Patent Description:
When not worn by a user, audio headphones are sometimes stored in a headphone case. In addition to storing headphones, headphone cases protect headphones during transport. Some headphones include a rechargeable battery to support wireless listening. Wireless listening is convenient because cables are not needed to connect the headphones to another device. Users can move freely, without restrictions of a cable tethering the headphones to a device.

<CIT> discloses a prior art charging case for a headset.

The present invention relates to a charging case for headphones according to claim <NUM>. Advantageous embodiments are recited in dependent claims.

All examples and features mentioned herein can be combined in any technically possible manner.

In aspects, the charging case includes a volume for holding headphones and a battery coupled to a charging cable having a charging connector. The headphone charging case may switch between a docked mode and a charging mode. In the docked mode, charging cable management features help secure the charging cable and charging cable connector in place. In the charging mode, the charging cable is extended by pulling either the charging cable or the charging cable connector away from the charging cable management features to increase the length of exposed charging cable. The charging cable connector attaches to the headphones while the headphones are positioned in the charging case to charge the headphones.

Aspects describe a charging case for headphones comprising: a top cover; a bottom cover, the bottom cover comprising a bottom cover top side and a bottom cover bottom side, the top cover coupled to the bottom cover wherein, in a closed position, the top cover and the bottom cover bottom side form the charging case; an inner tray comprising an inner tray top side and an inner tray bottom side, the inner tray top side molded to hold the headphones in a volume defined by the top cover and the inner tray top side, the inner tray bottom side and the bottom cover top side form an enclosure that houses a battery coupled to a charging cable for charging the headphones; an opening in the inner tray extending from the inner tray top side to the inner tray bottom side; a top charging cable insert and a bottom charging cable insert, wherein the inner tray is disposed between the top charging cable insert and the bottom charging cable insert, the top charging cable insert covering the opening on the inner tray top side and comprising an aperture to receive the charging cable from the enclosure, and the bottom charging cable insert covering a majority of the opening on the inner tray bottom side; and a magnet attached to the bottom charging cable insert, the magnet disposed in the enclosure, wherein in a docked mode, the magnet helps secure a charging connector of the charging cable in place, and in a charging mode, the charging cable attaches to the headphones while the headphones are positioned in the volume on the inner tray top side.

In aspects, the top charging cable insert comprises a receiving space for holding the charging connector of the charging cable in the docked mode, the receiving space extending below the inner tray bottom side. In aspects, the bottom charging cable insert comprises a structure for supporting the magnet, the structure partially surrounding a bottom side of the receiving space that extends below the inner tray bottom side. In aspects, the structure comprises a first wall, a second wall, and a third wall; the first wall and the third wall are substantially parallel to each other and are coupled together via the second wall.

In aspects, the top charging cable insert and the bottom charging cable insert snap together.

In aspects, the charging case further comprises a printed circuit board assembly (PCBA) cap in the enclosure, the PCBA cap comprising a slot for receiving the charging cable and a post protruding from the PCBA cap towards the inner tray, wherein the charging cable forms a loop around the post and is received in the aperture, wherein the loop is larger in the docked mode and smaller in the charging mode. In aspects, the charging case further comprises a charging cable cap, the charging cable cap coupled to the PCBA cap to secure the loop between the PCBA cap and the charging cable cap. In aspects, the post is approximately <NUM> in diameter.

In aspects, to switch from the docked mode to the charging mode, the charging cable is pulled through the aperture, decreasing a size of the loop around the post, and the charging cable extends such that the charging connector of the charging cable connects to an earpiece of the headphones.

In aspects, to switch from the charging mode to the docked mode, the charging cable is retracted into the space between the PCBA cap and the charging cable cap, the retracting increasing the size of the loop around the post.

In aspects, the charging cases further comprises a stiffener disposed in the inner tray, a first side of the stiffener following a profile of a portion of the inner tray and a second side of the stiffener, substantially opposite the first side of the stiffener, following a profile of a portion of the headphones. In aspects, in the charging mode, a clearance exists between the charging connector of the charging cable connected to an earpiece of the headphones and a bottom edge of the inner tray.

Certain aspects provide a charging case for headphones comprising: a bottom cover, the bottom cover comprising a bottom cover top side and a bottom cover bottom side; an inner tray comprising an inner tray top side and an inner tray bottom side, the inner tray top side molded to hold the headphones, the inner tray bottom side and the bottom cover top side form an enclosure that houses a battery coupled to a charging cable for charging the headphones; an opening in the inner tray extending from the inner tray top side to the inner tray bottom side; a top charging cable insert snapped to a bottom charging cable insert, wherein the inner tray is disposed between the top charging cable insert and the bottom charging cable insert; a magnet attached to the bottom charging cable insert, the magnet disposed in the enclosure, wherein in a docked mode, the magnet helps secure a charging connector of the charging cable in place, and in a charging mode, the charging cable attaches to the headphones while the headphones are positioned on the inner tray top side; and a printed circuit board assembly (PCBA) cap in the enclosure, the PCBA cap comprising a post protruding from the PCBA cap towards the inner tray, wherein the charging cable forms a loop around the post and is received in a space above the inner tray, wherein the loop is larger in the docked mode and smaller in the charging mode.

In aspects, the charging case further comprises a stiffener disposed in the inner tray, a first side of the stiffener following a profile of a portion of the inner tray and a second side of the stiffener, substantially opposite the first side of the stiffener, following a profile of a portion of the headphones.

In aspects, the top charging cable insert comprises a receiving space for holding the charging connector of the charging cable in the docked mode, the receiving space extending below the inner tray bottom side. In aspects, the bottom charging cable insert comprises a structure for supporting the magnet, the structure partially surrounding a bottom side of the receiving space that extends below the inner tray bottom side.

In aspects, the charging case further comprises a charging cable cap, the charging cable cap coupled to the PCBA cap to secure the loop between the PCBA cap and the charging cable cap.

In aspects, the charging cable is received in an aperture of the top charging cable insert covering the opening on the inner tray top side. In aspects, to switch from the docked mode to the charging mode, the charging cable is pulled through the aperture, decreasing the size of the loop around the post, and the charging cable extends such that the charging connector of the charging cable connects to an earpiece of the headphones. In aspects, to switch from the charging mode to the docked mode, the charging cable is retracted through the aperture, the retracting increasing the size of the loop around the post.

Advantages of a charging case for headphones including the features described herein with reference the accompanying figures will be apparent from the following description and claims.

<FIG> illustrates an example charging case for headphones ("charging case") in a closed position <NUM>, in accordance with aspects of the present disclosure. The charging case includes a top cover <NUM> and a bottom cover <NUM>.

The bottom cover includes a top side of the bottom cover ("bottom cover top side") <NUM> (shown, for example, in <FIG>) and a bottom side of the bottom cover ("bottom cover bottom side") <NUM> (labeled, for example, in <FIG>). In a closed position, the bottom cover bottom side <NUM> is exposed. The top cover <NUM> and the bottom cover <NUM> are coupled together. Specifically, in the closed position <NUM>, the top cover <NUM> and the bottom cover bottom side <NUM> form the boundaries of the charging case.

<FIG> illustrates the charging case in an open position and docked mode <NUM>, in accordance with aspects of the present disclosure. The charging case includes an inner tray <NUM> (labeled in <FIG>). The inner tray <NUM> includes a top side of the inner tray ("inner tray top side") <NUM> and a bottom side of the inner tray ("inner tray bottom side") <NUM>. The inner tray <NUM>, inner tray top side <NUM>, and inner tray bottom side <NUM> are shown in <FIG>. In the open position docked mode <NUM>, the inner tray top side <NUM> is exposed. The inner tray top side <NUM> is molded or otherwise shaped to hold headphones. In the closed position <NUM>, headphones are held in a volume defined by the inner tray top side <NUM> and the top cover <NUM>.

<FIG> illustrates the inner tray top side <NUM> of the charging case in a charging mode <NUM>, in accordance with aspects of the present disclosure. Charging cable management features of the charging case manage a charging cable <NUM> used to charge headphones while the headphones are secured in the charging case. <FIG> show additional details of various portions of the cable management features.

In the charging mode <NUM>, the charging cable <NUM> is extended such that the charging connector <NUM> connects to headphones to couple the battery <NUM> (shown in <FIG>) to the headphones to charge the headphones.

The charging cable <NUM> is coupled to a battery that is housed between the inner tray bottom side <NUM> and the bottom cover top side <NUM> (shown in <FIG>). As illustrated in <FIG>, in the docked mode of an assembled charging case for headphones, the charging cable <NUM> is substantially not visible. A majority of the charging cable is enclosed between the inner tray bottom side <NUM> and the bottom cover top side <NUM>. In the docked mode, a charging connector <NUM> of the charging cable <NUM> rests in a receiving space that extends from the inner tray top side <NUM> to the inner tray bottom side <NUM>. Some features regarding the opening in the inner tray are described in more detail with reference to <FIG>.

<FIG> illustrates an exploded view of the area between the bottom cover top side <NUM> and the inner tray bottom side <NUM> in accordance with aspects of the present disclosure. The battery <NUM> is coupled to a printed circuit board assembly (PCBA) <NUM>. The PCBA is coupled to a light feature, such as a light pipe <NUM>. In aspects, the light pipe <NUM> is coupled to a light leakage sponge <NUM> and a light leakage felt <NUM>. The PCBA <NUM> and components coupled to the PCBA <NUM>, including the battery <NUM>, are housed between a PCBA cap <NUM> and a PCBA bottom <NUM>.

The PCBA cap <NUM> includes a post <NUM>. The post <NUM> protrudes from the PCBA cap towards the inner tray <NUM>. The PCBA cap <NUM> is coupled to a charging cable cap <NUM>. In the docked mode, the majority of the charging cable <NUM> (not illustrated in <FIG>) is housed in an area between the charging cable cap <NUM> and the PCBA cap <NUM> between the bottom cover top side <NUM> and the inner tray bottom side <NUM>.

In aspects, the bottom cover bottom side <NUM>, includes a button <NUM> and an input/output (IO) cover <NUM>. When the button <NUM> is pressed, the light pipe <NUM> provides a visual indication through the IO cover <NUM> representing the amount of available charge left in the battery <NUM>. In an aspect, the visual indication is visible through the openings <NUM> in the IO cover <NUM>. The light leakage sponge <NUM> and the light leakage felt <NUM> help direct the light from the light pipe <NUM> towards the IO cover <NUM>. In aspects, the IO cover <NUM> is coupled to charging port <NUM> (shown in <FIG>) for recharging the battery <NUM>. The charting port <NUM> is part of the PCBA <NUM>, which is coupled to the battery <NUM>. A power source may be coupled to the battery <NUM> using the charging port <NUM>.

<FIG> illustrates a portion of the inner tray top side <NUM>, charging cable <NUM>, and charging connector <NUM>, when the headphone case is in a docked mode. An opening exists in the inner tray <NUM>, from the inner tray top side <NUM> to the inner tray bottom side <NUM>. A top charging cable insert <NUM> covers the opening on the inner tray top side <NUM> and a bottom charging cable insert <NUM> covers, at least a substantial portion of the opening on the inner tray bottom side <NUM>.

The inner tray <NUM> is positioned between tire top charging cable insert <NUM> and the bottom charging cable insert <NUM>. In an aspect, the top charging cable insert <NUM> and the bottom charging cable insert <NUM> snap together. In aspects, the top charging cable insert <NUM> and the bottom charging cable insert <NUM> are, at least partially, adhered together.

Aperture <NUM> in the top charging cable insert <NUM> receives the charging cable <NUM> from a space between the bottom cover top side <NUM> and the inner tray bottom side <NUM>. In aspects, in the docked mode, the majority of the charging cable <NUM> is stored between the charging cable cap <NUM> and the PCBA cap <NUM>. The aperture <NUM> receives the charging cable <NUM> from an opening in the charging cable cap <NUM>. In the charging mode, the amount of cable stored between the charging cable cap <NUM> and the PCBA cap <NUM> decreases, as the charging cable <NUM> is extended to connect to the headphones.

<FIG> illustrates a portion of the inner tray bottom side <NUM> showing tire top charging cable insert <NUM> and the bottom charging cable insert <NUM>, in accordance with aspects of the present disclosure. The top charging cable insert <NUM> includes a receiving space <NUM> for holding the charging connector <NUM> of the charging cable <NUM>. The receiving space <NUM> extends below the inner tray bottom side <NUM>. In the docked mode, the charging connector <NUM> rests in the receiving space <NUM>.

The bottom charging cable insert <NUM> comprises a structure, at least partially surrounding the receiving space <NUM> that extends below the inner tray bottom side <NUM>, for supporting a magnet <NUM> (shown in <FIG>). The magnet <NUM> attracts the charging connector <NUM> and helps secure the charging connector <NUM> in the receiving space <NUM>.

In <FIG>, the structure includes a first wall <NUM>, a second wall <NUM>, and a third wall <NUM>. The first wall <NUM> and the third wall <NUM> are substantially parallel. In aspects, the second wall <NUM> is substantially perpendicular to both the first wall <NUM> and the third wall <NUM>. The first wall <NUM> and the third wall <NUM> are coupled together by the second wall <NUM>.

As shown in <FIG>, the first wall <NUM>, second wall <NUM>, and third wall <NUM> support the magnet <NUM>. The magnet <NUM> is proximate to the receiving space <NUM> and helps secure the charging connector <NUM> in place while in the docked mode. In aspects, the magnet <NUM> is glued to any combination of the first wall <NUM>, the second wall <NUM>, and the third wall <NUM>. The charging cable management features securing the charging connector <NUM> reduces the chances the charging cable <NUM>, including the charging connector <NUM>, move into an area above the inner tray top side <NUM> absent intent by a user.

<FIG> illustrates the charging cable <NUM> and the charging connector <NUM> extending from an area between the charging cable cap <NUM> and the PCBA cap <NUM>, in accordance with aspects of the present disclosure. The opening <NUM> for the charging cable <NUM> is substantially defined by the charging cable cap <NUM>. In aspects, as illustrated in <FIG>, the opening <NUM> is a slot with a rounded top. The opening <NUM> allows the charging cable <NUM> to exit the space between the charging cable cap <NUM> and the PCBA cap <NUM>.

In aspects, a grommet <NUM> is molded on a portion of the charging cable between the electronics (the battery <NUM>, PCBA <NUM>, and light pipe <NUM>) and the PCBA cap <NUM>. The grommet helps anchor the charging cable <NUM>, thereby regulating the length of the charging cable <NUM> in the area between the charging cable cap <NUM> and the PCBA cap <NUM> and available to couple the charging connector <NUM> to the headphones. The grommet <NUM> helps prevent the cable from being removed from the charging case if a user pulls too firmly on the charging cable <NUM>.

<FIG> illustrates the PCBA cap <NUM>, post <NUM>, charging cable <NUM>, and grommet <NUM> in a docked mode, in accordance with aspects of the present disclosure. In <FIG>, the charging cable cap <NUM> is removed, thereby exposing the charging cable <NUM>. The charging cable <NUM> forms a loose loop around the post <NUM> in the docked mode.

<FIG> illustrates the PCBA cap <NUM>, post <NUM>, charging cable <NUM>, and grommet <NUM> in a charging mode, in accordance with aspects of the present disclosure. Similar to <FIG>, in <FIG>, the charging cable cap <NUM> is removed, thereby exposing the charging cable <NUM>. To switch from the docked mode to the charging mode, a user pulls the charging cable <NUM> or the charging connector <NUM> and the loop becomes smaller or tighter around the post <NUM>. The size of the charging cable loop decreases as more of the charging cable <NUM> is exposed above the inner tray top side <NUM> to allow the charging connector <NUM> to attach to the headphones.

In aspects, the post <NUM> is approximately <NUM> in diameter. The size of the post is selected to help prevent damage to the charging cable <NUM> if the charging cable <NUM> or charging connector <NUM> is pulled too firmly. A charging cable that is pulled too hard may become damaged if the post <NUM> had a smaller diameter.

<FIG> illustrates an example charging connector, in accordance with aspects of the present disclosure. In aspects, the charging connector <NUM> includes at least one or more ribs <NUM> on each side of the charging connector <NUM>. While one rib <NUM> is illustrated in <FIG>, in aspects, a rib <NUM> is present on each side of the charging connector <NUM>. For example, the charging connector <NUM> includes the illustrated rib <NUM>, and another substantially identical rib on the opposite side of the charging connector not visible in <FIG>.

The one or more ribs <NUM> help the user grip and pull the charging connector <NUM> and connect the charging connector <NUM> to the headphones. The ribs <NUM> also help the user retract, or gently push back, the charging cable <NUM> into the space between the PCBA cap <NUM>. and the charging cable cap <NUM> and place the charging connector <NUM> in the receiving space <NUM>.

<FIG> illustrates an example exploded view of the inner tray <NUM> showing the charging cable <NUM> in a docked position at <NUM> and in a charging position at <NUM>.

Initially, the charging case may be in a docked mode. To switch from the docked mode to the charging mode, the charging cable <NUM> is pulled through tire aperture <NUM>, which decreases the size of the charging cable loop around the post <NUM> as shown in <FIG>. The charging cable <NUM> smoothly extends to space above the inner tray top side <NUM> such that the charging connector <NUM> is able to connect to the headphones. In an example, the charging connector <NUM> connects to an earpiece of the headphones. To switch from the charging mode to the docked mode, the user disconnects the charging connector <NUM> from the headphones and gently pushes the charging cable <NUM> towards the aperture <NUM>. The charging cable <NUM> retracts into the space between the PCBA cap <NUM> and the charging cable cap <NUM>. The retraction increases the size of charging cable loop around the post <NUM> as shown in <FIG>.

<FIG> also illustrates a stiffener <NUM> that is disposed on the inner tray bottom side <NUM>. The stiffener <NUM> is molded to have a shape that, on a first side, substantially follows the profile of the headphones and, on a second side, substantially follows the profile of the inner tray <NUM>. In <FIG>, the stiffener <NUM> follows the profile of a bottom edge of the inner tray <NUM>. In aspects, the first side of the stiffener is substantially opposite the second side of the stiffener. The stiffener <NUM> provides reinforcement along a bottom edge of the inner tray <NUM>. In the charging mode, the stiffener <NUM> helps protect the charging connector <NUM> from impact that bottom edge of the charging case may experience.

<FIG> illustrates the stiffener <NUM> and a clearance <NUM> between the charging connector <NUM> and bottom edge of the inner tray <NUM>, in accordance with aspects of the present disclosure. If the charging case is dropped or experiences impact on the bottom edge of the inner tray <NUM> while in a charging mode, the clearance <NUM> protects the charging connector <NUM> and the headphones by reducing the likelihood that the charging connector <NUM> pushes too far into the headphones. In aspects, the clearance <NUM>, in combination with the stiffener <NUM> provides further protection for the headphones.

Claim 1:
A charging case for headphones comprising:
a top cover (<NUM>);
a bottom cover (<NUM>), the bottom cover comprising a bottom cover top side (<NUM>) and a bottom cover bottom side (<NUM>), the top cover coupled to the bottom cover wherein, in a closed position (<NUM>), the top cover and the bottom cover bottom side form the charging case;
an inner tray (<NUM>) comprising an inner tray top side (<NUM>) and an inner tray bottom side (<NUM>),
the inner tray top side molded to hold the headphones in a volume defined by the top cover and the inner tray top side,
the inner tray bottom side and the bottom cover top side form an enclosure that houses a battery (<NUM>) coupled to a charging cable (<NUM>) for charging the headphones;
an opening in the inner tray extending from the inner tray top side to the inner tray bottom side;
a top charging cable insert (<NUM>) and a bottom charging cable insert (<NUM>), wherein the inner tray is disposed between the top charging cable insert and the bottom charging cable insert,
the top charging cable insert covering the opening on the inner tray top side and comprising an aperture (<NUM>) to receive the charging cable from the enclosure, and
the bottom charging cable insert covering a majority of the opening on the inner tray bottom side; and
a magnet (<NUM>) attached to the bottom charging cable insert, the magnet disposed in the enclosure, wherein in a docked mode, the magnet helps secure a charging connector (<NUM>) of the charging cable in place, and in a charging mode, the charging cable attaches to the headphones while the headphones are positioned in the volume on the inner tray top side.