Patent ID: 12225341

DETAILED DESCRIPTION

Open-ear headphones that are carried on the ear should provide high-quality sound, be stable on the ear, be comfortable to wear for long periods of time, be unobtrusive, and look stylish. These goals can be difficult to achieve, as in some respects they have been considered mutually exclusive. For example, stability typically translates into clamping on the outer ear, which can be uncomfortable for long-term wear and also may not look stylish. Also, for high-quality sound there must be sound delivery close to but not in the ear canal, meaning that headphone structure needs to overlie the ear and so may be highly visible to others. Also, for the best sound quality the sound should be delivered close to but not in the ear canal opening.

Examples of the open-ear headphones discussed herein are not limited in application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The headphones are capable of implementation in other examples and of being practiced or of being carried out in various ways. Examples of specific implementations are provided herein for illustrative purposes only and are not intended to be limiting. In particular, functions, components, elements, and features discussed in connection with any one or more examples are not intended to be excluded from a similar role in any other examples.

Examples disclosed herein may be combined with other examples in any manner consistent with at least one of the principles disclosed herein, and references to “an example,” “some examples,” “an alternate example,” “various examples,” “one example” or the like are not necessarily mutually exclusive and are intended to indicate that a particular feature, structure, or characteristic described may be included in at least one example. The appearances of such terms herein are not necessarily all referring to the same example.

Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. Any references to examples, components, elements, acts, or functions of the headphones herein referred to in the singular may also embrace embodiments including a plurality, and any references in plural to any example, component, element, act, or function herein may also embrace examples including only a singularity. Accordingly, references in the singular or plural form are not intended to limit the presently disclosed systems or methods, their components, acts, or elements. The use herein of “including,” “comprising,” “having,” “containing,” “involving,” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. References to “or” may be construed as inclusive so that any terms described using “or” may indicate any of a single, more than one, and all of the described terms.

In some examples herein the open-ear headphone includes a flexible arm that is configured to be located between and physically and electrically connect the acoustic module and the battery housing. The flexible arm defines an original resting length and position between the acoustic module and the battery housing. The flexible arm includes a flexible printed circuit that extends through the entire original resting length of the flexible arm. The flexible printed circuit includes one or more conductors that carry electrical energy between the acoustic module and the battery housing. A flexible material encases at least some of the flexible printed circuit. The length of the flexible printed circuit within the flexible arm is greater than the original resting length of the flexible arm. The flexible printed circuit can thus better accommodate tension or compression on the flexible arm as the flexible arm is bent from its original resting position.

In some examples the original resting position of the flexible arm lies along a curved axis. In an example the curved axis defines a simple open curve. In an example the curved axis is generally “C”-shaped. In an example the curved axis bisects the flexible arm, and different parts of a first surface of the flexible printed circuit lie on different sides of the curved axis. In an example the flexible printed circuit defines at least one simple open curve along its length within the flexible arm. In an example the flexible printed circuit defines a plurality of both simple open upward curves and simple open downward curves along its length within the flexible arm. In an example each simple open downward curve is adjacent to one more of the simple open upward curves.

In some examples the flexible material includes two mating members that each define a series of simple open curves along the original resting length of the flexible arm. In an example the simple open curves of the two mating members are complimentary. In an example the two mating members each define a wave-shaped mating surface wherein convex portions of one member are aligned with and fit into concave portions of the other member, and the flexible printed circuit is located between the mating surfaces of the two mating members. In an example the flexible arm also includes an over-mold that encircles the flexible material along at least most and preferably all of the original resting length of the flexible arm. In an example the over-mold further covers at least some and preferably all of the battery housing.

In some examples the flexible printed circuit defines one or more open curves along its length within the flexible arm. In an example the one or more open curves are simple open curves. In an example the flexible arm also includes a flexible printed circuit stress relief member proximate the flexible material. The stress relief member defines an opening through which the flexible printed circuit is threaded. In an example the flexible printed circuit defines an open slot along a portion of its length in the flexible arm, to accommodate twisting of the flexible printed circuit about its length.

In other examples herein the open-ear headphone includes a flexible arm that is located between and physically and electrically connects the acoustic module to the battery housing. The flexible arm defines an original resting length and position between the acoustic module and the battery housing. The original resting position of the flexible arm lies along a generally “C”-shaped curved axis. The arm includes a flexible printed circuit that extends through the entire original resting length of the arm. The flexible printed circuit includes one or more conductors that carry electrical energy between the acoustic module and the battery housing. A flexible material encases at least some of the flexible printed circuit. The flexible printed circuit defines at least one simple open curve along its length within the flexible arm, such that its length within the flexible arm is greater than the original resting length of the flexible arm. This allows the flexible printed circuit to better accommodate tension or compression on the flexible arm as the flexible arm is bent from its original resting position.

In an example the flexible printed circuit defines a plurality of both simple open upward curves and simple open downward curves along its length within the flexible arm, and each simple open downward curve is adjacent to a simple open upward curve. In an example the flexible arm also includes a flexible printed circuit stress relief member proximate the flexible material. The stress relief member defines an opening through which the flexible printed circuit is threaded.

FIG.1is a perspective view of open-ear headphone10. Headphone10is configured to be carried on an ear of a user such that its acoustic module12is located in the concha of the ear and battery housing14is located behind the ear. Flexible arm20is configured to pass over the outer side of the helix, anti-helix and/or lobule of the ear. Arm20has an original or resting position and length, illustrated inFIG.1. In some examples the original position generally defines a “C”-shape, as shown inFIG.1. Arm20is configured to be flexed at least along its length, so that the space between acoustic module12and battery housing14can be slightly increased. This allows headphone10to be donned and doffed from the ear without needing to push the headphone over the external ear, yet still provides a light clamping force on the ear to help keep headphone10in place on the ear as the user's head moves. Electrical signals need to be carried through arm20. In some examples the electrical signals include the power from the battery (not shown) in battery housing14to the acoustic transducer (not shown) in acoustic module12, and audio signals from wireless reception and processing circuitry (not shown) that can be located in one or both of arm20and battery housing14. In some examples these electrical signals are carried by conductors of a flexible printed circuit. The flexible printed circuit needs to be able to flex as arm20is flexed, yet at the same time needs to carry necessary electrical signals. Flexible printed circuits are well known in the electrical/electronics fields and so are not further described herein.

Additional details of an open-ear headphone, including but not limited to its construction, operation, and details of its acoustic performance, are disclosed in U.S. Pat. No. 11,140,469, the entire disclosure of which is incorporated herein by reference and for all purposes. Aspects of the present open-ear headphone that are disclosed in this patent are not further described herein.

FIGS.2A and2Bare perspective and side exploded views of portion30of a flexible arm for an open-ear headphone. Portion30includes flexible printed circuit31which itself includes one or more conductors (not shown). In some examples flexible printed circuit31extends through the entire original resting length of the flexible arm in which it is used. Flexible material40encases at least some of flexible printed circuit31. In this example flexible material40comprises separate mating portions42and44. In some examples portions42and44are made from a compliant material such as silicone. To accommodate flexing of the arm in which portion30is used, the length of the flexible printed circuit within the flexible arm is greater than the original resting length of the flexible arm, such that the flexible printed circuit can better accommodate tension or compression on the flexible arm as the flexible arm is bent from its original resting position. In this example, portions42and44each define a series of alternating concave and convex portions that are configured to mate when portions42and44are assembled together, as depicted inFIG.2C.

FIG.2Cis an assembled view of the partial flexible arm ofFIGS.2A and2B. A result is a wave or general sinusoid shape imparted on the flexible printed circuit. In this example convex and concave adjacent simple open curves52,54,56,58, and60are imparted on flexible printed circuit31. These curves partially lie on both sides of arm central longitudinal axis33. One or more curves accomplish a conductor length that is longer than the original resting length of the flexible arm in which portion30is used. If the arm is bent, the extra length will accommodate the bending with less stress on or bending of the conductors of the flexible printed circuit. Since the conductors of the flexible printed circuit are generally metal (e.g., copper traces) that can be fatigued and may break when flexed or bent, the additional length helps the flexible printed circuit to survive repeated donning and doffing of the open-ear headphone.

In examples herein the longer length of flexible printed circuit31is accomplished by configuring it such that defines one or more open curves along its length within the flexible arm. In some examples the one or more open curves are simple open curves. In some examples the original resting position of the flexible arm lies along a curved axis and the flexible printed circuit defines at least one simple open curve along its length within the flexible arm. In some examples the curved axis of the arm defines a simple open curve. In an example the curved axis is generally “C”-shaped. In an example the curved axis bisects the flexible arm, and different parts of a first surface of the flexible printed circuit (e.g., the top or bottom surface) lie on different sides of the curved axis. In an example the flexible printed circuit defines a plurality of both simple open upward curves and simple open downward curves along its length within the flexible arm. In an example each simple open downward curve of the flexible printed circuit is adjacent to one more of the simple open upward curves.

In some examples the flexible material comprises two mating members that each define a series of simple open curves along the original resting length of the flexible arm. In an example the simple open curves of the two mating members are complimentary. In an example the two mating members each define a wave-shaped mating surface wherein convex portions of one member are aligned with and fit into concave portions of the other member, and wherein the flexible printed circuit is located between the mating surfaces of the two mating members.

In some examples herein an over-mold encircles the flexible material that encases the flexible printed circuit along at least most of the original resting length of the flexible arm. For example, flexible arm portion70,FIG.2D, includes over-mold72that fully covers most or all of flexible material40.FIG.2Dillustrates more of the flexible arm that is partially depicted inFIGS.2A-2C. In an example over-mold72is a silicone material. Over-mold72also helps to increase the environmental stability of the flexible arm by sealing openings between portions42and44and/or the ends of material40while retaining the flexibility of the arm.

FIG.3illustrates a partially assembled open-ear headphone with a flexible arm100. Arm100is connected to housing member80of battery housing14. Over-mold90comprises the outer layer of arm100and also covers some or all of member80and so also defines the outer layer of some or all of battery housing14. Over-mold90can be accomplished using an insert molding technique. Enlarged overmolding end106represents a part of the over-molding that would overlie or abut the acoustic module, not shown in this view. Also shown in this view is enlarged end104of an arm internal member that functions to help mechanically couple arm100to the acoustic module and also provide stress relief for flexible printed circuit102. Flexible printed circuit102passes through the entire length of arm100, is terminated in battery housing14and would also be terminated in the acoustic module. In some examples and as further described below the flexible printed circuit stress relief member defines an opening through which flexible printed circuit102is threaded. Also, in some examples and as further described below, the flexible printed circuit defines an open slot along a portion of its length in the flexible arm, to accommodate twisting of the flexible printed circuit about its length.

FIG.4illustrates an alternative assembly120for a flexible arm. In some examples assembly120is an alternative to portion30illustrated inFIGS.2A-2C. Assembly120includes a flexible printed circuit124partially encased in a flexible material122. This is an alternative to sandwiching the flexible printed circuit between two discrete flexible members as inFIG.2A. In assembly120flexible printed circuit124is seated within pre-formed serpentine recess121in a single flexible member122. This illustrates one non-limiting manner of maintaining a flexible printed circuit length in the flexible arm that is longer than the original resting length of the arm. In some examples flexible material122is molded from a silicone material, or a different elastomer. Material122is molded with an internal slot121that is created using a removable insert. Flexible printed circuit124is then placed into slot121as shown. Material122thus fixes flexible printed circuit124in the configuration of slot121. Slot121defines one or more curves along its length, such that it is longer than is a central longitudinal axis of the material122. When assembly120is used in a flexible arm, the flexible printed circuit in the arm is longer than the original resting length of the arm.

FIG.5Ais a schematic illustration of aspects140of a flexible arm. Flexible printed circuit142passes through the entire length of the arm. Portion145of flexible printed circuit142has a number of simple open curves that are held in place by flexible material144that encases at least some of flexible printed circuit142. Members150and160are located at the ends of arm140and each act as both stress relief members of the flexible printed circuit and to mechanically couple the arm to the battery housing and the acoustic module (neither shown in this drawing). In some examples members150and160are made of an engineered plastic such as a nylon or acrylonitrile butadiene styrene (ABS) and act to reinforce the arm and strengthen it at its distal locations that are coupled to the battery housing and the acoustic module.

Member150is also illustrated inFIG.5B. It can be made by injection molding or machining or stamping. In some examples it is a unitary member. Member150includes body152with one or both of openings155and156and enlarged end154that is configured to be mechanically coupled to one of the battery housing and the acoustic module such as by an interference fit and/or by an adhesive. As shown inFIG.5A, in some examples flexible printed circuit142passes through one of openings155and156, which helps to provide stress relief. In some examples the arm is completed by over-molding with a flexible material which encases all or substantially all of aspects140. The over-molding will fill or at least substantially fill openings155and156, thus anchoring member150in the arm. In some examples second member160includes one or more openings (not shown) that are also filled with the over-molded material. In some examples member160acts as a guide for flexible printed circuit142, which can pass over the back of member160as shown inFIG.5A. Member160also includes enlarged end164that is configured to be mechanically coupled to one of the battery housing and the acoustic module such as by an interference fit and/or by an adhesive.

FIG.6partially illustrates a flexible printed circuit assembly180for a flexible arm. Assembly180includes flexible printed circuit182. In order to accommodate twisting of the arm about its longitudinal axis with less disruption to flexible printed circuit182, flexible printed circuit182has an open slot184along a portion of its length. If flexible printed circuit182is twisted, the stress will at least in part be relieved by open slot184. This may result in less stress on any metal conductors of flexible printed circuit182, which may increase the useful life of the conductors.

Having described above several aspects of at least one example, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure and are intended to be within the scope of the invention. Accordingly, the foregoing description and drawings are by way of example only, and the scope of the invention should be determined from proper construction of the appended claims, and their equivalents.