produced by the speaker assembly102can be directly related to how well the acoustic volume of the housing105is sealed. For example, if the housing105is poorly sealed, then the passive speaker assembly120will be prevented from producing a desired sound quality. Furthermore, the seals used in the audio speaker101can also be used to prevent the ingress of dirt and water into the interior region107of the housing105. Dirt and water can damage the electronics of the audio speaker101as well as reduce the quality of sound produced by the audio speaker101. Preventing the ingress of dirt and water is also important to meet the use requirements of active portable lifestyles of today, such as when the audio speaker101is being used outdoors and is potentially exposed to situations where the audio speaker101may become submerged in water or drenched during water related activities or rain. Thus, a compromised seal at any of the openings through the housing105, such as at the locations of the speaker assembly102or the electrical connector200can lead to reduced sound quality or damage to the audio speaker101. In this disclosure, the electrical connector200includes a number of features described in detail below to reduce the likelihood of reduced sound quality or damage to the audio speaker101that could be caused by a compromised seal at the opening106of the housing105.

The onboard power source135may be a battery, super capacitor, or other similar energy storage device that is rechargeable. The charging circuit130can include electronic components to supply a controlled voltage and current to the power source135for recharging. For example, the charging circuit130can include electronic components to supply a constant current and/or constant voltage to the power source135during different periods of recharging the power source135. In some embodiments, one or more components of the charging circuit130may also be located within the charging stand300. The charging circuit130receives electrical power from the charging stand300through the electrical connector200.

The Electrical Connector

Referring toFIGS. 1A-1D, the electrical connector200is described. The electrical connector200can include an interface portion210(e.g., first portion) and a connection portion220(e.g., second portion) (FIGS. 1B-1C). The interface portion210can extend outward through the opening106of the housing105. The interface portion210includes a core211. The core211is a central portion of the interface portion210. For example, the core211can include threads or another mechanical feature for coupling the interface portion210to the connection portion220. The interface portion further includes an outer body212disposed around the core211. The outer body212can be configured to fit over and/or surround the bump310when the audio speaker101is being charged on the charging stand300. The interface portion210further includes an optional frame215coupled to and disposed around the outer body212. In some embodiments, the frame215can assist a user in coupling the interface portion210to the connecting portion220. In some embodiments, the interface portion210and the connection portion220are largely fabricated from a metallic material, such as stainless steel, nickel or a nickel plated metal (e.g., nickel plated aluminum).

As shown inFIG. 1B, the outer body212includes a base218. As shown inFIG. 1C, the base218can be placed on the first and second contact pins321,322when the audio speaker101is placed on the charging stand300. Thus, the base218, which is electrically isolated from an electrical contact214within the core211, can form part of the ground connection between the electrical connector200and the charging stand300. In some embodiments, such as the embodiment shown inFIG. 1D, the base218can form a ring, such as a circular ring that fully surrounds the bump310when it is placed on the charging stand300. Using the base218that fully surrounds the bump310alleviates the need for the user to align the audio speaker101with the charging stand300in angular direction about the Z-axis. Also, because the base218completely surrounds the bump310, the likelihood of the electrical connector200failing to make electrical contact with at least one the contact pins321,322is significantly reduced.FIG. 1Cshows an example of the electrical contact between the base218and the contact pins321,322. Thus, the risk a user attempting to charge the audio speaker101, but failing to charge the audio speaker101due to a slight misalignment between the electrical connector200and the charging stand300is also significantly reduced. Furthermore, the base218being an integral part of the interface portion210has a robust structure that is unlikely to suffer significant wear and tear over the lifetime of the charging system100.

The interface portion210further includes an inner recess213. The outer body212is disposed around the inner recess213. The inner recess213forms a cavity that can be placed over the bump310when the audio speaker101is placed on the charging stand300allowing electrical contact to be made between an electrical contact214of the interface portion210of the electrical connector200and the third contact pin323, and between the base218of the interface portion210and one or more of the first and second contact pins321,322. The shape of the inner recess213can substantially match the exterior shape of the bump310. For example, inFIG. 1Bthe bump310and the inner recess213each have a shape primarily of a truncated cone. In some configurations, the matching truncated cone portions of the inner recess213and the bump310may further include a cylindrical portion disposed near the top of the bump310and a cylindrical portion of the inner recess213, which is formed near an electrical contact214described below.

The interface portion210includes an electrical contact214disposed in the inner recess213, a first portion conductor216, and a first portion insulation217. The electrical contact214or outer surface of the electrical contact214can be formed of silver, gold, copper, platinum, or an alloy thereof. As shown inFIG. 1C, the electrical contact214is positioned to contact the third contact pin323when the audio speaker101is placed on the charging stand300. The electrical contact214is connected to the first portion conductor216. The first portion insulation217is disposed around the electrical contact214and the first portion conductor216to electrically isolate the electrical contact214and the first portion conductor216from the core211, the outer body212, and the frame215. Conversely, the core211, the outer body212, and the frame215are each electrically connected to each other. Furthermore, in some embodiments, the core211and the outer body212can be formed of the same block of material.

In some embodiments, an injection molding or over overmolding process can be used to mold the first portion insulation217around the first portion conductor216creating a water-tight and air-tight seal in the space between the first portion conductor216and the core211as well as the space between electrical contact214and the outer body212. Using an injection molding or overmolding process can help maintain the integrity of the seal formed by the first portion insulation217relative to a press-fit insulation portion. For example, an injection molded or overmolded first portion insulation217can maintain a seal better than a corresponding press-fit insulation portion after repeated exposure to mechanical stresses and other stresses, such as changes in temperature. Thus, the injection molded or overmolded first portion insulation217can help maintain desired sound quality and prevent damage to the audio speaker101due to ingress of moisture, dirt, or other contaminants through the opening106of the housing105. Furthermore, an injection molded or overmolded first portion insulation217can help prevent the electrical contact214from disconnecting from the first portion conductor216, such as a disconnection caused by repeated contact with the bump contact pin323or exposure to another external stress.

In some embodiments, the optional frame215can have a shape of a partial ring or full ring around the outer body212. In some embodiments, the frame215can surround at least half of the outer body212. For example,FIG. 1Dshows the frame215having a shape of a D-shaped ring. The frame215can be rotatable about the Y-axis and can be used to help a user connect and disconnect the interface portion210to and from the connection portion220.

The interface portion210is removably connected to the connection portion220at a connection point209. The connection point209between the interface portion210and the connection portion220creates a mechanical and electrical connection between the two portions210,220. In the embodiment shown inFIG. 1B, the connection point209is a threaded connection in which the interface portion210has external threads and the connection portion220has internal threads to receive the external threads of the interface portion210. In one configuration, the threads on one or more of the interface portion210and the connection portion220can be tapered to help seal the interface portion210to the connection portion220at the connection point209. In another configuration, the threads of interface portion210and the connection portion220can be a standard straight thread (e.g., ¼-20 UNC or ⅜-16 UNC thread) allowing for the audio speaker to be connected to other types of equipment, such as equipment other than the interface portion210and/or charging stand300. For example, in one embodiment the interface portion210can be removed and the connection portion220can then be secured to external threads of a speaker tripod or other speaker support for an improved audio experience for the user. Although a threaded connection is shown, other types of connections may also be used to form the connection point209between the interface portion210and the connection portion220.

The connection portion220of the electrical connector200extends into the interior region107of the housing105. InFIG. 1B, the parts of the electrical connector200included in the connection portion220are shown filled with a hatched pattern unless otherwise specified to distinguish these parts from the parts included in the interface portion210. The connection portion220can include a core221and a flange222disposed around the core221. In some embodiments, the flange222can contact the housing105to form part of the seal between the interior region107of the housing105and the external region60. In other embodiments, a separate sealing material (e.g., a gasket or an elastomeric material overmolded onto the flange222) may be placed between the flange222and the housing105. In some embodiments, portions of the housing105can surround relieved portions221A of the core221to help form a reliable seal and also support the connection portion220when the threaded portion of the interface portion210is inserted within the connection point209. In either configuration, the core221, and/or flange222, and mating portion of the housing105form a seal that prevents gases or liquids from moving between the external region60and interior region107. Furthermore, in some embodiments the flange222may include a notch (not shown), and the audio speaker101may include a corresponding tab or other projection (e.g., a tab extending from the housing105) to be positioned in the notch to prevent any rotation of the flange222relative to the housing105about the Z-axis. Rotation of the flange222relative to the housing105could disrupt the seal formed between the outside surface of the electrical connector200and the housing105.

The connection portion220further includes a second portion conductor226, and a second portion insulation227. InFIGS. 1B-1C, the second portion insulation227is hatched so that the second portion insulation227can be easily distinguished from the second portion conductor226. The second portion conductor226can be electrically connected to the first portion conductor216when the external threads of the interface portion210are threaded into the internal threads of the connection portion220at the connection point209. In some embodiments, the interface portion210can include a pin and the connection portion220can include an electrical contact, which may be similar to the electrical contact214described above, to ensure sufficient electrical connection between the first portion conductor216and the second portion conductor226when the threaded connection is made. In some embodiments, the first portion conductor216is spring loaded by a spring216A in the Z-direction (FIG. 1B) to ensure sufficient contact is reliably achieved between the first portion conductor216and the second portion conductor226due to positional tolerance stack-up issues created between these components.

The second portion insulation227is disposed around the second portion conductor226to electrically isolate the second portion conductor226from the core221and the flange222. Conversely, the core221and the flange222are each electrically connected to each other, and/or are formed from the same block of material. Furthermore, when the threaded connection is made at the connection point209, the core221can be electrically connected to the core211and/or to the outer body212of the interface portion210. In some embodiments, an injection molding over overmolding process can be used to mold the second portion insulation227around the second portion conductor226creating a water-tight and air-tight seal in the space between the second portion conductor226and the core221as well as the space between the second portion conductor226and the flange222. Thus, the second portion conductor226, second portion insulation227and core221form a sealed assembly that prevents gases or liquids from moving through a central region of the connection portion220between the external region60and interior region107.

The second portion conductor226can be electrically connected to a positive terminal228A (FIG. 1B) of the charging circuit130while the core221or the flange222can be electrically connected to the ground terminal228B (FIG. 1B) of the charging circuit130. Thus, when the threaded connection is made at the connection point209, and the electrical connector200is placed over the bump310so that the electrical contact214contacts the third contact pin323and the base218contacts one or more of the first and second contact pins321,322, then power can flow from the power supply circuit330through the respective contact pins321-323, through the electrical connector200, and through the charging circuit130to charge the power source135in the audio speaker101. In some embodiments, the charging circuit130is formed on a surface of the circuit board160, as schematically illustrated inFIG. 1B.

FIG. 1Eis a side cross-sectional view of portions of the charging stand300and the audio speaker101after the audio speaker101has been placed on the charging stand300, according to one embodiment. InFIG. 1E, the electrical connector200of the audio speaker101is not aligned properly with the bump310of the charging stand300. Despite being improperly aligned, the outer body212of the electrical connector200is unable to contact both the first contact pin321and the third contact pin323, which prevents a short circuit between the third contact pin323and the first contact pin321. In this embodiment, the electrical connector200is disposed in a recess104formed in the housing105. In this configuration, the structural shape of the recess104and position of the electrical connector200on the housing105causes an outer portion103of the recess104portion of the housing105to contact the first surface301of the body305of the charging stand300in an effort to physically prevent portions of the outer body212of the electrical connector200from contacting one of the base contact pins (e.g. first contact pin321inFIG. 1E) and the third contact pin323simultaneously. The recess104and the outer portion103can be symmetrical about the Z-axis, so that the structural shape of the recess104and the outer portion103can also prevent the outer body212of the electrical connector200from contacting the second contact pin322and the third contact pin323simultaneously. Use of the recess104and the outer portion103is one example of a design for how the outer body212can be prevented from short circuiting the first or second contact pins321,322and the third contact pin323. However, one skilled in the art could make modifications to the disclosure herein to develop other ways to prevent the outer body212from contacting the first or second contact pins321,322and the third contact pin323simultaneously.

FIG. 1Fis a side cross-sectional view of portions of the charging stand300and an external object25, according to one embodiment. By placing the first contact pin321and the second contact pin322at a different position in the Z-direction and X and/or Y-directions relative to the third contact pin323, a flat external object25can be prevented from causing an electrical short by preventing the contact between the external object25and the third contact pin323and the one or more base contact pins (e.g., first contact pin321and the second contact pin322) simultaneously. The bump310has the shape of a truncated cone except for a top portion318proximate the top of the bump310. The top portion318can have a shape of a cylinder, where the side312of the bump extends in a substantially vertical direction (i.e., the Z-direction inFIG. 1F). Excluding the top portion318, the side312of the bump310can extend at an angle312A relative to the first surface301from about 25° to about 55° relative to the Z-axis, such as from about 35° to about 45° relative to the Z-axis.

FIG. 2is a side cross-sectional view of portions of a charging stand400, according to another embodiment. Charging stand400is similar to the charging stand300described above except that the bump310is replaced with a differently shaped bump410. The bump410has a convex surface416. The convex surface416can prevent any portion of the third contact pin323from being within a direct line of sight of any portion of the first contact pin321. Line431is a closest line of sight extending from the third contact pin323towards the first contact pin321to illustrate that the third contact pin323is not within a line of sight of the first contact pin321. Similarly line432is a closest line of sight extending from the third contact pin323towards the second contact pin322to illustrate that the third contact pin323is not within a line of sight of the second contact pin322. Thus, a flat surface of an external object cannot touch the third contact pin323and one or more of the first contact pin321and the second contact pin322simultaneously. Thus, the bump410having the convex surface416can further reduce the likelihood of an electrical short caused by an external object contacting both the third contact pin323and one or more of the first contact pin321and the second contact pin322simultaneously.

FIG. 3is a process flow diagram of a method400of charging the audio speaker101with the charging stand300, according to the embodiment ofFIG. 1A. Although the method400is described in reference to the blocks shown onFIG. 3, persons skilled in the art would understand that the method steps in other suitably adapted orders is also within the scope of the embodiments disclosed.

At block402, the audio speaker101is positioned on the charging stand300. For example, referring toFIG. 1C, the audio speaker101can be positioned so that the electrical connector200is placed over the bump310enabling the bump contact pin323to make electrical contact with the electrical contact214and also enabling the base218to make electrical contact with the base contact pins321,322.

At block404, the one or more sensors380of the charging stand300can detect the presence of the audio speaker101. For example, the one or more sensors380in the charging stand300may include one or more physical position sensors (not shown), such as a pressure or proximity sensor to determine when the audio speaker101is appropriately placed on the charging stand300.

At block406, communication can optionally be established between the audio speaker101and the charging stand300. For example, in one embodiment, the audio speaker101can optionally be paired (e.g., a Bluetooth pairing) with the charging stand300to enable wireless communication between the audio speaker101and the charging stand300.

At block408, the charging stand300can determine that an electrical circuit appropriate for charging the audio speaker101has been created or formed between the bump contact pin323and the base contact pins321,322. For example, in one embodiment, the one or more sensors380can include a sensor to determine that an appropriate electrical circuit exists between the bump contact pin323and the base contact pins321,322by detecting that current can flow through the formed circuit and/or by measuring the impedance between the output of the switching device335and ground of the power supply circuit330. In cases where the appropriate circuit is not formed, the charging stand300may send a command prompt to the audio speaker101, via the wireless communication link, that will then cause the processor in the audio speaker101to generate and cause the delivery of audio information to a user (e.g., tone(s)) to let the user know that the charging process cannot start due to the appropriate circuit not being formed.

At block410, after the charging stand300confirms than an appropriate electrical circuit exists between the bump contact pin323and the base contact pins321,322, the charging stand300can begin charging the audio speaker101with the second voltage V2(e.g., 5 V) as the output voltage Vout from the switching device335. In some embodiments, the charging stand300can wait to receive a confirmation (e.g., a wireless confirmation) from the audio speaker101that the audio speaker101is ready to receive charging before supplying the second voltage V2to charge the audio speaker101.

At block412, the charging stand300can use one of the one or more sensors380to measure the current being supplied to the audio speaker101. The processor can then determine if the measured current is greater and/or less than one or more desired values stored in the memory of the charging stand300. The process of determining that the current is greater than a certain value or is within an expected range can be used as an indicator that the audio speaker101is successfully being charged. In cases where the current is not within a desired range, or is above or below a desired first value stored in memory, the charging stand300may halt the charging process or remain at the second voltage V2until the charging process has been completed or until the current reaches a desire value.

At block414, after determining that the current is greater than a certain value or is within an expected range for a predetermined amount of time the charging stand300can provide the third voltage V3as the output voltage Vout from the switching device335to more rapidly recharge the power source135in the audio speaker101. In some embodiments, the charging stand300may confirm that the audio speaker101is capable of receiving a higher voltage for charging. For example, in one embodiment, the audio speaker101may send a wireless message to the charging stand to confirm that the audio speaker101can receive the higher voltage charging. In cases where the measured current is within a desired range within block414, or is above or below a second value stored in memory, the charging stand300may continue to apply the third voltage V3. In cases where the measured current is not within a desired range within block414, or is above or below a third value stored in memory, the charging stand300may continue on to block416or revert back to block412.

At block416, the charging stand300can determine when the audio speaker101is fully charged or removed from the charging stand. For example, in one embodiment, the audio speaker101can send a wireless message to the charging stand300to end the charging process when the audio speaker determines that the power source135is fully charged. In another embodiment, the charging stand300can determine that the audio speaker101is fully charged when the current being provided to the audio speaker101, as sensed by one of the one or more sensors380, drops below a predetermined level, such as the third value or a fourth value stored in memory.

At block418, the charging stand300can reduce the output voltage Vout back to 0 V and the process of charging the audio speaker101can be halted. In some embodiments, the charging stand300may send a command prompt to the audio speaker101, via the wireless communication link, that will then cause the audio speaker101to deliver audio information to a user to let the user know that the charging process has ended. In one example, the audio information delivered may include the delivery of one or more audible tones through the speaker, wherein the one or more tones are generated from information stored in the memory of the audio speaker101.