Earphone with solid body

In an embodiment, an earphone having a solid earphone body is provided. A first mounting recess is formed in a first end of the earphone body. A first acoustic driver is disposed in the first mounting recess. At least a first sound bore is formed in the solid earphone body. The at least a first sound bore fluidly communicates with the first mounting recess and a first exit port formed at a second end of the earphone body. The second end of the earphone body is configured to be placed in an ear canal of a user. The earphone can be fabricated by a method that includes defining negative spaces for the first acoustic driver and the at least a first sound bore in a virtual model of the earphone body.

FIELD

The present disclosure relates to earphones and methods of their design. Particular embodiments provide solid earphone bodies that include negative spaces for acoustic drivers, sound modifying or transmitting components, or both.

BACKGROUND

The design and fabrication of electronic devices to be used in small operating environments can be challenging. For example, earphones are required to include drivers and various sound channels in a very small space—particularly for in-ear earphones. Tradeoffs often arise between considerations such as sound quality, durability, and ease of manufacturing. Accordingly, room for improvement exists.

SUMMARY

Described herein are embodiments of an earphone having a solid body, as well as embodiments of methods for designing and fabricating such earphones.

In some embodiments, a disclosed earphone includes a solid body. A first mounting recess is formed in a first end of the earphone body. A first acoustic driver is disposed within the first mounting recess. At least one sound bore is formed in the solid earphone body and fluidly communicates with the first mounting recess and a first exit port formed at a second end of the earphone body. The second end of the earphone body is configured to be placed in an ear canal of a user.

In a particular embodiment, the solid earphone body can include additional features, such as a sound chamber formed in the solid earphone body and in fluid communication with the at least a first sound bore.

In another embodiment, a second mounting recess is formed in the first end of the earphone body. A second acoustic driver is disposed in the second mounting recess. At least a second sound bore is formed in the earphone body and fluidly communicates with the second mounting recess and a second exit port formed at the second end of the earphone body. In another embodiment, the at least a second sound bore communicates with the second mounting recess and the at least a first sound bore. A vent can be formed in the earphone body. When a cap is included, the vent can communicate with a vent formed in the cap.

Embodiments of a disclosed earphone can be tubeless. For example, in such embodiments, tubes do not form part of a connection pathway between the first mounting recess and the first exit port.

In further embodiments, a disclosed earphone includes a solid earphone body. A mounting recess is formed in a first end of the earphone body. A first acoustic driver is disposed in the mounting recess. A cap covers the mounting recess.

In a disclosed method of manufacturing an earphone, a virtual model of at least one physical earphone component and a virtual model of at least a first sound bore are created. A first virtual model of an earphone body is created. The virtual model of the at least one physical earphone component and the virtual model of the at least a first sound bore are positioned at least partially within the virtual model of the earphone body. One or more negative spaces are defined in the virtual model of the earphone body, corresponding to the virtual model of the at least one physical earphone component and the virtual model of the at least a first sound bore. The defining creates a second virtual model of the earphone body.

In an embodiment, the method includes creating a solid earphone body using the second virtual model of the earphone body, such as by injection molding or 3D printing. The at least one physical earphone component can be positioned within a recess in the solid earphone body, where the recess corresponds to a portion of the negative space of the second virtual model of the earphone body corresponding to at least a portion of the virtual model of the at least a first earphone component. A cap can be placed over the recess.

The manufacturing method, in an embodiment, can include obtaining a representation of a user's ear. The representation can be converted to at least a portion of the first virtual model of the earphone body.

In another embodiment, the virtual model of the at least one physical earphone component can be stored. The stored virtual model of the at least one physical earphone component can be made available for selection during the design of another earphone body.

DETAILED DESCRIPTION

Overview

The design and fabrication of electronic devices to be used in small operating environments can be challenging. For example, earphones are required to include drivers and various sound channels in a very small space—particularly for in-ear earphones. Tradeoffs often arise between considerations such as sound quality, durability, and ease of manufacturing. Accordingly, room for improvement exists.

For example, earphones typically will include one or more drivers and one more channels for transmitting sound from the drivers to a user's ear. The channels are often in the form of fixed or flexible plastic tubes. Additional components that can be included in an earphone are electrical connections, such as to deliver power/audio signals to the drivers. Typically, all of these components are included in a shell or housing. In some cases, the housing can be a standardized form factor, and a portion of the earphone to be inserted into the user's ear (e.g., a “spout”) can include a rubber tip to comfortably secure the earphone in the user's ear. In other cases, the housing can, at least in part, be custom molded to fit the ear of a particular user.

Housings are commonly provided having a plurality of separable portions, such as a portion of the housing that includes a tip to be inserted into the user's ear, and portion of the housing that will face outwardly, and be maintained within structures of the outer ear such as the tragus, antitragus, concha, and crus helix. During manufacturing, the drivers and other electronic components are typically secured in a cavity formed in a first portion of the housing. Clips or other securing means can be included in the first housing portion in order to secure the drivers or other components in place. A second housing portion can be secured over the open side of the first housing portion, such as using a snap or friction fit, including by inserting a gasket or other sealing means between coapting ends of the first and second housing portions. Other means of securing or sealing the two housing portions can be used, such as using adhesives or by fusing (e.g., thermally) a seam formed at the juncture of the housing portions.

While above-described methods of assembling earphones can be acceptable in some cases, such as to mass produce large quantities of standard earphones having acceptable sound quality, they can be problematic. For example, when one or more portions of an earphone housing include relatively larger cavities, the acoustic properties of the earphones can suffer. In addition, clips or other means used to secure drivers and other components within the housing can be prone to breakage, or to having the components slip outside of the clips, particularly if they are adjacent to open space within the cavity. Thus, earphones made using traditional techniques can suffer from durability issues, particularly if dropped or otherwise subjected to impact forces.

Similar issues can arise when tubes are used in an earphone. In a particular design, a portion of the housing may have interior passages that lead between an interior portion of the housing and an exterior portion of the housing. For example, a portion of the housing intended to be inserted into a user's ear canal can have one or more passages that extend from the inside of the housing to the exterior of the housing in order to transmit sound to the user. Tubes, including flexible tubes, may be used to couple the passage to a physical component, such as a driver, located in the cavity of the housing. These tubes can become disconnected or dislodged, which can affect sound quality, and more typically results in the earphones being unusable.

The components, and manufacturing techniques, typically used for earphones also can limit the sound reproduction properties of the earphones. For example, as mentioned, a large cavity may have undesirable acoustic properties, and tubes may be used to more precisely transmit sound from sound-generating components of the device to the user's ear. However, there are typically a limited number of properties of the tubes than can be modified in order to adjust their acoustic properties. Tube properties such as the diameter of the tube, the shape of the ends of the tube (used to attach to other structures of the earphones), and the material from which the tube is constructed may be modified to an extent. However, even potential changes to these properties can be constrained by limitations in the volume of the cavity, space taken by other components, and the length of the tube, and any curvature, needed to couple the different components. Moreover, the length of the tube, apart from perhaps one or both of the ends, typically has a substantially constant diameter, and the ability to bend or shape the tube can be limited.

The present disclosure provides an earphone that can address some or all of the problems in prior earphone designs, as well as methods of designing and manufacturing such earphones. One disclosed technology provides an earphone with a solid body that includes one or more negative spaces, or receptacles, for receiving hardware components of the earphone, such as a driver. A negative space for a hardware component can be configured to securely retain the hardware component within an assembled earphone. In some cases, the hardware component can be secured without the need for additional securing elements, such as adhesives or clips.

For example, if a hardware component has a plurality of sides, or edges (e.g., for a circle, edges can be considered points connected by a diameter of the circle), the negative space can be configured to receive at least one less than the plurality of sides, with material of the solid body contacting the received sides. At least one side of a hardware component is received by a negative space, and is contacted by surrounding material of the solid body. In further cases, at least two sides of component are received by the negative space, and is contacted by surrounding material of the solid body. Generally, a negative space for receiving a hardware component has an exterior end and an interior end, where the exterior end defines an opening for receiving the hardware component.

Another disclosed technology provides an earphone having a solid body defining negative spaces in the form of tunnels or through holes that connect earphone hardware components to an exterior surface of the earphone, such as for transmitting sound to a user. These types of tunnels or through holes are generally referred to herein as sound bores. The tunnels can also be used to interconnect hardware components, or acoustic features of the earphone, including features defined by negative spaces within a solid body of the earphone.

The tunnels can include (either integrally or being coupled to) one or more sound chambers, in the form of larger diameter negative spaces that are formed at intermediate sections of the tunnels, or at an end of a tunnel. Tunnels can also be present in the form of vents, such as vents used to adjust pressure in the earphone (including when worn by a user), or to adjust acoustic properties of the earphone.

As used herein, tunnels, including sound bores and vents, and sound chambers, are negative spaces with a solid earphone body. Tunnels are distinguished from tubes, where tubes consistent of a lumen defined by tube surface, where the outer surface of the tube is not surrounded by solid material. In particular examples, the disclosed tunnels extend through the body of the earphone and are surrounded by the solid portion of the earphone body for their entire length. However, in some cases, tubes can be inserted through all or a portion of the disclosed tunnels.

In a particular implementation, a disclosed earphone includes a generally solid body, defining negative spaces for hardware components, tunnels, or both, and forms a unitary surface. That is, the solid body is free of seams and is constructed as an integral, unitary mass of material. In particular examples, a solid earphone body, when drivers and other physical components have been installed into negative spaces formed in the earphone body, includes less than about 25% of unfilled space (e.g., non-solid material) compared with the total volume of the earphone body, such as less than about 20%, less than about 15%, less than about 10%, or less than about 5% of unfilled space. In particular examples, “about” means within 10% of the recited number. In further examples, an earphone body includes less than 25% of unfilled space, such as less than 20%, less than 15%, less than 10%, or less than 5%.

In further examples, a solid earphone body, when drivers and other physical components have been installed into negative spaces formed in the earphone body, is substantially free of unfilled space other than space associated with tuning elements (e.g., sound bores, vents, and sound chambers, or other negative-space features, where tuning elements more generally can include features such as acoustic damper). Substantially free of unfilled space, in this context, can mean less than about 15% of unfilled space compared with the total volume of the earphone body, such as less than about 12%, less than about 10%, less than about 8%, less than about 5%, or less than about 2% of unfilled space. In particular examples, “about” means within 10% of the recited number. In further examples, an earphone body includes less than 15%, 12%, 10%, 8%, 5%, or 2% of unfilled space.

The solid body can define an opening that provides access to negative spaces formed in the solid body. After hardware components are inserted into the earphone, a cap or plug can be placed over the opening. In particular implementations, compared with the overall surface area of the earphone body, the opening is less than about 25% of the total surface area, such as less than about 20%, less than about 15%, less than about 10%, or less than about 5% of the total surface area. In particular examples, “about” means within 10% of the recited number. In further examples, the opening is less than 25% of the total surface area of the earphone body, such as less than 20%, less than 15%, less than 10%, or less than 5% of the total surface area. However, in other implementations, the opening can be 20% or more of the total surface area of the earphone body.

According to a disclosed method, modeling software can be used to create negative spaces within a three-dimensional representation of a solid earphone body. The negative spaces can include tunnels or through holes, negative spaces for hardware, or a combination thereof, as described above. The solid earphone body can be a standardized body that will be mass produced, or can be a custom body that can adapted for the particular ear shape of an individual end user. Three-dimensional designs produced by modeling negative spaces in a solid earphone body can be fabricated into solid components using techniques such as 3D printing or injection molding.

Compared with prior approaches, the innovative disclosed earphones can be faster and easier to manufacture, in that fewer parts (e.g., tubes) may be needed, and installation of hardware components can be facilitated by having custom negative spaces (or voids) for receiving them. Having components secured within negative spaces, and/or fewer components, can make the earphones more robust, such as being better able to withstand both normal handling, and accidents involving sharp impacts, without internal parts becoming dislodged. Further, flexibility in placing internal earphone components, and the shape and position of tunnels, include the fabrication of chambers intermediate or at an end of one or more tunnels, can allow for better earphone performance, and the design of features that can improve sound quality.

One or more of these benefits can be achieved with a design process that it is easily adaptable, such as to provide different general earphone designs (e.g., different hardware and/or acoustic channel designs), or to facilitate adapting an earphone design to the ear shape of a particular user.

Method of Designing and Fabricating an Earphone with a Solid Body

FIGS.1A-1Fare a series of schematic drawings illustrating components of an earphone according to disclosed embodiments, and how an earphone can be designed and constructed.FIG.1Aillustrates an earphone body104having a first end106, configured to be inserted into the ear canal108of a user's ear102, and a second end110, typically configured to be retained in the ear by physical structures of the user's outer ear.

In some cases, the earphone body104can be molded from, or otherwise represent, the anatomical features of an individual user's ear. For example, a mold or impression can be made of the user's ear, and converted to a three-dimension representation in a software design program, such as AUTODESK INVENTOR or FUSION360(both available from Autodesk, Inc., of San Rafael, Calif., and which can be used for the remaining steps associated withFIGS.1A-1F). In other cases, a three-dimensional representation of the user's ear can be obtained by digitally scanning the user's ear. In further cases, the earphone body104can represent a standardized shape that is designed to satisfactorily fit any user, or at least a majority of users.

The first end106of the earphone body is typically shaped to securely, but comfortably, fit within the ear canal108. In the case of earphone bodies104that are not customized, and intended to be used with many different users, the first end106can be covered with a tip, typically of rubber or another elastomer, that helps secure the earphone body104within the ear, while maintaining user comfort. In addition to helping secure the earphone body104in position, a secure fit with the ear canal108, either through custom fitting or tips, can help improve the sound quality of the earphone, such as by prevent leakage of sound outside the earphone body, and helping reduce the intrusion of external sounds into the user's ear.

In a similar manner, the second end110is typically configured to help secure the earphone body104in position by nestling between, or wedging against, natural anatomic structures of the outer ear. Custom molded earphones can include a second end110that is also shaped to mate with native ear anatomy of a particular user. Mass produced, or general purpose, earphones can have a second end110that is shaped to mate with a variety of ear shapes.

FIG.1Billustrates outline representations of various hardware components114that can be used in an earphone. The outline representations can be two or three dimensional representations of physical hardware components that will be used in an earphone. In some cases, the outline representations can be obtained by scanning the actual hardware components. In other cases, the outline representations can be manually created, and can approximate the actual shape of the physical components. For example, many hardware components114are rectangular, or include rectangular portions, or are circular, or include circular portions, that are easily created using modelling software.

The hardware components114can include sound drivers (i.e., acoustic drivers), such as balanced armature drivers116and a dynamic driver118. Hardware components114can further include a cable socket120, which can be used to deliver electrical signals to the drivers116,118, to power the drivers and produce sound to be rendered to a user.

FIG.1Cillustrates outline representations of sound modifying and transmission structures122that can be included in an earphone, and can be represented in design software. The sound modifying structures and transmission structures122can include sound bores124, acoustic chambers126, and vents128. Sound bores124can transmit sound from the drivers116,118to the user's ear. Vents128can be used to allow air movement within the user's ear, or within the earphone, which can be used to tune the acoustic properties perceived by the user (e.g., to enhance bass). Similarly, acoustic chambers126can be used to condition sound to be transmitted to a user, and improve overall audio quality. Note that the acoustic chambers126can be a significant advantage of disclosed technologies, as typical methods of earphone production are not capable of incorporating acoustic chambers into an earphone body.

The representations of the hardware components114and the representations of the sound modifying and transmission structures122in modelling software can be used to generate negative spaces. That is, the representations themselves can indicate negative space, or can represent positive structures that are subtracted from a model (such as a model of the earphone body104) in order to create negative spaces in the model.

FIG.1Dillustrates how the representations of the hardware components114and the sound modifying and transmission structures122can be arranged to form subassemblies, such as in a modelling software program. As shown, a subassembly130is formed by placing the dynamic driver118intermediate an acoustic chamber126aand an acoustic chamber126b, where the acoustic chamber126bcommunicates with a sound bore124a. Note that the end of the sound chamber126bproximate the dynamic driver118has an enlarged opening, like a funnel, in order to capture sound transmitted by the dynamic driver, but tapers to a significantly narrower diameter in adjoining/transitioning into the sound bore124a, which then passes though the earphone body104towards the first end106.

A subassembly132includes a balanced armature driver116aproximate a sound bore124b, while a subassembly134include a balanced armature driver116bproximate a sound chamber126c, which in turn is proximate an end of a sound bore124c. Note that while sound bores124and sound chambers126are shown as separate components, they can be treated (including being modelled) as unitary components. For example, in a solid body of a physical earphone, a sound bore may have an acoustic chamber at an end, or at an intermediate portion. In a corresponding model from which the physical earphone was created, the combined sound bore/acoustic chamber can be represented as an acoustic chamber overlying a sound bore, or a portion of the sound bore can be manipulated (e.g. stretched, or otherwise having a larger diameter than a remainder of the sound bore) to represent the acoustic chamber. The two modelling approaches can be considered equivalent from the standpoint of the physical solid earphone body.

In some cases, the virtual representations of one or more of the hardware components114, the sound modifying and transmission structures122, or the subassemblies134can be stored. For example, a variety of earphone models, either custom or standardized, can be created from different combinations of hardware components114. At least many of the sound modifying and transmission structures122can also be standardized, or at least substantially standardized. That is, for example, the length and conformation of a particular sound bore124can be reasonably consistent between earphone models or custom versions of a specific model, with minor changes to length and/or orientation being made to adapt to changes in the size or shape of the solid earphone body104or the particular hardware components114being used, and the particular location and orientation thereof.

FIG.1Eillustrates how the subassemblies130,132,134can be incorporated into a virtual model138of an earphone body, such as the earphone body104. The subassemblies130,132,134can be positioned within the model138in order to achieve desired acoustic properties, and to accommodate other hardware components of the earphones, such as the cable socket120, and other sound modifying or transmitting features (e.g., sound bores, sound chambers, or vents), such as the vent128. For example, the sound bores124and the vent128are positioned such that their ends extend to open at a first end142of the virtual model138, corresponding to the first end106of the earphone body104. The hardware components114, including the drivers116,118are placed towards a second end144of the virtual model138, corresponding to the second end110of the earphone body104, where there is a greater interior volume to house the components. The cable socket120is also placed at the second end144of the virtual model, to allow electrical connection with internal components of the earphone body, such as acoustic drivers.

FIG.1Fillustrates a cross section of a solid earphone body150produced using the virtual model ofFIG.1E. The hardware components114and sound modifying and transmission structures122included in the virtual model138are represented as negative spaces148in the solid earphone body150.

InFIG.1F, some of the negative spaces are shown as connecting, which others are shown as disconnected/non-contiguous. For example, the entire negative spaces148a-148cfor each subassembly130,132,134is shown as individually contiguous, but each of those negative spaces is shown as disconnected from the other. At least a portion of the negative spaces148may be disconnected, but, in practice, at least a portion of the negative spaces can be connected, but such connection is not shown in the particular cross section ofFIG.1F.

In some cases, two or more negative spaces in an earphone body can be disconnected. However, it can be beneficial to have the negative spaces for multiple components be connected. In particular, it can be beneficial to have negative spaces148corresponding to at least a portion of the hardware component114connected, as this can facilitate manufacturing of an earphone, as will be further described.

In practice, a user can design an earphone by creating or loading (e.g., selecting saved components from a menu) a virtual model138of an earphone, the virtual models of the desired hardware components114, and the virtual models of the sound modifying and transmission components122, including as incorporated in subassemblies (e.g., subassemblies130,132,134). After the hardware components114and sound modifying and transmission components122have been appropriately positioned, the components can optionally be converted to negative representations (i.e., if the representations were not already negative representations) such that the volume for these components is subtracted from portion of the virtual model138representing solid material, thus defining negative spaces (e.g., negative spaces148) corresponding to the components. An earphone according to the model can then be fabricated, such as by injection molding or 3D printing.

However, various modifications can be made to the above-method. For example, an earphone design or manufacturing process can include carrying out one or more, including all, of the steps associated withFIG.1B,FIG.1C, orFIG.1D. After the virtual models of the relevant hardware components and/or sound modifying or transmission components have been created, including as parts of subassemblies, a virtual model of an earphone body can be created, as described with respect toFIG.1A, and the process can then continue as described with respect toFIG.1EandFIG.1F.

For example, in many cases, it can be beneficial to first design subassemblies of an earphone to achieve desired performance/acoustic properties, including a selection of hardware components and tuning elements. That particular collection of components and tuning elements can then be incorporated into one or more earphone body shapes as desired. In some cases, minor adjustments, such as to the length and conformation of tuning elements, can be made to adapt a particular earphone design to a particular body shape.

Example Solid Body Earphones

FIGS.2-4illustrate different earphones designs that can be produced using the technique described in conjunction withFIGS.1A-1F. The different earphones designs can represent designs that allow different acoustic properties to be achieved, as well as earphones meeting different price/performance objectives.

FIG.2Aillustrates a cross-sectional view of an earphone204that includes a single dynamic driver206. The earphone204is formed from a unitary body208, onto which a cap210can be placed. Both the body208and the cap210can incorporate negative spaces, both to house hardware components and to allow for sound modification or transmission. The body208includes a first end212that is configured to be placed in the user's ear. The body208includes a second end214, where the second end is completed when the cap210is inserted onto the body208.

The body208is constructed from a solid material, such as plastic or metal (or combinations thereof), or from ceramics, including zirconia ceramics. Various negative spaces are formed in the body208, including a mounting section216configured to receive the dynamic driver206. A sound-transmitting end218of the dynamic driver206can abut a bottom portion of the mounting section216, where the mounting section can be in the form of a well having a wider section220that abuts the lateral sides222of the dynamic driver, and a narrower section224that abuts the sound transmitting end218of the dynamic driver.

The bottom of the mounting section216opens into a sound chamber228that in turn is connected to a main sound bore230that passes through the body208to an exit port284at the first end212. The sound chamber228and the main sound bore230represent negative spaces in the body208, and can be formed during production of the body, such via an injection molding or by 3D printing (including when plastics or ceramics are used for the body208). The body208also includes a pressure relief vent234that extends from an upper surface236of the body to an exit port286at the first end212.

The cap210and the body208can include mating negative spaces240,242for receiving a cable socket244. Cables, or other wiring, not shown, can be connected to the cable socket244, which in turn is electrically coupled (e.g., via wires) to the dynamic driver206. The cap210further defines a negative space in the form of a recess250for receiving an upper end252of the dynamic driver. The upper end252of the dynamic driver206can have a narrower cross sectional width than the sound transmitting end218. The side walls256of the recess250can be configured to be inserted into a gap between the walls of the mounting section216and the lateral sides of the upper end of the dynamic driver206.

The cap210can include a vent bore260that extends to a lateral side262of the cap, and which can mate withe the pressure relief vent234. The vent bore260can also extend to, and open into, the recess250of the cap210.

An earphone204can be constructed by arranging representations of the dynamic driver206, cable socket244, sound chamber228, main sound bore230, and relief vent234in a virtual model of the earphone. The representations can be negative space representations, or can be subtracted from a volume of the virtual model of the earphone204to create corresponding negative spaces. The cap210can be created in a similar manner Once the models of body208and the cap210have been created, they can be used to create the physical body and cap, such as via 3D printing or injection molding.

The dynamic driver206can be inserted into the mounting section216, and electrically connected to the cable socket244. The cap210can then be placed over the dynamic driver206and the cable socket244, such that the sides256of the recess250are inserted around the upper end252of the dynamic driver. The cap210can be further secured by using an adhesive (such as a rubberized adhesive), or other fastening means, such as screws. A faceplate270can be coupled to the first end212of the body208.

FIG.2Bpresents an exploded view of the earphone204. The body208is shown in a generalized fashion (e.g., a cube), as the disclosed technology is not necessarily limited to any particular body shape. The body208is shown as including a negative space280. The negative space280can be represented in a virtual model as negative space282. That is, removing negative space282from a virtual model of a solid earphone body results in the earphone body208having the negative space280. As described above, the negative space282can include the sound chamber228, the sound bore230, the vent234, the dynamic driver206, and at least a portion of the cable socket244. Additional views of the negative space282are provided inFIGS.2C and2D.

InFIG.2B, the body208is shown with the exit port284for the sound bore230and the exit port286for the vent234. The negative space representation282shows wells288for receiving threaded screw inserts290, which can receive screws292inserted through openings294in the cap210.

An acoustic damper296can be inserted within the vent bore260(e.g., the vertical portion that mates with the vent234). An end cap299, having an opening298to the vent bore260, can be placed over the cable socket244, and secured to the cap210.

FIG.2Eillustrates a side view of the body208and the cap210, whileFIG.2Fillustrates a cross-sectional view of the body and cap taken along line C-C ofFIG.2E. InFIG.2E, the driver206is shown within the mounting section216.

FIG.3illustrates an earphone304having a plurality of balanced armature drivers316,318,320instead of the dynamic driver206ofFIG.2A. The earphone304includes a body308and a cap310. The body308is constructed from a solid material, such as plastic or metal (or combinations thereof), or from ceramics, including zirconia ceramics, and can be formed using methods such as 3D printing (including when the body is made from plastic or ceramic materials) or injection molding.

The body308defines a plurality of negative spaces, in the form of recessed portions322,324,326that are dimensioned to receive and secure first longitudinal ends of the respective balanced armature drivers316,318,320. The recessed portions322,324,326can result from modeling the first longitudinal ends of the balanced armature drivers316,318,320as negative space, or subtracting representations of the balanced armature drivers from a virtual model of the body308.

The balanced armature drives316,318,320are positioned next to (e.g., abutting) sound modification or transmission features formed as negative spaces in the body308. In particular, each balanced armature driver316,318,320is positioned next to a sound chamber330(respectively, to each balanced armature driver, sound chambers330a,330b,330c). The sound chambers330can represent a larger diameter space compared with respective sound bores332,334,336that extend from lower ends (e.g., towards a first end338of the body308, which end is configured to be placed in a user's ear) of the respective sound chamber, through the body308to the first end and a respective exit port340. The sound chambers330can be used, in some cases, to cause resonance in acoustic waves produced by the balanced armature drivers316,318,320. For example, sound chamber330acan function as a Helmholtz resonator.

Note that the sound bore334and the sound bore336intersect to end at a common sound bore342, having an exit port340. Coupling sound bores334and336can be used to adjust to audio qualities of the earphone304, including to adjust resonance properties, in a similar manner as the sound chambers330.

A faceplate348can be placed over the first end338, where the faceplate has openings350configured to be located over the exit ports340.

The cap310defines a recess352that is configured to fit over the second longitudinal ends of the balanced armature drivers316,318,320, which extends towards a second end354of the body308. The cap310and the body308can include mating negative spaces356,358for receiving a cable socket360. Cables, or other wiring, not shown, can be connected to the cable socket360, which in turn is electrically coupled (e.g., via wires) to the balanced armature drivers316,318,320.

An earphone304can be constructed by arranging representations of the balanced armature drives316,318,320, cable socket360, sound bores332,334,336and sound chambers330in a virtual model of the earphone. The representations can be negative space representations, or can be subtracted from a volume of the virtual model of the earphone304(e.g., the body308, and optionally the cap310) to create corresponding negative spaces. The cap310can be created in a similar manner Once the models of body308and the cap310have been created, they can be used to create the physical body and cap, such as via 3D printing or injection molding.

The balanced armature drivers316,318,320can be inserted into their respective recesses322,324,326, and coupled to the cable socket360. The cap310can then be placed over the balanced armature drivers316,318,320and the cable socket360, such that the upper longitudinal ends of the balanced armature drivers are within the recess352. The cap310can be further secured by using an adhesive, or other fastening means, such as screws. The faceplate348can be coupled to the first end338of the body308.

FIG.3Bpresents an exploded view of the earphone304. The body308is shown in a generalized fashion (e.g., a cube), as the disclosed technology is not necessarily limited to any particular body shape. The body308is shown as including a negative space370. The negative space370can be represented in a virtual model as negative space372. That is, removing negative space372from a virtual model of a solid earphone body results in the earphone body308having the negative space370. As described above, the negative space372can include the sound bores332,334,336, the sound chambers330, the balanced armature drivers316,318,320, and at least a portion of the cable socket360. Additional views of the negative space372are provided inFIGS.3C and3D.

InFIG.3B, the negative space representation372shows wells376for receiving threaded screw inserts378, which can receive screws380inserted through openings382in the cap310. Acoustic dampers384can be inserted in the sound chambers330b,330c, as best shown inFIG.3F. An end cap390can be placed over the cable socket360, and secured to the cap310.

In general, it is noted that the acoustic properties of a particular earphone can be tuned by incorporating different tuning elements into an earphone body (including different combinations of tuning elements, and tuning elements properties), and by adjusting the properties of the tuning elements (e.g., the length, diameter, and conformation of sound bores and vents, the shape and size of sound chambers). Combinations of tuning elements can include placing acoustic dampers proximate other tuning elements, such as sound bores or vents, including placing acoustic dampers within the path/length of a sound bore or vent.

FIG.3Eillustrates a side view of the body308and cap310, whileFIG.3Fillustrates a cross-sectional view of the body and cap taken along line C-C ofFIG.3E. InFIG.3E, the balanced armature drivers316,318,320are shown within their respective recesses322,324,326.

FIG.4illustrates an earphone402that includes a dynamic driver406and two balanced armature drivers408,410. The earphone402can be formed from a cap403and a body404. The body404is constructed from a solid material, such as plastic or metal (or combinations thereof), or from ceramics, including zirconia ceramics, and can be formed using methods such as 3D printing (including when the body is made from plastic or ceramic materials) or injection molding.

The body404can have negative spaces, in the form of recesses412,414,416, formed in a second end417of the body, for receiving the dynamic driver406and the balanced armature drivers408,410, respectively, that are accessible through an opening418to the body404. The recess412, for the dynamic driver406, can be at least generally similar to the recess216ofFIG.2. The recesses414,416, for the balanced armature drivers408,410, can be at least generally similar to the recesses324,326ofFIG.3.

The body404can have negative spaces, in the form of recesses412,414,416, for receiving the dynamic driver406and the balanced armature drivers408,410, respectively. The recess412, for the dynamic driver406, can be at least generally similar to the recess216ofFIG.2. The recesses414,416, for the balanced armature drivers408,410, can be at least generally similar to the recesses324,326ofFIG.3.

The recess412communicates with a funnel-shaped sound chamber424, which in turn communicates with a sound bore426that passes through the body404to an exit port428at a first end430of the body. The balanced armature driver408communicates with a sound bore432that passes through the body404to an exit port434, while the balanced armature driver410communicates with a sound chamber436that in turn communicates with a sound bore438that passes through the body to an exit port440.

The cap403and the body404can include mating negative spaces446,444for receiving a cable socket448. Cables, or other wiring, not shown, can be connected to the cable socket448, which in turn is electrically coupled (e.g., via wires) to the dynamic driver406and the balanced armature drivers408,410.

The cap403further defines a negative space in the form of a recess450for receiving an upper end of the dynamic driver406, in similar manner as described for the cap210ofFIG.2. The cap403can include a vent bore454that extends to a lateral side456of the cap403, and which can mate with a pressure relief vent458that is formed in the body404and extends through the body from an opening459to an exit port460. The vent bore454can also extend to, and open into, the recess450of the cap403.

An earphone402can be constructed by arranging representations of the dynamic driver406, balanced armature drivers408,410, cable socket448, sound bores426,432,438, sound chambers424,436, and relief vent458in a virtual model of the earphone. The representations can be negative space representations, or can be subtracted from a volume of the virtual model of the earphone402to create corresponding negative spaces. The cap403can be created in a similar manner. Once the models of body404and the cap403have been created, they can be used to create the physical body and cap, such as via 3D printing or injection molding.

The dynamic driver406can be inserted into the mounting recess412, and electrically connected to the cable socket448. The balanced armature drivers408,410can be inserted into their respective mounting recesses414,416and electrically connected to the cable socket448. The cap403can then be placed over the dynamic driver406and the cable socket448, such that the sides of the recess450surround the upper end of the dynamic driver. The cap403can be further secured by using an adhesive, or other fastening means, such as screws. A faceplate470can be coupled to the first end430of the body404, and can include apertures472for communicating with the exit ports428,434,440,460.

In some implementations, a spout (such as an elongated, optionally tapered structure) configured to be placed into a user's ear, including when covered by a tip (e.g., a plastic or rubber material), can be used instead of, or in addition to, the faceplate470. The spout can be integrally formed at the first end430of the earphone body404, or can be coupled to the first end (e.g., by snap or friction fit, thermal means, such as welding, or using an adhesive). Although described with respect to the earphone402, a spout may also be included in other earphone designs, including the earphone204or the earphone304.

Example Manufacturing Method

FIG.5presents a flowchart of an example method500for manufacturing an earphone. At510, a virtual model of at least one physical earphone component is created. The at least one physical earphone component can be, for example, an acoustic driver (such as a balanced armature driver or a dynamic driver), a cable socket, screw mounts/inserts, or acoustic dampers. A virtual model of at least a first sound bore is created at515. At520, a first virtual model of an earphone body is created, such as from a mold of a user's ear, from a 3D scan of a user's ear, from a 3D scan of an earphone body, or by another method. The virtual model of the at least one physical earphone component the virtual model of the at least a first sound bore are positioned, at525, at least partially within the first virtual model of the earphone body. At530, one or more negative spaces are defined in the first virtual model of the earphone body corresponding to the virtual model of the at least one physical earphone component and the virtual model of the at least a first sound bore to create a second virtual model of the earphone body.

The method500can optionally include one or more additional steps. For example, at535, a solid earphone body can be fabricated from the second virtual model of the earphone body, such by 3D printing or injection molding. A cap, to be placed over at least part of a portion of the earphone body, can be fabricated at540, such as by machining, molding, or 3D printing. At545, the at least one physical earphone component can be installed in the earphone body, such as in a recess corresponding to a negative space in the virtual model corresponding to the virtual model of the at least one physical earphone component. The cap can be installed on the earphone body at550.

As used herein, the terms “a”, “an” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element.

As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C” or “A, B and C.”

As used herein, the term “coupled” generally means physically coupled or linked and does not exclude the presence of intermediate elements between the coupled items absent specific contrary language. “Directly coupled” refers to two components that are directly physically coupled or linked, and excludes the presence of intermediate elements. As used herein, the terms “integrally formed” and “unitary construction” refer to a construction that does not include any welds, fasteners, or other means for securing separately formed pieces of material to each other, or features resulting from securing separately formed pieces, such as joints, seams, or discontinuities of shape or material.

As used herein, “in fluid communication” means that two components are coupled via a common transmission medium, such as a sound transmission medium (e.g., air). Two components can be referred to as in “direct fluid communication” when a transmission medium can flow directly between the two components, such as without passing through intermediate spaces, such as a tube.