Abstract:
A water resistant/proof speaker module with improved performance and bass reflection is provided. The speaker module comprises a housing into which an audio unit fits. The speaker module is provide with a speaker face having at least 50% of the speaker face open to improve audio characteristics. Seals are provided along the speaker module to inhibit moisture from entering the device housing.

Description:
CLAIM OF PRIORITY UNDER 35 U.S.C. §119 
       [0001]    None. 
       CLAIM OF PRIORITY UNDER 35 U.S.C. §120 
       [0002]    None. 
       REFERENCE TO CO-PENDING APPLICATIONS FOR PATENT 
       [0003]    None. 
       BACKGROUND 
       [0004]    1. Field 
         [0005]    The present relates generally to audio modules, and more specifically to water resistant or water proof audio modules for wireless devices. 
         [0006]    2. Background 
         [0007]    Telephony and other wireless equipment is frequently used in a hands free environment. To accomplish this, many devices incorporate a microphone and a speaker into the telephony device. For example, many wireless handsets incorporate a speaker in the housing of the handset. 
         [0008]    Because telephony and other wireless equipment are become more and more ubiquitous, there has arisen a need to provide equipment that operates in less than ideal environments for electronic devices. The equipment may be used, for example, in hazardous environments, moisture leaden environments, or other less than suitable conditions. Using cellular telephones in a rainy environment is one particularly common example today. 
         [0009]    Many devices feature or include a water proof or water resistant housing to facilitate the use of telephones and other wireless equipment in less than suitable operating conditions. Many of these devices build a speaker directly into the device housing and seal the device using either an adhesive or single gasket. While potentially water resistant, building the speaker directly into the housing may have other consequences, such as, reduced audio performance, difficult manufacturing, costly, or the like. Moreover, many of these devices become less effective in the event of a single failure of the water bearer. For example, water may penetrate the device on a gasket failure or defect. Alternatively, an adhesive may separate causing a leak path. 
         [0010]    Thus, it would be desirous to provide a speaker/audio device that address at least some of the above described concerns. 
       SUMMARY 
       [0011]    Embodiments disclosed herein address the above stated needs by providing a speaker module for an electronic device. The speaker module comprising a housing with a base, a top edge opposite the base, at least one sidewall extending from the base to the top edge, and an intermediate shoulder extending radially inward from the at least one sidewall between the base and the top edge. An electrical conduit resides in the sidewall. An audio unit comprising an audio unit base, an audio unit top edge opposite the audio unit base, and an audio unit sidewall fits in the housing such that the audio unit base is supported by the intermediate shoulder and the audio unit sidewall is in sliding relation to the at least one sidewall. A first seal resides between the audio unit base and the intermediate shoulder to provide at least a water resistant seal. A second seal is aligned with the audio unit top edge. A speaker face aligned with the top edge and a third seal, such that the speaker module is made water resistant. 
         [0012]    The foregoing and other features, utilities, and advantages of the technology of the present application will be apparent from the following more particular description of the technology of the present application that is illustrated by the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of an electronic device having a speaker compartment; 
           [0014]      FIG. 2  is a perspective view of a speaker module; 
           [0015]      FIGS. 3 ,  4 ,  6 , and  7  are perspective, partially exploded views of the speaker module of  FIG. 2 ; 
           [0016]      FIG. 5  is a cross sectional view of an exemplary seal; 
           [0017]      FIG. 8  is a perspective view of the speaker module heatstaked; and 
           [0018]      FIG. 9  is a cross section view of another speaker face. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The technology of the present application will now be described with reference to the figures. While the technology of the present application will be described with particular reference to an audio module insertable into the backplane of a wireless device, one of ordinary skill in the art will recognize the audio module could be insertable into any portion of the housing and would be usable with any device providing a speaker or similar audio module. Moreover, the word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, unless specifically identified, all embodiments described herein should be considered exemplary embodiments of the technology. 
         [0020]    Referring first to  FIG. 1 , a perspective view of a device  100  having a speaker  102  is shown. Device  100  is shown as a portable device, but device  100  does not need to be portable. Moreover, device  100  may be a cellular telephone, a two-way radio, a combination thereof, an MP-3 player, a portable digital assistant, a Blackberry mounted telephony equipment, mounted speaker units, other telecommunications equipment or the like. Device  100  is shown as having a housing  104  with a back panel  106  and a front panel  108 . Back panel  106  further contains a battery compartment  110 . Speaker  102  is a separate module that fits into a speaker compartment  112  in back panel  106 . As shown, speaker compartment  112  can be countersunk such that speaker  102  is flush or recessed with respect to back panel  106  as shown or not countersunk such that speaker  102  is raised from back panel  106 . Moreover, while shown as associated with back panel  106 , speaker  102  could be placed on anywhere on housing  104  with sufficient surface area. 
         [0021]    Referring now to  FIG. 2 , a speaker module  200  is shown that fits in speaker compartment  112 . Speaker module  200  could be connected or coupled to speaker compartment  112  using any number of conventional connection mechanisms including welding, adhesives, rivets, screws, press-fit, snap rings, or the like. As shown, speaker module  200  has a plurality of protrusions  202  extending from a housing  204 . Protrusions  202  have bores  206 . Pins, rivets, or the like (not specifically shown) can be sued to couple speaker module  200  to speaker compartment  112 . Housing  204  can be any number of shapes and is generally defined by the requirements of the manufacturer of device  100 . However, typically speaker modules are circular in shape. 
         [0022]    Referring now to  FIGS. 3-8 , speaker module  200  is described in more detail. Referring first to  FIG. 3 , a perspective, exploded view of housing  204  and audio unit  302  is provided. Audio unit  302  is any conventional unit and will only be described as it relates to the present technology. Housing  204  comprises a base  306 , which would be internal to housing  104  and speaker compartment  112 . Extending from base  306  toward back panel  106  of housing  104  is a lower sidewall  308 . Lower sidewall  308  terminates at a intermediate shoulder  310 . Base  306  and lower sidewall  308  define a first recess  312 . Intermediate shoulder  310  extends radially outward from lower sidewall  308 . Upper sidewall  314  extends from intermediate shoulder  310  to a top edge  316  of housing  204 , which in the embodiment shown in  FIG. 1  would be slightly recessed from back panel  106 . Alternatively to considering intermediate shoulder  310  as extending radially outward from lower sidewall  308 , shoulder  310  may be considered as extending laterally inward from upper sidewall  314 . Protrusions  202  extend radially outward from upper sidewall  314 . Intermediate shoulder  310  and upper sidewall  314  define a second recess  318 . Second recess is sized to fit audio unit  302 . Audio unit  302  has an audio unit base  322  and audio unit sidewalls  324 . Audio unit base  302  rests on shoulder  310  and sidewalls  324  are slidably engaged with upper sidewalls  314 . Upper sidewall  314  further includes at least one electrical conduit  326 , which is shown as a channel extending from shoulder  310  to top edge  316  in upper sidewalls  314 . Electrical cables (not shown) would electrically connect audio unit  302  to device  100 . 
         [0023]    A first seal  328  resides between shoulder  310  and audio unit base  322 . First seal  328  provides a water resistant or water proof barrier to the internals of device  100  via the speaker module  200 . First seal  328  may be any number of conventional seals, such as, for example, a gasket, an o-ring, a silicone epoxy, an adhesive, or the like. First seal  328  also should seal electrical conduit  326 . For example, a silicone epoxy may wick around the various electrical cables or a watertight strain relief can form a seal. 
         [0024]    Referring now to  FIG. 4 , speaker module  200  is shown partially exploded after audio unit  302  is fitted into second recess  318 . A second seal  402  is provided. Second seal  402  is aligned with an audio unit top edge  404 . Second seal  402  provides a second water resistant or water proof barrier to the internals of device  100  via the speaker module  200 . Second seal  402  may be any number of seals, such as, for example, a gasket, an o-ring, a silicone epoxy, an adhesive, or the like.  FIG. 5  provides a cross-sectional view of one embodiment of second seal  402  that works well. Second seal  402  in this embodiment encompasses a audio facing gasket  502 , a cloth mesh  504 , and a speaker face facing gasket  506 . Audio facing gasket  502  may be a double sided adhesive gasket to bond to audio unit top edge  404  and cloth mesh  504 . Speaker face facing gasket  506  also may be a double sided adhesive gasket to bond to cloth mesh  504  and a speaker face, which will be explained further below. Cloth mesh typically provides a dust cover for audio unit  302 . Moreover, audio unit  302  is provided with a top face  406  that is itself water proof or water resistant. 
         [0025]    Referring now to  FIGS. 6 ,  7 , and  8 , speaker module  200  is shown partially exploded in  FIGS. 6 and 7  after second seal  402  is provided and assembled in  FIG. 8 . First, speaker face  602  is aligned with alignment protrusions  604  extending from top edge  316 . Speaker face  602  would couple to speaker face facing gasket  506 . Speaker face  602  may be formed of a plastic, composite, or metal material having opening  606 . A surface area SA of speaker face  602  should have a sufficient number of opening  606  to provide satisfactory audio performance. It has been found having 50% or more of surface area SA to comprise openings provides satisfactory audio performance. Referring to  FIG. 7 , a third seal  702  is provided. Third seal  702  may be any type of sealant previously mentioned, but is shown as a gasket. Third seal  702  has alignment bores  704 . Alignment bores align with alignment protrusions  604 . Ideally, after aligning and placing third seal  702 , compressive force would be applied and the unit locked or clamped under compression to increase the effectiveness of one or more of the seals. For example, alignment protrusions, may comprise a thermoset material that may act as a heatstake  802  to retain the compression. 
         [0026]    Referring now to  FIG. 9 , a speaker grill  900  is provided as an alternative to flat speaker face  602 . Speaker grill  900  comprises a flanged surface  902  that extends under third seal  702  and may be heatstaked using heatstakes  802  as provided in  FIG. 8 . Speaker grill  900 , however, includes a raised grill wall  904  extending away from audio module  302  and a grill face  906 . Grill face  906  would have surface area SA with openings  606  similar to speaker face  602 , ideally with over 50% of surface area SA being open. 
         [0027]    The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.