PATENT DOCUMENT

Publication Number: US-10681445-B2
Application Number: US-201715696810-A
Country: US
Kind Code: B2

Title: Earphone assemblies with wingtips for anchoring to a user

Abstract:
Earphone assemblies with wingtips are provided for anchoring to a user during use. A wing may extend from and between two different ends coupled to a housing of an earphone, while each of the at least one flex arm may extend along the wing. At least one flex arm may be rigid enough to prevent at least a portion of the wing from bending out of a plane of the wing such that a portion of the wing may maintain a functional position under and/or behind at least a portion of a crus of an anti-helix of a user&#39;s ear to anchor the earphone to the user&#39;s ear during use, while at least a portion of the wing may be flexible enough to provide comfort to the user&#39;s ear.

Claims:
What is claimed is: 
     
       1. An earphone assembly to be worn by a user&#39;s ear, the earphone assembly comprising:
 a housing having an audio port; 
 a speaker disposed within the housing and aligned to emit sound through the audio port; 
 a sheath removably coupled to the housing; 
 a deformable wing sized and shaped to anchor the earphone assembly to a user&#39;s ear and having first and second ends coupled to first and second anchoring locations, respectively, on the sheath; 
 a first flex arm body positioned within the deformable wing and extending from the first anchoring location and terminating at a location between the first and second ends; and 
 a second flex arm body positioned within the deformable wing and extending from the second anchoring location and terminating at a location between a distal end of the first flex arm and the second end, wherein the first flex arm body has a length that is at least twice as long as a length of the second flex arm body and wherein a material of the first and second flex arm bodies is more rigid than a material of the deformable wing. 
 
     
     
       2. The earphone assembly of  claim 1 , wherein the first anchoring location is different than the second anchoring location. 
     
     
       3. The earphone assembly of  claim 1 , wherein a length of the first flex arm body comprises between 20% and 60% of a length of the deformable wing; and a length of the second flex arm body comprises between 1% and 20% of the length of the deformable wing. 
     
     
       4. The earphone assembly of  claim 1 , wherein the first flex arm body and the second flex arm body extend along distinct portions of the length of the deformable wing. 
     
     
       5. The earphone assembly of  claim 1 , wherein the first and second flex arm bodies exist within a wing plane; and the first and second flex arm bodies are configured to prevent at least a majority of the wing from moving out from the wing plane. 
     
     
       6. The earphone assembly of  claim 5 , wherein the first and second flex arm bodies are configured to enable at least a portion of the wing to bend within the wing plane. 
     
     
       7. The earphone assembly of  claim 5 , further comprising a nozzle member extending from the housing along a sound axis and defining the audio port such that the audio port directs sound emitted by the speaker out from the earphone assembly along the sound axis, wherein the wing plane forms a sound wing angle with the sound axis in a range between 57° and 97°. 
     
     
       8. The earphone assembly of  claim 1 , wherein a portion of the deformable wing is operative to be positioned under an anti-helix crus of the user&#39;s ear when the earphone assembly is worn by the user&#39;s ear. 
     
     
       9. An earbud comprising:
 a housing having an audio port; 
 a speaker disposed within the housing and aligned to emit sound through the audio port; 
 a sheath coupled to the housing; 
 a deformable wing sized and shaped to anchor the earbud to a user&#39;s ear and having first and second ends coupled to first and second anchoring locations, respectively, on the sheath; and 
 a first flex arm body positioned within the deformable wing and extending from the first anchoring location and terminating at a location between the first and second ends, and a second flex arm body positioned within the deformable wing and extending from the second anchoring location and terminating at a location between a distal end of the first flex arm body and the second end; 
 wherein the first flex arm body has a length that is at least twice as long as a length of the second flex arm body, the first and second flex arm bodies have a constant width and thickness along at least a majority of their lengths, a material of the first and second flex arm bodies is more rigid than a material of the deformable wing, and the first and second flex arm bodies provide greater resistance when the deformable wing is bent in a first direction than when the deformable wing is bent in a second direction different than the first direction. 
 
     
     
       10. The earbud set forth in  claim 9  wherein the sheath encases the housing and defines outer surfaces of the deformable wing. 
     
     
       11. The earbud set forth in  claim 9  wherein a length of the deformable wing between the first and second ends forms a loop with the housing. 
     
     
       12. An earbud comprising:
 a housing having an audio port; 
 a speaker disposed within the housing and aligned to emit sound through the audio port; 
 a sheath removably coupled to the housing; 
 a deformable wing sized and shaped to engage an anti-helix portion of a user&#39;s ear thereby anchoring the earbud to the user&#39;s ear, the deformable wing having first and second ends coupled to first and second anchoring locations, respectively, on the sheath; 
 a first flex arm body positioned within the deformable wing and extending from the first anchoring location and terminating at a location between the first and second ends; and 
 a second flex arm body positioned within the deformable wing and extending from the second anchoring location and terminating at a location between a distal end of the first flex arm body and the second end 
 wherein the first flex arm body has a length that is at least twice as long as a length of the second flex arm body and wherein a material of the first and second flex arm bodies is more rigid than a material of the deformable wing and the first and second flex arm bodies provide greater resistance when the wing is bent in a first direction than when the wing is bent in a second direction different than the first direction. 
 
     
     
       13. The earbud set forth in  claim 12  wherein the sheath encases the housing and defines outer surfaces of the deformable wing. 
     
     
       14. The earbud set forth in  claim 12  wherein a length of the deformable wing between the first and second ends forms a loop with the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims the benefit of prior filed U.S. Provisional Patent Application No. 62/384,124, filed Sep. 6, 2016, which is hereby incorporated by reference herein in its entirety. 
    
    
     TECHNICAL FIELD 
     This can relate to earphone assemblies, including earphone assemblies with wingtips for anchoring to a user. 
     BACKGROUND OF THE DISCLOSURE 
     Earphone assemblies are often worn by users that are exercising or performing other activities. However, such active use often dislodges an earphone assembly from its functional position with respect to a user&#39;s ear. 
     SUMMARY OF THE DISCLOSURE 
     Earphone assemblies with wingtips are provided for anchoring to a user during use. 
     As an example, an earphone assembly to be worn by a user&#39;s ear includes a housing, an audio output component positioned at least partially within the housing, a flex arm extending from a flex free end to a flex housing end held at a housing flex arm location with respect to the housing, and a wing extending from a first wing housing end to a second wing housing end, wherein the flex arm extends along a portion of the wing, and wherein a material of the flex arm is more rigid than a material of the wing. 
     As another example, an assembly to be worn by a user&#39;s ear includes a housing, a sheath fitted about the housing, a wing extending between a first wing end coupled to a first wing platform of the sheath and a second wing end coupled to a second wing platform of the sheath, and a flex arm extending within a portion of the wing between the first wing end and the second wing end, wherein the flex arm is configured to prevent at least the portion of the wing from moving out of a wing plane, and wherein the flex arm is configured to enable at least the portion of the wing to move within the wing plane. 
     As yet another example, an assembly to be worn by a user&#39;s ear includes a housing, a sheath fitted about the housing, a first flex arm extending between a first flex arm portion of the sheath and a first flex free end, a second flex arm extending between a second flex arm portion of the sheath and a second flex free end, and a wing including a wing portion extending between the first flex free end and the second flex free end, wherein at least a portion of the wing portion is operative to maintain contact with the user&#39;s ear when the assembly is worn by the user&#39;s ear. 
     This Summary is provided only to summarize some example embodiments, so as to provide a basic understanding of some aspects of the subject matter described in this document. Accordingly, it will be appreciated that the features described in this Summary are only examples and should not be construed to narrow the scope or spirit of the subject matter described herein in any way. Unless otherwise stated, features described in the context of one example may be combined or used with features described in the context of one or more other examples. Other features, aspects, and advantages of the subject matter described herein will become apparent from the following Detailed Description, Figures, and Claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The discussion below makes reference to the following drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a perspective view of an illustrative earphone assembly that may be provided with at least one wingtip subassembly; 
         FIG. 2  is an exploded perspective view of an earbud subassembly of the earphone assembly of  FIG. 1  without a wingtip subassembly; 
         FIG. 3  is a side elevational view of the earbud subassembly of  FIGS. 1 and 2  without a wingtip subassembly and with portions of the earbud subassembly partially transparent; 
         FIG. 4  is a front elevational view of a wingtip subassembly for the earbud subassembly of  FIGS. 1-3 ; 
         FIG. 5  is a bottom elevational view of the earbud subassembly of  FIGS. 1-3  with the wingtip subassembly of  FIG. 4 ; 
         FIG. 6  is a front elevational view of the earbud subassembly of  FIGS. 1-3 and 5  with the wingtip subassembly of  FIGS. 4 and 5 ; 
         FIG. 7  is a rear elevational view of the earbud subassembly of  FIGS. 1-3, 5, and 6  with the wingtip subassembly of  FIGS. 4-6 ; 
         FIG. 8  is a rear elevational view of the earbud subassembly of  FIGS. 1-3 and 5-7  with the wingtip subassembly of  FIGS. 4-7  anchored to an ear of a user; and 
         FIG. 9  is a perspective view of another illustrative earphone assembly that may be provided with at least one wingtip subassembly. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Earphone assemblies with wingtips are provided and described with reference to  FIGS. 1-9 . 
     This disclosure describes a system to improve stability for earphones (e.g., wired or wireless in-ear earphones or for any other suitable type of earphones), particularly for active and sport use cases where the earphones can move and/or become dislodged, either ruining the sound quality or falling out completely from a functional position with respect to a user&#39;s ear. A housing of the earphone may house at least a portion of a sound emitting component of the earphone, and each of at least one flex arm may extend from the housing to a free end. A wing may extend from and between two different ends coupled to the housing, while each of the at least one flex arm may extend along the wing. At least one flex arm may be rigid enough to prevent at least a portion of the wing from bending out of a plane of the wing such that a portion of the wing may maintain a functional position under and/or behind at least a portion of a crus of an anti-helix of a user&#39;s ear to anchor the earphone to the user&#39;s ear during use, while at least a portion of the wing may be flexible enough to provide comfort to the user&#39;s ear. 
     Any suitable type of headphone or earphone assembly may be provided with one or more wingtips for anchoring to a user during use. For example, wingtips may be provided for an occluding earphone assembly that may include one or more occluding earbuds or earphones configured to be at least partially inserted into an ear canal of a user (e.g., an in-ear headphone or in-ear monitor or canalphone assembly) (see, e.g., earbud subassembly  200  and/or earbud subassembly  300  of earphone assembly  100  of  FIGS. 1-3 and 5-8 ). Alternatively, wingtips may be provided for a non-occluding earphone assembly that may include one or more non-occluding earbuds or earphones configured not to be at least partially inserted into the ear canal of the user but that may fit directly in the outer ear (e.g., within a concha of the ear) and face the ear canal (see, e.g., earbud subassembly  930  and/or earbud subassembly  940  of earphone assembly  900  of  FIG. 9 ). A wingtip may be removably coupled to an earbud of an earphone assembly, such that the wingtip may only be used when desired and/or such that different wingtips of different sizes may be interchangeably coupled to an earbud of an earphone assembly based on the size of the user&#39;s ear. Alternatively, a wingtip may be an integral part of an earphone assembly, such as a wingtip that is molded to or otherwise fixed to an earbud or other portion of the earphone assembly. 
     As shown in  FIG. 1 , an earphone assembly  100  that may be provided with one or more wingtip subassemblies may include a first earbud subassembly  200 , a second earbud subassembly  300 , a power supply subassembly  500 , a logic subassembly  600 , an input subassembly  700 , and various cable subassemblies that may electrically couple the other subassemblies of earphone assembly  100 , such as a first cable subassembly  110  that may electrically couple earbud subassembly  200  with input subassembly  700 , a second cable subassembly  120  that may electrically couple earbud subassembly  300  with power supply subassembly  500 , a third cable subassembly  130  that may electrically couple input subassembly  700  with logic subassembly  600 , and a fourth cable subassembly  140  that may electrically couple power supply subassembly  500  with logic subassembly  600 . Each one of first earbud subassembly  200  and second earbud subassembly  300  may be operative to receive audio data electrical signals (e.g., from cable subassembly  110  and cable subassembly  120 , respectively), to convert or transduce the received electrical signals into corresponding sound waves, and to emit the sound waves towards an eardrum of a user wearing the earbud subassembly. First earbud subassembly  200  and second earbud subassembly  300  may be substantially the same in function, shape, and/or size, but may be mirror images of one another, such that each may be configured for comfortable use within a respective one of a user&#39;s left and right ears, where, for example, first earbud subassembly  200  may be configured for use in a user&#39;s left ear and second earbud subassembly  300  may be configured for use in a user&#39;s right ear. Power supply or battery subassembly  500  may include a battery or any other suitable power supply operative to receive and store power that may then be used to power various other subassemblies of assembly  100 , where such power may be shared with one or more of subassemblies  200 ,  300 ,  600 , and/or  700  via one or more of cable subassemblies  110 ,  120 ,  130 , and/or  140 . The power supply may be rechargeable via a charging port of assembly  100  (e.g., a charging port of power supply subassembly  500  and/or of logic subassembly  600 ) and/or may be replaceable. Power supply subassembly  500  may include a power button that may be used to turn assembly  100  on and off. Logic or main logic board (“MLB”) subassembly  600  may include any suitable components for controlling the functionality of assembly  100 , such as, but not limited to, a processor component, a memory component, a wireless communication component for receiving audio data information from a media player or radio source, a wired connector for connecting via a cable with a media player (not shown), a media player application if no remote media source is to be used, a charging port for the power supply of power supply assembly  500 , and/or the like, each of which may be at least partially provided on an MLB. Input or user communication box subassembly  700  may include any suitable components for receiving user input commands for controlling assembly  100 , such as, but not limited to, a microphone, one or more buttons that may be configured to receive user input for controlling volume and/or media selection, and/or the like. In some embodiments, assembly  100  may include other components not combined or included in those shown or several instances of the components shown. 
     As shown in one or more of  FIGS. 2-8 , earbud subassembly (hereinafter “earbud”)  200  may include various components for receiving and transducing audio data electrical signals into corresponding sound waves as well as various components for maintaining a functional position within a user&#39;s outer ear and emitting the sound waves towards an eardrum of a user when worn by the user in the functional position. For example, earbud  200  may include an eartip  210 , a front housing  230 , a sound emitting subassembly or driver or transducer  250 , a rear housing  270 , and a wingtip subassembly  400 . Front housing  230  and rear housing  270  may be operative to be coupled to one another to define an interior housing space within which at least a portion of sound emitting subassembly  250  may be held. An adhesive and/or mechanical snap-fit features and/or any other suitable coupling technique(s) may be used to hold front housing  230  and rear housing  270  together (e.g., to hold rear face  239  of front housing  230  to front face  271  of rear housing  270 ) and/or to hold sound emitting subassembly  250  to one or both of front housing  230  and rear housing  270 . Earbud  200  may include a transducer adhesive  293  that may be operative to adhere to both a front face  251  of sound emitting subassembly  250  and to a rear face of front housing  230 . Moreover, front housing  230  and rear housing  270  may be operative to communicatively couple a portion of front face  251  of sound emitting subassembly  250  to an inner eartip space  225  extending between a rear end opening  229  and a front end opening  221  of an inner eartip member  220  of eartip  210 . For example, when held between front housing  230  and rear housing  270 , an audio opening  252  provided through front face  251  of sound emitting subassembly  250  for emitting sound waves from sound emitting subassembly  250  (e.g., from a diaphragm and/or membrane of subassembly  250 ) may be communicatively aligned with a sound axis S that may also be aligned with an inner nozzle space  245  extending between a rear end opening  249  and a front end opening  241  of a nozzle member  240  of front housing  230  and that also may be aligned with inner eartip space  225  of inner eartip member  220 . One or more mating features  228  along an outer surface of inner eartip member  220  may be operative to removably or fixedly mate with one or more mating features  248  along an inner surface of nozzle member  240  for communicatively coupling inner eartip space  225  defined by inner eartip member  220  of eartip  210  with inner nozzle space  245  defined by nozzle member  240  of front housing  230 , such that sound waves emitted from sound emitting subassembly  250  (e.g., from audio opening  252 ) may be carried along a sound path (e.g., in the +S direction along sound axis S) through rear end opening  249  of nozzle member  240 , along both inner nozzle space  245  and inner eartip space  225 , and then out from front end opening  221  of inner eartip member  220  of eartip  210 . Any suitable filter or mesh  291  may be provided along or across the sound path, such as over front end opening  241  of nozzle member  240 , for enabling sound to pass therethrough and out from eartip  210  while preventing debris (e.g., dust and/or liquids) to pass therethrough and into inner nozzle space  245 . 
     Eartip  210  may be operative to provide a comfortable fit for earbud  200  at least partially within an ear canal of a user and/or to form an acoustic seal between earbud  200  and the ear canal and/or to pass sound through the ear canal via front end opening  221  when earphone assembly  100  is worn by the user. For example, an external eartip structure  214  of eartip  210  may extend from a front end opening  211  (e.g., at front end opening  221  of inner eartip member  220 ) rearwards to a rear end opening  219  that may surround a portion of front housing  230  (e.g., nozzle member  240 ) to define an outer eartip space  215  between an internal surface of external eartip structure  214  and an external surface of inner eartip member  220 , such that external eartip structure  214  may be deformable to fit within any suitable portion of a user&#39;s ear, such as an ear canal for forming the acoustic seal between earbud  200  and the user&#39;s ear. A front vent opening  233  may be provided through front housing  230  for enabling pressure relief of a front chamber  253  that may be defined by a space between front face  251  of sound emitting subassembly  250  and a portion of front housing  230  and a portion of eartip  210  and that may channel sound emitted from audio opening  252  of sound emitting subassembly  250  through front end opening  211 / 221  of eartip  210 . Front vent opening  233  may be positioned so as not be covered or otherwise blocked by external eartip structure  214  or any other portion of eartip  210  when earbud  200  is held by a user&#39;s ear. A rear vent opening  237  may be provided through front housing  230  for enabling pressure relief of a rear chamber  257  that may be defined by a space between a side face  255  and/or a rear face  259  of sound emitting subassembly  250  and a portion of front housing  230  and a portion of rear housing  270 . Any suitable filter or mesh  292  may be provided along the pressure relief path of rear vent opening  237 , such as over opening  237  and against an internal surface of front housing  230  between front housing  230  and sound emitting subassembly  250 , for enabling sound or other suitable air to pass therethrough and out from rear chamber  257  via opening  237  while preventing debris (e.g., dust and/or liquids) to pass therethrough and into rear chamber  257 . 
     Rear housing  270  may include a cable opening  277  through which a portion of cable subassembly  110  may pass, such that an end of one or more conductors at an end of cable subassembly  110  (not shown) may be positioned within earbud  200  (e.g., within rear chamber  257  defined by rear housing  270 ) in order to be electrically coupled to one or more respective contacts of sound emitting subassembly  250 . For example, as shown, cable opening  277  may be provided at a bottom end of a cable external strain relief structure  276  of rear housing  270  that may extend from a side structure  274  of rear housing  270  extending between front face  271  and rear face  279  of rear housing  270 . Earbud  200  may also include an internal strain relief structure  294  that may be coupled to rear housing  270  for protecting at least a portion of the physical coupling between cable subassembly  110  and earbud  200  (e.g., to provide additional strain relief to that connection). A magnet  295  may be positioned against rear face  279  of rear housing  270  by any suitable mechanism(s), such as by an adhesive  296 , and/or by a rear plate  297  that may be coupled to rear face  279  of rear housing  270 . A complimentary magnet may be provided at a similar position on earbud  300 , such that the magnets may magnetically hold earbud  200  and earbud  300  together when they are not in use (e.g., when earbuds  200  and  300  are not positioned within a user&#39;s ears), which may prevent the cable subassemblies of earphone assembly  100  from becoming tangled and/or may keep earphone assembly  100  compact. 
     As shown in  FIGS. 4-8 , wingtip subassembly (hereinafter “wingtip”)  400  of earbud assembly  200  may include various components for comfortably maintaining a functional position of earbud assembly  200  within a user&#39;s outer ear during use. For example, wingtip  400  may include a housing sheath  430  and a wing subassembly  450  extending from sheath  430 . 
     Sheath  430  may include a sheath structure  434  that may extend from a front end opening  431  to a rear end opening  439  for defining an interior sheath space  435 , such that sheath  430  may be deformed or otherwise manipulated to be fitted about front housing  230  and/or rear housing  270  (e.g., such that at least a portion of front housing  230  and/or at least a portion of rear housing  270  may be positioned and held within interior sheath space  435 ). For example, once front housing  230  and rear housing  270  have been coupled to one another about sound emitting subassembly  250  (e.g., as shown in  FIG. 3 ), but before eartip  210  has been coupled to nozzle member  240  of front housing  230  or once eartip  210  has been removed from nozzle member  240  of front housing  230  (e.g., as shown in  FIGS. 5 and 6 ), sheath  430  may be operative to be fitted over a portion of front housing  230  and/or rear housing  270 . As shown in  FIG. 5 , rear end opening  439  may lead sheath structure  434  of sheath  430  first in the direction of arrow S′ (e.g., in the −S direction along sound axis S of nozzle member  240 ) about nozzle member  240  and then further in the direction of arrow T (e.g., rearward in the −Z direction) about a rear portion of front housing  230  and/or about a front portion of rear housing  270  (e.g., sheath structure  434  may be used to removably couple wingtip subassembly  400  to housings  230 / 270 ). In some embodiments, when fitted, sheath structure  434  may be operative to cover (e.g., hide at least a portion or the entirety of) any seam that may exist between front housing  230  and rear housing  270  (e.g., a coupling between rear end  239  of front housing  230  and front end  271  of rear housing  270 ). 
     Sheath structure  434  may include a notch  438  that may be aligned with (e.g., positioned at least partially about) cable external strain relief structure  276  and/or cable opening  277  of rear housing  270  when sheath structure  434  is properly fitted about rear housing  270  to help align sheath structure  434  with rear housing  270  and/or to help prevent sheath structure  434  from being dislodged from its appropriate position with respect to rear housing  270  (e.g., to prevent sheath structure  434  from rotating about the Z-axis and/or to prevent structure  434  from traveling further laterally along the −Z direction (e.g., along the direction of arrow T)). Additionally or alternatively, sheath structure  434  may include an opening  437  that may be aligned with (e.g., positioned at least partially about) rear vent opening  237  when sheath structure  434  is properly fitted about front housing  230  and/or rear housing  270 , such that vent opening  237  may not be blocked by sheath structure  434  but instead may be enabled to relieve pressure via opening  237  of sheath structure  434  when wingtip  400  is in use. A raised lip portion of front housing  230  about rear vent opening  237  may be operative to extend outwardly away from front housing  230  (e.g., in the −Y direction (e.g., similarly to strain relief structure  276  of rear housing  270 )) through opening  437  of sheath structure  434  to help align sheath structure  434  with front housing  230  and/or to help prevent sheath structure  434  from being dislodged from its appropriate position with respect to front housing  230  (e.g., to prevent sheath structure  434  from rotating about the Z-axis and/or to prevent structure  434  from traveling laterally along the Z-axis). Therefore, interaction between sheath notch  438  and rear housing  270  (e.g., strain relief structure  276 ) and/or interaction between sheath opening  437  and front housing  230  (e.g., rear vent opening  237 ) may be operative to key sheath structure  434  of wingtip subassembly  400  to the housing subassemblies of earbud subassembly  200  when being fitted thereon. The undeformed state (e.g., resting and/or natural state) of structure  434  may be configured to define interior sheath space  435  with a size that is the same or slightly smaller than the space occupied by the portion of front housing  230  and rear housing  270  to be fitted with structure  434 , such that a tight fit may be provided between the housings and structure  434 . However, at least a portion of structure  434  about notch  438  may be rigid enough to interact with strain relief structure  276  for maintaining a proper fitted position of structure  434  with respect to rear housing  270  (e.g., to prevent sheath structure  434  from rotating about the Z-axis and/or to prevent structure  434  from traveling further laterally along the −Z direction (e.g., along the direction of arrow T)). In some embodiments, as shown, when fitted on housing  230  and/or  270 , sheath structure  434  may be configured not to block front vent opening  233  of front housing  230  (e.g., front end opening  431  may be fitted rearward of front vent opening  233 ). Alternatively, sheath structure  434  may include an opening operative to align with front vent opening  233  when sheath structure  434  is properly fitted, so as to enable front vent opening to function properly via such a sheath structure opening. Moreover, as shown, sheath structure  434  may be configured to have any suitable thickness ST, such as a thickness in a range between 0.3 millimeters and 0.7 millimeters or a thickness of 0.5 millimeters, such that the overall dimension of front housing  230  and/or rear housing  270  may not be increased more than 1 millimeter by fitting sheath structure  434  thereabout. 
     Wing subassembly  450  may include at least one flex arm, such as an anterior flex arm  460  and/or a posterior flex arm  470 , that may extend away from sheath structure  434  through a respective wing arm of a unitary wing  480 , such as an anterior wing arm  482  and a posterior wing arm  488  that may be coupled by a top wing portion  485  of wing  480 . As shown, wing subassembly  450  may be operative to extend away from sheath structure  434  within any suitable W-X wing plane that may form any suitable rear wing angle RWθ with any suitable X-Y plane that may include rear plate  297  and/or that may include the portion of sheath structure  434  defining rear end opening  439 . Rear wing angle RWθ may be any suitable angle, such as any angle in a range between 3° and 17° or an angle of 10° as may be shown in  FIGS. 5-8  (e.g., a positive angle where the wing assembly may extend forwards towards front housing  230  with respect to rear housing  270 ). Alternatively, rear wing angle RWθ may be any suitable angle, such as any angle in a range between −3° and −17° or an angle of −10° (e.g., a negative angle where the wing assembly may extend rearwards from rear housing  270  and front housing  230 ). Alternatively, rear wing angle RWθ may be equal to 0°, such that the W-X wing plane may be parallel to or the same as an X-Y plane that may include rear plate  297  and/or that may include the portion of sheath structure  434  defining rear end opening  439 . As also shown, an X-Y plane that may include rear plate  297  and/or that may include the portion of sheath structure  434  defining rear end opening  439  may form a rear sound angle RSθ with sound axis S (e.g., the axis along which nozzle member  240  may extend), where such a rear sound angle RSθ may be any suitable angle, such as any angle in a range between 47° and 87° or an angle of 67°. As also shown, a W-X wing plane within which wing subassembly  450  may be operative to extend away from sheath structure  434  may form a sound wing angle SWθ with sound axis S (e.g., the axis along which nozzle member  240  may extend), where such a sound wing angle SWθ may be any suitable angle, such as any angle in a range between 57° and 97° or an angle of 77°. In other embodiments, axis S may be perpendicular to rear face  279  such that rear sound angle RSθ may be 90°. In such embodiments, sound wing angle SWθ may be any suitable angle, such as any angle in a range between 80° and 120° or an angle of 100°. 
     Anterior flex arm  460  may include an anterior flex arm body  464  extending from an anterior flex sheath end  461  at sheath structure  434  to an anterior flex free end  469  (e.g., at a position along arm  482  between ends  481  and  483 ). Anterior flex body arm  464  may include a front anterior flex arm face  463 , an opposite rear anterior flex arm face  467 , and a side anterior flex arm face  465  extending between front anterior flex arm face  463  and rear anterior flex arm face  467  to define a thickness AT of anterior flex arm body  464  that may be consistent along at least the majority of if not the entirety of the length of anterior flex arm body  464 . Additionally, flex arm body  464  may have a width AW that may be consistent along at least the majority of if not the entirety of the length of anterior flex arm body  464 . In some embodiments, anterior flex arm  460  may also include an anterior flex platform  462  at and extending from sheath structure  434  about anterior flex sheath end  461  and along a portion of the length of anterior flex arm body  464 , where anterior flex platform  462  may be operative to reinforce the joint between anterior flex arm body  464  and sheath structure  434 . Anterior wing arm  482  may be an anterior wing arm body extending from an anterior wing sheath end  481  at sheath structure  434  (or at a top of optional anterior flex platform  462 ) to an anterior wing top end  483 . Anterior wing arm  482  may have any suitable cross-sectional shape, such as circular with a cross-sectional diameter WD, that may be consistent along at least the majority of if not the entirety of the length of anterior wing arm  482 . In some embodiments, thickness AT of anterior flex arm body  464  may be substantially similar to cross-sectional diameter or thickness WD of anterior wing arm  482 , such that each one of front anterior flex arm face  463  and opposite rear anterior flex arm face  467  may define a portion of the external surface of wing subassembly  450  along with anterior wing arm  482  (e.g., such that thickness AT of anterior flex arm body  464  may extend through the entirety of the thickness of anterior wing arm  482  for at least a portion of anterior flex arm body  464  (e.g., such that anterior flex arm body  464  may bisect at least a portion of anterior wing arm  482 )). Width AW of flex arm body  464  may be any suitable magnitude, such as a magnitude in a range between 0.35 millimeters and 0.65 millimeters or a magnitude of 0.50 millimeters. One or each of thickness AT and thickness WD may be any suitable magnitude, such as a magnitude in a range between 2.0 millimeters and 3.6 millimeters or a magnitude of 2.8 millimeters. For example, the diameter WD or the entirety of wing  480  may be 2.8 millimeters and the thickness AT of flex arm body  464  may be 2.8 millimeters along its length. Alternatively, thickness AT of anterior flex arm body  464  may be smaller than cross-sectional diameter or thickness WD of anterior wing arm  482  such that anterior flex arm body  464  may be surrounded by anterior wing arm  482  for at least a portion of anterior flex arm body  464  (e.g., encompassing flex arm body  464 ) and such that the external surface of wing subassembly  450  may not be defined by at least that portion of anterior flex arm body  464  (e.g., anterior flex arm body  464  may extend completely within wing arm  482 ). In some embodiments, anterior flex platform  462  may have a cross-sectional shape that is the same as that of anterior wing arm  482  with cross-sectional diameter WD such that anterior wing arm  482  may extend directly away from the top of anterior flex platform  462  and such that the external surface of wing subassembly  450  across the junction of anterior wing arm  482  and anterior flex platform  462  may be smooth and continuous. Alternatively, anterior flex platform  462  may have a cross-sectional shape that is smaller than that of anterior wing arm  482  with cross-sectional diameter WD such that anterior wing arm  482  may extend about and along the length of anterior flex platform  462  all the way to sheath structure  434  (e.g., encompassing platform  462 ) such that the external surface of wing subassembly  450  may not be defined by platform  462 . Anterior flex arm body  464  may extend along any suitable portion of the length of anterior wing arm  482  between anterior wing ends  481  and  483 , such as in a range of 5% to 45% of the length of anterior wing arm  482  or about 25% of the length of anterior wing arm  482 . In some embodiments, the length of anterior flex arm body  464  may be in a range of 2 millimeters to 6 millimeters or about 4 millimeters. 
     Posterior flex arm  470  may include a posterior flex arm body  474  extending from a posterior flex sheath end  471  at sheath structure  434  to a posterior flex free end  479  (e.g., at a position along arm  488  between ends  487  and  489 ). Posterior flex body arm  474  may include a front posterior flex arm face  473 , an opposite rear posterior flex arm face  477 , and a side posterior flex arm face  475  extending between front posterior flex arm face  473  and rear posterior flex arm face  477  to define a thickness of posterior flex arm body  474  that may be consistent along at least the majority of if not the entirety of the length of posterior flex arm body  474  (e.g., similar to thickness AT of anterior flex arm body  464 ). Additionally, flex arm body  474  may have a width that may be consistent along at least the majority of if not the entirety of the length of flex arm body  474  (e.g., similar to width AW of anterior flex arm body  464 ). In some embodiments, posterior flex arm  470  may also include a posterior flex platform  472  at and extending from sheath structure  434  about posterior flex sheath end  471  and along a portion of the length of posterior flex arm body  474 , where posterior flex platform  472  may be operative to reinforce the joint between posterior flex arm body  474  and sheath structure  434  (e.g., with a height of about 0.5 millimeters or any other suitable height). Posterior wing arm  488  may be a posterior wing arm body extending from a posterior wing sheath end  487  at sheath structure  434  (or at a top of optional posterior flex platform  472 ) to a posterior wing top end  489 . Posterior wing arm  488  may have any suitable cross-sectional shape, such as circular with a cross-sectional diameter, that may be consistent along at least the majority of if not the entirety of the length of posterior wing arm  488  (e.g., similar to diameter WD of anterior wing arm  482 ). In some embodiments, the thickness of posterior flex arm body  474  between front posterior flex arm face  473  and rear posterior flex arm face  477  may be substantially similar to the cross-sectional diameter of posterior wing arm  488 , such that each one of front posterior flex arm face  473  and opposite rear posterior flex arm face  4767  may define a portion of the external surface of wing subassembly  450  along with posterior wing arm  488  (e.g., such that the thickness of posterior flex arm body  474  may extend through the entirety of the thickness of posterior wing arm  488  for at least a portion of posterior flex arm body  474  (e.g., such that posterior flex arm body  474  may bisect at least a portion of posterior wing arm  488 )). Alternatively, the thickness of posterior flex arm body  474  may be smaller than the cross-sectional diameter of posterior wing arm  488  such that posterior flex arm body  474  may be surrounded by posterior wing arm  488  for at least a portion of posterior flex arm body  474  (e.g., encompassing flex arm body  474 ) and such that the external surface of wing subassembly  450  may not be defined by at least that portion of posterior flex arm body  474  (e.g., posterior flex arm body  474  may extend completely within wing arm  488 ). In some embodiments, posterior flex platform  472  may have a cross-sectional shape that is the same as that of posterior wing arm  488  such that posterior wing arm  488  may extend directly away from the top of posterior flex platform  472  and such that the external surface of wing subassembly  450  across the junction of posterior wing arm  488  and posterior flex platform  472  may be smooth and continuous. Alternatively, posterior flex platform  472  may have a cross-sectional shape that is smaller than that of posterior wing arm  488  such that posterior wing arm  488  may extend about and along the length of posterior flex platform  472  all the way to sheath structure  434  (e.g., encompassing platform  472 ) such that the external surface of wing subassembly  450  may not be defined by platform  472 . Posterior flex arm body  474  may extend along any suitable portion of the length of posterior wing arm  488  between posterior wing ends  487  and  489 , such as in a range of 45% to 100% of the length of posterior wing arm  488  or about 50% or 66% or 75% of the length of posterior wing arm  488 . In some embodiments, the length of posterior flex arm body  474  may be in a range of 10 millimeters to 30 millimeters or about 20 millimeters. As the stability of wing  480  is provided by one or more of flex arms  460  and  470 , there is no need for a significant amount of material to be provided at a joint between sheath structure  434  and/or housing  270  and wing  480 , which may improve the comfortability of wearing assembly  200  within an ear. 
     Top wing portion  485  may be provided to couple anterior wing arm  482  to posterior wing arm  488  to form a unitary structure wing  480 . For example, top wing portion  485  may extend from an anterior end  484  at anterior wing top end  483  of anterior wing arm  482  to a posterior end  486  at posterior wing top end  489  of posterior wing arm  488 , such that a closed wing space  455  of wing subassembly  450  may be defined by unitary wing  480  and sheath structure  434  within a W-X wing plane. In some embodiments, as shown, each sheath end of wing subassembly  450  (e.g., platforms  462  and  472  and/or ends  481  and  487 ) may be distinct and not structurally coupled to one another by another portion of wing subassembly  450  extending along sheath structure  434  but only by a portion of sheath structure  434 , whereby wing space  455  may be defined by at least a portion  433  of sheath structure  434 . Alternatively, in some embodiments, platforms  462  and  472  may provide a unitary structure. One, some, or each one of wing arms  482  and  488  and top wing portion  485  of wing  480  may have a particular radius of curvature (e.g., within a W-X wing plane), where each radius of curvature may be the same as one another or different than one another. For example, a length along an inner periphery of wing  480  (e.g., defining a portion of space  455 ) may be defined by the length along the inner periphery between ends  481  and  483 , which may be 10.9 millimeters, the length along the inner periphery between ends  484  and  486 , which may be 1.5 millimeters, and the length along the inner periphery between ends  489  and  487 , which may be 14.2 millimeters, and a length along an outer periphery of wing  480  may be defined by the length along the outer periphery between ends  481  and  483 , which may be 8.1 millimeters, the length along the outer periphery between ends  484  and  486 , which may be 4.3 millimeters, and the length along the outer periphery between ends  489  and  487 , which may be 17.0 millimeters (e.g., whereby the length of the inner periphery plus the diameter of wing  480  (e.g., 2.8 millimeters) may equal the length of the outer periphery). In some embodiments, a length of wing  480  between ends  481  and  487  may be in a range between 20 millimeters and 40 millimeters or about 30 millimeters, while a length of posterior flex arm body  474  along wing  480  may be in a range between 5 millimeters and 20 millimeters or about 12 millimeters (e.g., in a range between 20% and 60% or about 40% of the length of wing  480 ), while a length of anterior flex arm body  464  along wing  480  may be in a range between 1 millimeters and 5 millimeters or about 3 millimeters (e.g., in a range between 1% and 20% or about 10% of the length of wing  480 ). The exterior surface of wing  480 , which may include a portion of front anterior flex arm face  463  and/or rear anterior flex arm face  467  and/or front posterior flex arm face  473  and/or rear posterior flex arm face  477 , may be polished before use by an end user such that the entire outer surface of wing  480  may be smooth and continuous and may have a circular or other smooth shape periphery at each cross-section along its length, to promote a comfortable experience for a user. 
     Any suitable materials and/or assembly processes may be used to provide wingtip subassembly  400 . For example, in some embodiments, at least one or each of the one or more of flex arms  460  and  470  may be provided by a more rigid material than the material used to provide unitary wing  480 . As one example, at least one or each of the one or more of flex arms  460  and  470  may be provided by a first material with a first hardness (e.g., first durometer (e.g., 85-95 or 90 Shore D durometer)), such as a relatively rigid nylon (e.g., TR90 nylon) (e.g., through a stereolithographic process or molding process), while unitary wing  480  may be provided by a second material with a second hardness (e.g., second durometer (e.g., 35-65 or 50 Shore A durometer)) that is less than the first hardness, such as silicone (e.g., through a stereolithographic process or molding process). While the less rigid and more flexible second material of wing  480  may provide for a more comfortable interaction with a user&#39;s ear and allow for additional manipulation along portions of wing  480  through which a flex arm does not extend (e.g., top wing portion  485 ), the more rigid and less flexible first material of the one or more of flex arms  460  and  470  may be operative to limit certain types of motion possible by wing subassembly  450  (e.g., when fitted within an ear of a user). For example, the rigidity of the structure of one or more of flex arms  460  and  470  may be configured to prevent wing arms  482  and  488  (or at least any other majority portion) of unitary wing  480  from laterally deflecting or rotating out from a W-X wing plane of wing subassembly  450 , such as in a rearward −D direction and/or in a forward +D direction along a D-axis that may be perpendicular to a W-axis of the W-X wing plane of wing subassembly  450 . Additionally, the rigidity of the structure of one or more of flex arms  460  and  470  may be configured to prevent wing arms  482  and  488  of unitary wing  480  from rotating about an axis within a W-X wing plane of wing subassembly  450  (e.g., torquing of wing arms  482  and  488  may be prevented by the structure of flex arm  460  and/or flex arm  470 ). Additionally, the rigidity of the structure of one or more of flex arms  460  and  470  may be configured to allow one or both of wing arms  482  and  488  of unitary wing  480  to bend within a W-X wing plane of wing subassembly  450 , such as to allow wing arm  488  to bend towards wing arm  482  within the W-X wing plane of wing subassembly  450  and/or to allow wing arm  482  to bend towards wing arm  488  within the W-X wing plane of wing subassembly  450 . As mentioned, while wing subassembly  450  is shown to include not only anterior flex arm  460  through anterior wing arm  482  but also posterior flex arm  470  through posterior wing arm  488 , it is to be understood that only flex arm  460  but not flex arm  470  may be provided in certain other embodiments or that only flex arm  470  but not flex arm  460  may be provided in yet other embodiments. In any embodiment, the rigidity of the structure of one or more of flex arms  460  and  470  may be operative to limit certain types of motion possible by wing subassembly  450  (e.g., when fitted within an ear of a user to anchor earbud subassembly  200  to the ear during use of earbud subassembly  200 ). 
     As shown in  FIG. 8 , wingtip subassembly  400  of earbud subassembly  200  may be operative to anchor earbud subassembly  200  to an ear  800  of a user during use, where ear  800  may include a helix  802 , a concha  804 , an anti-helix  806 , an anti-helix crus  808 , a tragus  810 , an ear canal  812 , an anti-tragus  814 , and a lobe  816 . As shown, the length of posterior flex arm body  474  of posterior flex arm  470  may be long enough to provide stability to wing  480  all the way up to the portion of wing  480  at anti-helix crus  808 , where end  479  of posterior flex arm body  474  may be positioned under and/or behind at least a portion of anti-helix crus  808  or may be positioned just below anti-helix crus  808  such that only wing  480  (e.g., top wing portion  485 ) but not portion of any flex arm may be positioned under and/or behind at least a portion of anti-helix crus  808 . In any event, posterior flex arm body  474  and/or anterior flex arm body  464  may provide enough stability to the entirety of wing  480  to prevent wing  480  from deflecting or rotating out from the W-X wing plane of wing subassembly  450 , a portion of which may be positioned under anti-helix crus  808 , thereby maintaining the functional position of wing  480  with respect to ear  800  of  FIG. 8 , which may also include at least a portion of eartip  210  positioned within ear canal  812 . Therefore, a rigidity of posterior flex arm  470  may be operative to distribute a load that may be applied to wingtip  400  by ear  800  to promote comfortability. As shown in  FIG. 8 , in some embodiments, posterior wing arm  488  may be operative to extend along at least a portion of anti-helix  806  (e.g., up to anti-helix crus  808  before another portion of posterior wing arm  488  or top wing portion  485  may extend under anti-helix crus  808 ). 
     Different sized versions of wingtip subassembly  400  may be provided for use by a user on earbud subassembly  200  (e.g., based on the size of ear  800 ). For example, different wingtips  400  may be provided with a notch  438  of different sizes (e.g., different notches  438  may have different depths along the Z-axis) which may vary a distance RD between rear end  439  of each sheath structure  434  and rear end plate  297  coupled to rear housing  270  when each sheath structure  434  may be fitted on housings  230 / 270 . Therefore, while an earbud distance ED between rear end plate  297  and front end  241  of nozzle member  240  may be fixed for a particular earbud assembly  200 , varying distance RD between rear end  439  of sheath structure  434  and rear end plate  297  (e.g., by varying the depth of notch  438  between different sized wingtips  400 ) may vary a wingtip nozzle distance WND between wing  480  and front end  241  of nozzle member  240 , which may account for at least a portion of a difference in size between two different ears (e.g., a longer magnitude of distance WND may provide a more comfortable fit within a larger ear). Additionally or alternatively, a length of wing  480  (e.g., from sheath structure  434  to top wing portion  485 ) may be varied between wingtips  400 , which may account for at least a portion of a difference in size between two different ears. 
     The first material or material combination that may be used to provide at least one or each of the one or more of flex arms  460  and  470  may also be used to provide at least a portion of at least one or each of the one or more of flex platforms  462  and  472 . The first material or material combination that may be used to provide at least one or each of the one or more of flex arms  460  and  470  may also be used to provide at least a portion of sheath structure  434 , such as at least one or each of the portions of sheath structure  434  at which which flex arm  460  and/or flex platform  462  and/or flex arm  470  and/or flex platform  472  may be coupled to sheath structure  434 . The first material or material combination that may be used to provide at least one or each of the one or more of flex arms  460  and  470  may also be used to provide the entirety of sheath structure  434  or at least the portion of sheath structure rearward of sheath structure opening  437  to help prevent rotation of sheath structure  434  with respect to rear housing  270  (e.g., about the Z-axis). In some embodiments, at least a portion or the entirety of sheath structure  434  may be molded during a first single shot molding process that also includes molding each of the one or more of flex arms  460  and  470  and each of any of platforms  462  and  472 , such as using the first material or first material combination. Then, wing  480  may be molded onto sheath structure  434  and/or each of the one or more of flex arms  460  and  470  and each of any of platforms  462  and  472  during a second single shot molding process, such as using a second material or second material combination that is less rigid or more flexible than the first material or first material combination of the first single shot molding process. In some embodiments, if only a first (e.g., a rear portion) of sheath structure  434  may be formed during the first single shot molding process, the remainder or at least another portion (e.g., a front portion) of sheath structure  434  may be formed during the second single shot molding process or during a third single shot molding process that may use at least one material different than that used in either the first or second shot molding processes. In some embodiments, at least a portion or the entirety of front housing  230  and/or at least a portion of eartip  210  and/or at least a portion of rear housing  270  may be formed as a portion of a unitary structure that may also include wingtip  400  (e.g., during the same first molding shot as may be used to form each of the one or more of flex arms  460  and  470  and each of any of platforms  462  and  472  and/or at least a portion of sheath structure  434 , or during the same second molding shot as may be used to form at least a portion of wing  480 , or during a third molding shot distinct from each of the first and second molding shots). 
     As mentioned, any suitable non-occluding earphone or headset assembly may be provided with wingtips for securing the assembly to a user. For example, as shown in  FIG. 9 , an earphone assembly  900  may include a cable  910  that can electrically couple an audio connector component  920  to a left speaker component or left earbud subassembly  930  and/or to a right speaker component or right earbud subassembly  940 . Cable  910  may include a main region  912  that may extend between audio connector component  920  and a bifurcation (e.g., forked region)  914  of cable  910 . Cable  910  may also include a left region  916  that may extend between bifurcation  914  and left earbud subassembly  930 . Alternatively or additionally, cable  910  may include a right region  918  that may extend between bifurcation  914  and right earbud subassembly  940 . Any one or more of cable regions  912 ,  914 ,  916 , and  918  of cable  910  may include one or more conductors that may be configured to transmit data and/or power signals between audio connector component  920  and one or both of left earbud subassembly  930  and right earbud subassembly  940 . Earphone assembly  900  may be configured to communicate any suitable data signals, such as audio signals, video signals, control signals, and the like with a media device. Connector component  920  may be operative to be physically coupled to any suitable connector of any suitable media device (not shown) for enabling wired communication between assembly  900  and such a media device. Alternatively, assembly  900  may not include a connector component  920  but may be operative to wirelessly communicate with such a media device. Wingtip  400  may be coupled to left earbud subassembly  930  to anchor subassembly  930  within ear  800  in a similar fashion, despite no eartip being positioned within ear canal  812 . 
     While there have been described earphone assemblies with wingtips for anchoring to a user, it is to be understood that many changes may be made therein without departing from the spirit and scope of the disclosure. Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. 
     Therefore, those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation.

Metadata:
Filing Date: 20170906
Publication Date: 20200609
Grant Date: 20200609
Priority Date: 20160906
Inventors: HATFIELD, DUSTIN A.
STRINGER, CHRISTOPHER J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/1033", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1025", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2420/07", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/105", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2420/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/105", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2420/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/1025", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/105", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1033", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1008", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2420/07", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 59930771