Patent Description:
Earphones may have one or more ports. The ports can be used, for example, to tune the acoustic performance of the earphone or deliver sound into the ear canal. Ports can comprise an opening with a mesh material covering the opening.

The invention is defined by an earphone according to claim <NUM>. Optional implementation aspects of the earphone are defined in the dependent claims.

In one aspect, an earphone includes a first acoustic cavity, a second acoustic cavity, an electro-acoustic transducer configured to deliver acoustic energy into the first and second acoustic cavities, and a port that acoustically couples one of the first and second acoustic cavities to a different volume, wherein the port comprises an opening with a mesh structure that is insert molded into the port.

The port directly acoustically couples the first and second acoustic cavities. The earphone further comprises a frame that supports the transducer, and the port is integrated into the frame. The frame comprises an annular seat for the transducer, and an integral extension that comprises the port. The port comprises a port opening in the integral extension. There is also a bead of material on the extension and proximate the port opening.

The port may comprise an acoustically resistive element. The port may comprise an acoustically reactive element. The port may comprise a tube. The port may acoustically couple the second acoustic cavity to an environment external to the earphone. The port may comprise a nozzle that is configured to directly deliver acoustic energy into an ear canal. The mesh structure may comprise a moisture-resistant element.

The mesh structure may comprise a moisture-resistant element. The mesh structure may comprise a woven mesh material. The port may acoustically couple the first acoustic cavity to an environment external to the earphone.

In another aspect, an earphone includes a front acoustic cavity, a rear acoustic cavity, an electro-acoustic transducer configured to deliver acoustic energy into the front and rear acoustic cavities, and an internal port that directly acoustically couples the front and rear acoustic cavities, wherein the port comprises an opening with an acoustically resistive woven mesh material that is insert molded into the port.

The earphone may further comprise a mass port and a resistive port that acoustically couple the rear cavity to an environment external to the earphone. The earphone may further comprise a nozzle that is configured to directly deliver acoustic energy from the front cavity into an ear canal. The earphone may further comprise a moisture-resistant element mesh material that is insert molded into the nozzle. The earphone may further comprise an external port that acoustically couples the rear cavity to an environment external to the earphone and comprises an opening with a woven mesh material that is insert molded into the external port.

Earphones often use mesh material to provide a desired acoustic resistance in one or more ports of the earphone. Mesh materials can also be used to cover port openings so as to inhibit moisture or particulate ingression without substantial acoustic resistance. The mesh materials are typically applied in a post-molding operation, which increases earbud production costs and can lead to inhibited performance due to variation in performance between products. Integrating the mesh material into the port by insert molding the mesh in the earphone mold tool does away with the post-molding operation and leads to greater earphone operational uniformity. In addition, integrating the mesh material and attendant port into the frame of the electro-acoustic transducer simplifies assembly.

An earphone or a headphone refers to a device that typically fits around, on, in, or near an ear and that radiates acoustic energy into or towards the ear canal. Headphones and earphones are sometimes referred to as earpieces, headsets, earbuds, or sport headphones, and can be wired or wireless. An earphone includes an electro-acoustic transducer to transduce audio signals to acoustic energy. The electro-acoustic transducer may be housed in an earcup, earbud, or other housing. Some of the figures and descriptions following show a single earphone device. An earphone may be a single stand-alone unit or one of a pair of earphones (each including at least one electro-acoustic transducer), one for each ear. An earphone may be connected mechanically to another earphone, for example by a headband and/or by leads that conduct audio signals to an electro-acoustic transducer in the headphone. An earphone may include components for wirelessly receiving audio signals. An earphone may include components of an active noise reduction (ANR) system. Earphones may also include other functionality, such as a microphone. An earphone may also be an open-ear device that includes an electro-acoustic transducer to radiate acoustic energy towards the ear canal while leaving the ear open to its environment and surroundings.

In an around-the-ear, on-the-ear, or off-the-ear earphone, the earphone may include a headband and at least one housing that is arranged to sit on or over or proximate an ear of the user. The headband can be collapsible or foldable, and can be made of multiple parts. Some headbands include a slider, which may be positioned internal to the headband, that provides for any desired translation of the housing. Some earphones include a yoke pivotably mounted to the headband, with the housing pivotably mounted to the yoke, to provide for any desired rotation of the housing.

<FIG> is a perspective view of in-ear headphone, earphone, or earbud <NUM>. Earphone <NUM> includes body <NUM> that houses the active components of the earbud. Ear tip portion <NUM> is coupled to body <NUM> and is pliable so that it can be inserted into at least the entrance of the user's ear canal. Sound is delivered through opening <NUM>. Retaining loop <NUM> is constructed and arranged to be positioned in the outer ear, for example in the antihelix, to help retain the earbud in the ear. Earphones and earbuds are well known in the field (e.g., as disclosed in <CIT> and <CIT>, and so certain details of the earbud are not further described herein. An earbud is an example of an earphone according to this disclosure, but is not limiting of the scope, as earphones can also be located on or over the ear, or even on the head near the ear.

As shown in <FIG>, earphone <NUM> includes a rear acoustic chamber <NUM> and a front acoustic chamber <NUM> defined by shells <NUM> and <NUM> of the housing, respectively, on either side of an electro-acoustic transducer <NUM>. Note that in the drawings and the following description, non-limiting values of some variables are used. These values represent specific non-limiting examples, it being understood that the disclosure is in no way limited by these examples. In some examples, a <NUM> or <NUM> diameter electro-acoustic transducer can be used. Other sizes and types of electro-acoustic transducers could be used depending, for example, on the desired frequency response and performance of the earphone. The electro-acoustic transducer <NUM> separates the front and rear acoustic chambers <NUM> and <NUM>. The shell <NUM> of the housing extends the front chamber <NUM> via nozzle <NUM> to at least the entrance to the ear canal <NUM>, and in some examples into the ear canal <NUM>, through the ear tip portion <NUM> and ends at an opening <NUM> that may include element <NUM> that can be an acoustic resistance element or a moisture or particulate barrier element, for example. Element <NUM> may be a mesh structure. In some examples, element <NUM> is located within nozzle <NUM> rather than at the end, as illustrated. An acoustic resistance element dissipates a proportion of acoustic energy that impinges on or passes through it. In other examples, no resistance element is included, but a screen may be used in its place to prevent or inhibit moisture or debris from entering the front chamber <NUM>. The front chamber <NUM> does not have a pressure equalization (PEQ) port to connect the chamber <NUM> to an environment external to the earphone.

Instead, a PEQ port <NUM> acoustically couples the front acoustic chamber <NUM> and the rear acoustic chamber <NUM>. The port <NUM> serves to relieve air pressure that could be built up within the ear canal <NUM> and front chamber <NUM> when (a) the earphone <NUM> is inserted into or removed from the ear canal, (b) a person wearing the earphone <NUM> experiences shock or vibration, or (c) the earphone <NUM> is struck or repositioned while being worn. The port <NUM> preferably has a diameter of between about <NUM> to about <NUM>. The port <NUM> preferably has a length of between about <NUM> to about <NUM>. Port <NUM> can have a mesh structure (not shown) if desired, to alter the impedance of the port or provide environmental protection.

The amount of passive noise reduction that can be provided by a ported earphone is often limited by the acoustic impedance through the ports, and the air volume in front of or behind the electrodynamic transducer. Generally, more passive noise reduction is preferable. However, certain port geometry is often needed in order to have proper system performance. Ports can be used to improve acoustic output, equalize audio response, and provide a venting path during overpressure events. Impedance may be changed in a number of ways, some of which are related. Impedance is frequency dependent, and it may be preferable to increase impedance over a range of frequencies and/or reduce the impedance at another range of frequencies. The impedance has two components: a resistive component (DC flow resistance) and a reactive either mass component jω or compliance <NUM>/jω. The total impedance can be calculated at a specific frequency of interest by determining the magnitude or absolute value of the acoustic impedance |z|. The port <NUM> can have a desired absolute value |z| acoustic impedance at different frequencies.

The primary purpose of the port <NUM> is to avoid an over-pressure condition when, e.g., the earphone <NUM> is inserted into or removed from the user's ear <NUM>, or during use of the earphone. Pressure built up in the front acoustic chamber <NUM> escapes to the rear acoustic chamber <NUM> via the port <NUM>, and from there to the environment via back cavity ports <NUM> and <NUM>, mainly the mass port <NUM> (discussed in more detail below). Additionally, the port <NUM> can be used to provide a tuned amount of leakage that acts in parallel with other leakage that may be present. This helps to standardize response across individuals. Adding the port <NUM> makes a tradeoff between some loss in low frequency output and more repeatable overall performance. The port <NUM> provides substantially the same passive attenuation as completely blocking a typical front chamber PEQ port with similar architecture. The port <NUM> in series with the rear cavity ports <NUM> and <NUM> provides a higher impedance venting leak path compared with using a traditional front chamber PEQ instead of the port <NUM>. Surprisingly, however, it was found that this higher impedance results in a more linear behavior during pressure equalization events which reduces the negative impact of the higher impedance.

The rear chamber <NUM> is sealed around the back side of the electro-acoustic transducer <NUM> by the shell <NUM> except that the rear chamber <NUM> includes one or both of a reactive element, such as a port (also referred to as a mass port) <NUM>, and a resistive element, which may also be formed as a port <NUM>. The reactive element <NUM> and the resistive element <NUM> acoustically couple the rear acoustic chamber <NUM> with an environment external to the earphone, thereby relieving the air pressure mentioned above. <CIT> describes the use of parallel reactive and resistive ports in a headphone device. Although we refer to ports as reactive or resistive, in practice any port will have both reactive and resistive effects. The term used to describe a given port indicates which effect is dominant. A reactive port like the port <NUM> is, for example, a tube-shaped opening in what may otherwise be a sealed acoustic chamber, in this case rear chamber <NUM>. A resistive element like the port <NUM> can be, for example, a small opening <NUM> in the wall <NUM> of acoustic chamber <NUM>, covered by a material <NUM> that provides an acoustical resistance, for example, a wire or fabric screen (mesh) that allows some air and acoustic energy to pass through the wall of the chamber.

The reactive element <NUM> can have an absolute value acoustic impedance |zl in a desired range, which may differ at different frequencies. The resistive element <NUM> may have a desired acoustic impedance. The reactive element <NUM> preferably has a diameter of between about <NUM> to about <NUM>, and more preferably has a diameter of about <NUM>. The reactive element <NUM> preferably has a length of between about <NUM> to about <NUM>, and more preferably has a length of about <NUM>. The resistive element <NUM> preferably has a diameter of about <NUM> and a length of preferably about <NUM> covered with a <NUM> rayls or <NUM> rayls resistive material (e.g. woven cloth) <NUM>. These dimensions provide both the acoustic properties desired of the reactive port <NUM>, and an escape path for the pressure built up in the front chamber <NUM> and transferred to the rear chamber <NUM> by the port <NUM>. The ports <NUM> and <NUM> provide porting from the rear acoustic chamber <NUM> to an environment external to the earphone. Furthermore, in order to receive a meaningful benefit in terms of passive attenuation when using a front to back port <NUM> in a ported system, the ratio of the impedance of the ports <NUM> and <NUM> to the impedance of the port <NUM> is preferably greater than <NUM> and more preferably around <NUM> at <NUM>.

For an active noise reduction (ANR) earphone two functions (of many) of the ports <NUM>, <NUM> and <NUM> are to increase the output of the system (improves active noise reduction) and provide pressure equalization. In addition, it is desirable to maximize the impedance of these ports at frequencies that can improve the total system noise reduction. At certain frequencies (e.g., at low frequency) it may be preferable for the impedance to allow for venting pressure or increasing low frequency output, and at certain other frequencies (e.g., at <NUM>) it may be preferable for the impedance to be different in order to maximize passive noise reduction. Ports allow this to occur as they can have a different resistive DC component from the reactive frequency dependent component depending upon their design.

Any one or more of the ear tip portion <NUM>, cavities <NUM> and <NUM>, electro-acoustic transducer <NUM>, screen <NUM>, port <NUM>, and elements <NUM> and <NUM>, can have acoustic properties that may affect the performance of the earphone <NUM>. These properties may be adjusted to achieve a desired frequency response for the earphone. Additional elements, such as active or passive equalization circuitry, may also be used to adjust the frequency response. The rear chamber <NUM> preferably has a volume of between about <NUM><NUM> to about <NUM><NUM>, and more preferably has a volume of about <NUM><NUM> (this volume includes a volume behind a diaphragm of the electro-acoustic transducer <NUM> (inside the transducer), but does not include a volume occupied by metal, pcb, plastic or solder). Excluding the electro-acoustic transducer, the front chamber <NUM> preferably has a volume of between about <NUM><NUM> to about <NUM><NUM>, and more preferably has a volume of about <NUM><NUM>.

The reactive port <NUM> resonates with the back chamber volume. In some examples, the reactive port <NUM> and the resistive port <NUM> provide acoustical reactance and acoustical resistance in parallel, meaning that they each independently couple the rear chamber <NUM> to free space. In contrast, reactance and resistance can be provided in series in a single pathway, for example, by placing a resistive element such as a wire mesh screen inside the tube of a reactive port. In some examples, a parallel resistive port is made from an <NUM>×<NUM> Dutch twill wire cloth, for example, that available from Cleveland Wire of Cleveland, Ohio, and has a diameter of about <NUM>. Parallel reactive and resistive elements, embodied as a parallel reactive port and resistive port, provides increased low frequency response compared to an example using a series reactive and resistive elements. The parallel resistance does not substantially attenuate the low frequency output while the series resistance does. Using a small rear cavity with parallel ports allows the earphone to have improved low frequency output and a desired balance between low frequency and high frequency output.

Some or all of the elements described above can be used in combination to achieve a particular frequency response (non-electronically). In some examples, additional frequency response shaping may be used to further tune sound reproduction of the earphones. One way to accomplish this is with passive electrical equalization using circuitry (not shown). Such circuitry can be housed in-line with the earphones or within the housing of the earphones, for example. If active noise reduction circuitry or wireless audio circuitry is present, such powered circuits may be used to provide active equalization.

Any one or more of the ports (e.g., ports <NUM>, <NUM>, <NUM>, and/or <NUM>) can comprise an opening that is covered by a mesh structure. The mesh structure can be coupled to the structure that forms the port (e.g., the housing) by insert molding the mesh structure into the port. The mesh can be insert molded across the port at any location along the length of the port, up to and including either surface at the ends of the port. Insert molding is known in the field of plastic injection molding, and involves placing the mesh structure into a particular location in the mold tool and then injecting plastic that partially encapsulates the mesh structure while at the same time forming part or all of the structure that defines the port. For example, mesh structure <NUM> can be insert molded into shell <NUM>. As described below, a mesh structure <NUM> could likewise be insert molded to a frame of an electro-acoustic transducer as part of front-to-back PEQ <NUM>.

Insert molding of a mesh structure into a port of an earphone can substantially improve the earphone and simplify its fabrication. Insert molding is a variation on the same fundamental injection molding process which is already used to produce various parts of the earbud (e.g., shells <NUM> and <NUM>), including the opening of ports <NUM>, <NUM>, and <NUM>. Accordingly, there are no extra steps needed in order to fix the mesh structure to the port. This is in contrast to the current fabrication approaches that involve post-molding operations such as adhering the mesh material into the port (e.g., using a pressure sensitive adhesive (PSA)) or heat staking the mesh material into the port (which involves softening a thermoplastic port material post-molding and embedding the mesh material into the softened plastic, which then hardens and encapsulates the mesh). Insert molding can thus save time and effort during earbud fabrication. Also, insert molding is reliable in its ability to properly encapsulate the edges of the mesh material while leaving the material that spans the port opening open. This leads to less chance of acoustic leakage or water leakage around the mesh compared to the use of PSA, which can lead to incomplete adhesion and thus leakage, or even to the failure of the adhesive joint. As long as the edges of the mesh are encapsulated through the insert molding process, these benefits in consistency of seal and mesh integrity can be realized. Although benefits in ease of assembly are maximized when the port opening is integral to a larger structure, in its simplest form the port may be a stand-alone injection molded component comprising just a frame of injection molded plastic capturing the edges of the mesh. Adhering such a rigid plastic frame onto surrounding structure is a far less sensitive process than capturing the edges of the mesh. This type of variation may be used in cases where the plastic component containing the port opening is produced by sufficiently complex molding and tooling such that insert molding is no longer feasible. Also, with insert molding the port structure itself and the port opening are left intact and untouched. In contrast, the PSA in an adhesive joint and the softened and re-hardened plastic in a heat-staked joint can partially block the port and have an effect on the acoustic performance of the port. Insert molding is also a repeatable, mostly or fully-automated process, leading to less variation between products. The product consistency also allows acoustic earphone considerations, such as active noise reduction, to be implemented more aggressively than might be the case where there could be more variation product-to-product.

As is known in the technical field, the mesh structure can be designed to create an acoustic resistance and/or it can be used for environmental protection purposes, for example to inhibit the passage of moisture and/or particles. The mesh structures can comprise woven or nonwoven meshes. The mesh can be made of plastic, metal, or another material.

In one specific, non-limiting implementation of an earphone, the electro-acoustic transducer is mounted on open frame <NUM>, <FIG>. Frame <NUM> canbe an integral molded structure that comprises annular seat <NUM> on which the transducer can sit, opening <NUM> to accommodate the diaphragm and other structures of the transducer, and extension <NUM> with through-hole <NUM> into which mesh material <NUM> can be insert molded. Hole <NUM> with integral mesh <NUM> forms a port, e.g., a PEQ port that directly acoustically connects the front and rear acoustic cavities of the transducer. Frame <NUM> can be carried inside the earphone housing (not shown) as would be apparent to those skilled in the technical field.

<FIG> is a rear perspective view of frame <NUM> and transducer <NUM> mounted in the frame. A ridge or protrusion <NUM> is located or placed on top of extension <NUM> surrounding part of through-hole <NUM>. Ridge <NUM> can be an integral portion of the molded structure, or can be added separately. A purpose of ridge <NUM> is to inhibit any adhesive used to mount transducer <NUM> in frame <NUM> (or to mount frame <NUM> in the housing) from being pushed into hole <NUM> during assembly, as this could cause unwanted and uncontrolled changes to the performance of the PEQ port. The shape of the PEQ port can be optimized for noise. A goal is to conserve the area of the port opening. As depicted, the opening shape may be an elongated oval.

<FIG> is a schematic partial cross-section illustrating a manner in which frame <NUM> interfits with and is coupled to shells <NUM> and <NUM>. Transducer <NUM> can be coupled to frame <NUM> with adhesive. Frame <NUM> can carry chamfer <NUM> that acts as a location at which frame <NUM> is glued to shell <NUM>. Bead <NUM> is located between chamfer <NUM> and PEQ <NUM>, to prevent adhesive on chamfer <NUM> from being pushed into the PEQ port as the parts are assembled.

Claim 1:
An earphone (<NUM>), comprising:
a front acoustic chamber (<NUM>);
a rear acoustic chamber (<NUM>);
an electro-acoustic transducer (<NUM>) configured to deliver acoustic energy into the front and rear acoustic chambers;
a housing which includes the rear acoustic chamber (<NUM>) and the front acoustic chamber (<NUM>) defined by, respectively, a rear shell (<NUM>) and a front shell (<NUM>) of the housing on either side of the electro-acoustic transducer (<NUM>);
a port (<NUM>) that is configured to directly acoustically couple the front and rear acoustic chambers, wherein the port comprises an opening (<NUM>) with a mesh structure (<NUM>) that is insert molded into the port;
a frame (<NUM>) that is configured to support the transducer, wherein the port is integrated into the frame;
wherein the frame carried inside the housing comprises an annular seat (<NUM>) for the transducer, and an integral extension (<NUM>) that comprises the port,
wherein the port comprises a port opening in the integral extension, and further comprising a bead (<NUM>) of material on the extension and proximate the port opening,
wherein the frame (<NUM>) is arranged to carry a chamfer (<NUM>) that is configured to act as a location at which the frame is glued to the front shell (<NUM>) defining the front acoustic chamber, and wherein the bead (<NUM>) is located between the chamfer and the port so as to prevent adhesive on the chamfer from being pushed into the port as the parts are assembled.