PATENT DOCUMENT

Publication Number: US-10542338-B2
Application Number: US-201815989115-A
Country: US
Kind Code: B2

Title: Concealed connector for an electronic device

Abstract:
An electronic device includes a concealed electrical connector positioned within a speaker opening defined by an enclosure of the electronic device. A mating connector is configured to fit through the speaker opening and couple to the concealed electrical connector to form a bidirectional communications path with circuitry within the electronic device.

Claims:
What is claimed is: 
     
       1. An electronic device comprising:
 an enclosure defining a speaker aperture for emitting sound; 
 a speaker disposed within the enclosure and including a diaphragm acoustically coupled to the speaker aperture; 
 an acoustically permeable layer positioned between the diaphragm and the speaker aperture, wherein the acoustically permeable layer includes an inner surface adjacent the diaphragm and an outer surface adjacent the speaker aperture; and 
 a plurality of electrical contacts disposed within the speaker aperture and positioned at the outer surface of the acoustically permeable layer such that the electrical contacts are accessible by a mating connector inserted through the speaker aperture. 
 
     
     
       2. The electronic device of  claim 1  wherein the acoustically permeable layer includes a layer of acoustic mesh. 
     
     
       3. The electronic device of  claim 2  wherein the layer of acoustic mesh includes one or more electrically conductive fibers that are electrically coupled to at least one of the plurality of electrical contacts. 
     
     
       4. The electronic device of  claim 1  further comprising a backing plate disposed between the acoustically permeable layer and the diaphragm and positioned to support the acoustically permeable layer. 
     
     
       5. The electronic device of  claim 1  wherein the acoustically permeable layer includes a flexible circuit coupled to the plurality of electrical contacts. 
     
     
       6. The electronic device of  claim 1  wherein the acoustically permeable layer includes an insert-molded portion that is formed around the plurality of electrical contacts. 
     
     
       7. The electronic device of  claim 1  wherein the plurality of electrical contacts are electrically coupled to circuitry within the electronic device through a plurality of pins. 
     
     
       8. The electronic device of  claim 1  wherein a connector guide is formed around the plurality of electrical contacts to guide the mating connector into alignment with the plurality of electrical contacts. 
     
     
       9. The electronic device of  claim 1  wherein the speaker is disposed within a speaker housing and the speaker housing is sealed to the enclosure with one or more seals. 
     
     
       10. An electronic watch comprising:
 an enclosure formed from a housing and a display screen that are joined together to define an exterior surface of the electronic watch; 
 a speaker disposed within the enclosure and including a diaphragm; 
 a speaker opening defined by the enclosure and formed at the exterior surface of the electronic watch; 
 a processor disposed within the enclosure and coupled to the speaker with one or more conductors that carry signals causing the diaphragm to generate acoustic energy; 
 an acoustic chamber at least partially defined by the enclosure and coupling the diaphragm to the speaker opening; 
 an acoustically permeable layer positioned between the diaphragm and the speaker opening and having an outer surface facing the speaker opening; and 
 a plurality of electrical contacts disposed on the outer surface and accessible by a mating connector inserted through the speaker opening. 
 
     
     
       11. The electronic watch of  claim 10  wherein the speaker opening is configured to receive the mating connector that extends from an exterior environment through the enclosure and electrically couples to the plurality of electrical contacts. 
     
     
       12. The electronic watch of  claim 10  wherein the acoustically permeable layer includes a layer of acoustic mesh. 
     
     
       13. The electronic watch of  claim 12  wherein the layer of acoustic mesh includes one or more electrically conductive fibers that are electrically coupled to at least one of the plurality of electrical contacts. 
     
     
       14. The electronic watch of  claim 10  further comprising a backing plate disposed between the acoustically permeable layer and the diaphragm and positioned to support the acoustically permeable layer. 
     
     
       15. The electronic watch of  claim 10  wherein the acoustically permeable layer includes a flexible circuit coupled to the plurality of electrical contacts. 
     
     
       16. The electronic watch of  claim 10  wherein the acoustically permeable layer includes an insert-molded portion that is formed around the plurality of electrical contacts. 
     
     
       17. The electronic watch of  claim 10  wherein the plurality of electrical contacts are electrically coupled to circuitry within the electronic watch through a plurality of pins. 
     
     
       18. The electronic watch of  claim 10  wherein a connector guide is formed around the plurality of electrical contacts to guide the mating connector into alignment with the plurality of electrical contacts. 
     
     
       19. The electronic watch of  claim 10  wherein the speaker is disposed within a speaker housing and the speaker housing is sealed to the enclosure with one or more seals. 
     
     
       20. The electronic watch of  claim 10  wherein the acoustically permeable layer is integrally formed as a portion of a circuit board.

Description:
CROSS-REFERENCES TO OTHER APPLICATIONS 
     This application claims priority to U.S. provisional patent application Ser. No. 62/562,610, for “CONCEALED CONNECTOR FOR AN ELECTRONIC DEVICE” filed on Sep. 25, 2017 which is hereby incorporated by reference in entirety for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to electronic devices that employ acoustic electrical connectors for electronic devices. More particularly, the present embodiments relate to electronic connectors that can be concealed within an acoustic aperture or other port of an electronic device. 
     BACKGROUND 
     Currently there are a wide variety of electronic devices that have one or more external electronic connectors for communicating with internal circuitry within the electronic device. These external connectors can be used for charging the device and/or for performing uni-directional or bi-directional communications with the device. However, with small electronic devices it may be preferred to predominantly use wireless charging and/or wireless communications since the small electronic devices may not have room for external electrical connectors. Further, it may be desirable to not use external electrical connectors because they disrupt the exterior surface (e.g., the aesthetics) or they are difficult to seal for water resilient or waterproof electronic devices. 
     However, some electronic devices may still need an external electronic connector for performing settings at the factory and/or for performing repair and diagnostics on the device or for other uses. 
     New electronic devices may require new features or new methods of implementing external electronic connectors that are concealed, consume little space, provide uninterrupted device aesthetics, are water resilient and/or water proof. 
     SUMMARY 
     Some embodiments of the present invention relate to electronic devices having an electronic connector concealed within a speaker opening in the electronic device enclosure. A mating connector is configured to fit through the speaker opening and couple to the concealed electrical connector forming a bidirectional communications path with circuitry within the electronic device. The bidirectional communications path can be used to charge, program, diagnose and otherwise communicate with circuitry within the electronic device. 
     In some embodiments an electronic device comprises an enclosure defining a speaker aperture for emitting sound. A speaker is disposed within the enclosure and includes a diaphragm acoustically coupled to the speaker aperture. An acoustically permeable layer is positioned between the diaphragm and the speaker aperture, and a plurality of electrical contacts are disposed within the speaker aperture, positioned at an outer surface of the acoustically permeable layer and accessible through the speaker aperture. 
     In some embodiments the acoustically permeable layer includes a layer of acoustic mesh. In various embodiments the layer of acoustic mesh includes one or more electrically conductive fibers that are electrically coupled to at least one of the plurality of electrical contacts. In some embodiments the electronic device further comprises a backing plate disposed between the acoustically permeable layer and the diaphragm and is positioned to support the acoustically permeable layer. 
     In some embodiments the acoustically permeable layer includes a flexible circuit coupled to the plurality of electrical contacts. In various embodiments the acoustically permeable layer includes an insert-molded portion that is formed around the plurality of electrical contacts. In some embodiments the plurality of electrical contacts are electrically coupled to circuitry within the electronic device through a plurality of pins. In various embodiments a connector guide is formed around the plurality of electrical contacts to guide a mating connector into alignment with the plurality of electrical contacts. In some embodiments the speaker is disposed within a speaker housing and the speaker housing is sealed to the enclosure with one or more seals. 
     In some embodiments an electronic watch comprises an enclosure formed from a housing and a display screen that are joined together to define an exterior surface of the electronic watch. A speaker is disposed within the enclosure and includes a diaphragm. A speaker opening is defined by the enclosure and is formed at the exterior surface of the electronic watch. A processor is disposed within the enclosure and is coupled to the speaker with one or more conductors that carry signals causing the diaphragm to generate acoustic energy. An acoustic chamber is at least partially defined by the enclosure and couples the diaphragm to the speaker opening. An acoustically permeable layer is positioned between the diaphragm and the speaker opening and has an outer surface facing the speaker opening. A plurality of electrical contacts are disposed on the outer surface and accessible through the speaker opening. 
     In some embodiments the speaker opening is configured to receive a mating connector that extends from an exterior environment through the enclosure and electrically couples to the plurality of electrical contacts. In various embodiments the acoustically permeable layer includes a layer of acoustic mesh. In some embodiments the layer of acoustic mesh includes one or more electrically conductive fibers that are electrically coupled to at least one of the plurality of electrical contacts. In various embodiments the electronic watch further comprises a backing plate disposed between the acoustically permeable layer and the diaphragm and is positioned to support the acoustically permeable layer. 
     In some embodiments the acoustically permeable layer includes a flexible circuit coupled to the plurality of electrical contacts. In various embodiments the acoustically permeable layer includes an insert-molded portion that is formed around the plurality of electrical contacts. In some embodiments the plurality of electrical contacts are electrically coupled to circuitry within the electronic watch through a plurality of pins. In various embodiments a connector guide is formed around the plurality of electrical contacts to guide a mating connector into alignment with the plurality of electrical contacts. 
     In some embodiments the speaker is disposed within a speaker housing and the speaker housing is sealed to the enclosure with one or more seals. In various embodiments the acoustically permeable layer is integrally formed as a portion of a circuit board. 
     To better understand the nature and advantages of the present invention, reference should be made to the following description and the accompanying figures. It is to be understood, however, that each of the figures is provided for the purpose of illustration only and is not intended as a definition of the limits of the scope of the present invention. Also, as a general rule, and unless it is evident to the contrary from the description, where elements in different figures use identical reference numbers, the elements are generally either identical or at least similar in function or purpose. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electronic device according to embodiments of the disclosure; 
         FIG. 2  is a simplified cross-sectional view of the electronic device shown in  FIG. 1 ; 
         FIG. 3  is plan view looking into the speaker opening of the electronic device shown in  FIG. 1 ; 
         FIG. 4  is a magnified view of a plan view looking into the speaker opening of the electronic device shown in  FIG. 1 ; 
         FIG. 5  is a partial cross-sectional view of the connector plate illustrated in  FIG. 4 ; 
         FIG. 6  is a partial cross-sectional view of an alternative embodiment of a connector plate according to embodiments of the disclosure; 
         FIG. 7  is a simplified cross-sectional view of an alternative electronic device including electrically conductive pins according to embodiments of the disclosure; and 
         FIG. 8  is a simplified cross-sectional view of an alternative electronic device including a connector alignment feature according to embodiments of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Some embodiments of the present invention relate to electronic devices with a concealed electrical connector positioned within a speaker opening formed in an enclosure of the electronic device. A mating connector is configured to fit through the speaker opening and couple to the concealed electrical connector forming a bidirectional communications path with circuitry within the electronic device. The bidirectional communications path can be used to charge, program, diagnose and otherwise communicate with circuitry within the electronic device. By positioning the connector within the enclosure, the connector can be concealed from view, access to the connector can be restricted unless a specifically designed mating connector is used that can fit through the speaker opening and the electronic device is less susceptible to liquid ingression by reducing the number of openings formed in the enclosure since the speaker and the connector are combined within one opening. 
     While the present invention can be useful for a wide variety of configurations, some embodiments of the invention are particularly useful for electronic devices having small form factors with little space for electrical connectors, devices having aesthetic requirements that may be marred by an external visible electrical connector and/or or devices that need to be water resilient or waterproof, as discussed in more detail below. 
     For example, in some embodiments an electronic device can include a concealed electrical connector that enables a mating connector to establish one or more electronic communication channels with circuitry within the electronic device. The term concealed may be used to indicate that the connector is substantially imperceptible to the naked eye when viewing the outside of the electronic device. The concealed connector can be positioned within the enclosure of the electronic device and accessible through a speaker opening formed through the enclosure. The connector can include a plurality of contacts that are positioned at an outer surface of an acoustically permeable layer that is formed between a speaker positioned within the electronic device and the speaker opening formed in the enclosure. The plurality of contacts can be formed as a portion of a flexible circuit that couples the plurality of contacts to circuitry within the electronic device. A backing plate can be used to support the acoustic mesh and the plurality of contacts when a mating connector is inserted through the opening and pressed against the plurality of contacts. 
     In another example the plurality of contacts can be metallic studs that are insert-molded within a portion of the acoustically permeable layer and coupled to circuitry with a flexible circuit or with selective plating formed on a portion of the acoustically permeable layer. In another example a flexible circuit can be used to couple signals between the plurality of contacts and a feedthrough pin that couples signals from the flexible circuit through a waterproof speaker housing and to circuitry within the electronic device. In another example, a connector guide is formed around the plurality of contacts and includes features that guide the mating connector into alignment with the plurality of contacts. 
     In order to better appreciate the features and aspects of the present disclosure, further context for the disclosure is provided in the following section by discussing one particular implementation of an electronic device that includes a concealed connector according to embodiments of the disclosure. These embodiments are for explanatory purposes only and other embodiments may be employed in other electronic devices. For example, embodiments of the disclosure can be used with any device that receives or transmits audio, video or data signals. In some instances, embodiments of the disclosure are particularly well suited for use with portable electronic media devices because of their potentially small form factor. As used herein, an electronic media device includes any device with at least one electronic component that may be used to present human-perceivable media. Such devices may include, for example, wearable electronic devices (e.g., Apple&#39;s watch), portable music players (e.g., MP3 devices and Apple&#39;s iPod devices), portable video players (e.g., portable DVD players), cellular telephones (e.g., smart telephones such as Apple&#39;s iPhone devices), video cameras, digital still cameras, projection systems (e.g., holographic projection systems), gaming systems, PDAs, as well as tablet (e.g., Apple&#39;s iPad devices), laptop or other mobile computers. Some of these devices may be configured to provide audio, video or other data or sensory output. 
       FIG. 1  is an example electronic device  100  with a concealed connector (not shown in  FIG. 1 ) that enables a user to establish a wired connection with circuitry within the electronic device. In this example electronic device  100  is a smart watch configured to be worn on a user&#39;s wrist and secured thereto with band  110 . Electronic device  100  has an enclosure  115  defining an exterior surface  120 . A screen  125  is attached to a housing  130 , with the combination thereof forming enclosure  115 . Screen  125  functions as an input/output device along with one or more buttons  135  that allow a user to communicate with electronic device  100 . 
     A speaker opening  140  is formed through enclosure  115  and is coupled to a speaker (not shown in  FIG. 1 ) positioned within the enclosure that is used to emit sound to the external environment for a user to hear. The concealed connector (not shown in  FIG. 1 ) is positioned within enclosure  115  hidden from the user&#39;s view and is accessible through speaker opening  140 . A specially designed mating connector  145  can be mated with the concealed connector by inserting the mating connector through speaker opening  140  such that pins  147  of the mating connector contact the concealed connector, as described in more detail below. In some embodiments one or more alignment features  150  formed on housing  130  can assist in alignment of mating connector  145  and/or key the mating connector so it can only be inserted with the proper orientation. In various embodiments an external alignment tool can be used in addition to or instead of alignment features  150  to align mating connector  145  with speaker opening  140  and concealed connector (not shown in  FIG. 1 ). 
     In some embodiments speaker opening  140  can be a single opening as illustrated in  FIG. 1 , however in other embodiments it may include two, three or more openings. In some embodiments a length  155  of speaker opening  140  is between 2 and 40 millimeters while in other embodiments the length is between 5 and 30 millimeters and in other embodiments the length is between 10 and 20 millimeters. In some embodiments a width  160  of speaker opening  140  is between 0.25 and 4 millimeters and in other embodiments the width is between 0.5 and 2 millimeters and in various embodiments the width is between 0.75 and 1.25 millimeters. Although speaker opening  140  is illustrated in  FIG. 1  as an elongated slot, other embodiments can have one or more speaker openings that are circular, square, hexagonal, rectangular or any other shape. Accordingly, the geometry of mating connector  145  can be modified to fit any shape of speaker opening. 
       FIG. 2  illustrates a simplified cross-sectional view A-A formed through a portion of electronic device  100  illustrated in  FIG. 1 . As shown in  FIG. 2 , a speaker assembly  205  is positioned within enclosure  115  and includes a diaphragm  210  secured to a speaker housing  215  and one or more magnets (not shown in  FIG. 2 ). An acoustic chamber  220  is formed within enclosure  115  and couples diaphragm  210  to speaker opening  140  such that sound can be emitted from the speaker opening to external environment  225 . 
     An acoustically permeable layer  230  is disposed between diaphragm  210  and speaker opening  140 . Acoustically permeable layer  230  allows acoustic energy that is generated by diaphragm  210  to pass through and exit speaker opening  140 . Acoustically permeable layer  230  includes flexible circuit  250  and further includes a plurality of electrical contacts  235  attached to an outer surface  240  of the acoustically permeable layer. Outer surface  240  faces speaker opening  140 . Plurality of electrical contacts  235  form a portion of concealed connector  237  and are positioned such that they are accessible by mating connector  145  that can be inserted through speaker opening  140 . Acoustic chamber  220  includes a first portion  221  that is positioned between diaphragm  210  and acoustically permeable layer  230  and a second portion  222  that is positioned between acoustically permeable layer  230  and speaker opening  140 . 
     In some embodiments a backing plate  245  is disposed between acoustically permeable layer  230  and diaphragm  210  and positioned against the acoustically permeable layer to support the acoustically permeable layer when mating connector  145  is pushed against and mated to concealed connector  237 . 
     In the embodiment illustrated in  FIG. 2  concealed connector  237  includes multiple contacts  235  (only one of which is visible in  FIG. 2 ). In some embodiments plurality of contacts  235  are formed as a portion of a flexible circuit  250  as plated metal pads, however in other embodiments the plurality of pads are metallic pucks that are formed and attached to metal pads formed on the flexible circuit. Flexible circuit  250  is attached to acoustically permeable layer  230  using an adhesive or other material. In one embodiment, acoustically permeable layer  230  includes a layer of acoustic mesh that is laminated with flexible circuit  250  during the fabrication of the flexible circuit. In one example, the acoustic mesh is a woven layer of fabric (shown in  FIG. 2  as having longitudinal and transverse fibers) while in another example it is a perforated plate of plastic or metal. Flexible circuit  250  includes conductive traces coupled to each electrical contact of plurality of contacts  235  and are used to route signals to circuitry disposed within electronic device  100 . In some embodiments the conductive traces can be coupled to a processor that sends signals through the conductive traces to make diaphragm  210  move and generate acoustic energy. 
     In some embodiments, mating connector  145  includes multiple pins  147  that correspond in number to the number of contacts  235 . Each individual pin can be spring-loaded and deflect when the mating connector is pushed into contact with contacts  235 . Pins  147  can be used to accommodate variations in position of contacts  235  so a reliable connection is made. 
     One or more seals  255  can be positioned between speaker housing  215  and enclosure  115  to seal acoustic chamber  220  such that liquid, dust or other contaminants cannot pass beyond the speaker housing and damage circuitry within electronic device  100 . In some embodiments plurality of contacts  235  can be electrically decoupled from the internal circuitry via electrical means or mechanical means such that liquid that enters acoustic chamber  220  cannot short out concealed connector  237 . To couple the plurality of contacts  235  to the internal circuitry pressure may need to be exerted on mating connector  145  such that backing plate  245  deforms and the circuit is temporarily completed or electrical switches can be used to decouple contact pads from the circuitry within electronic device  100 . In further embodiments a non-electrically conductive self-healing elastomeric coating can be applied over plurality of contacts  235  that can be displaced and/or temporarily penetrated by pins  147  of mating connector  145 . 
     Flexible circuit  250 , as disclosed herein, describes a circuit that includes an insulating polymer film having conductive circuit patterns affixed thereto and can also include a polymer coating to protect the conductor circuits. Flexible circuits can include a single metal layer, double sided metal layers, multilayer and rigid/flex combination constructions. Flexible circuits can be formed by etching metal foil cladding (normally of copper) from polymer bases, plating metal or printing of conductive inks, among other processes. Flexible circuits can also include one or more electronic passive or active components attached thereto. Flexible circuits can be fabricated using a lamination process that adheres layers together with an adhesive or polymer under pressure, elevated temperature and/or vacuum. 
     Backing plate  245  as described herein can be fabricated as a portion of enclosure  115 , as a portion of speaker housing  215 , as a portion of acoustically permeable layer  230  or as a separate component. Backing plate  245  can be fabricated from metal (including powdered metal known as MIM), plastic, ceramic or any other material and has one or more openings to allow sound to pass through, as described in more detail below. 
       FIG. 3  illustrates a plan view looking into speaker opening  140 , with acoustically permeable layer  230  removed for clarity. As shown in  FIG. 3  backing plate  245  includes one or more openings  305  that allow sound to pass from diaphragm  210  (see  FIG. 2 ) through acoustically permeable layer  230  and out of speaker opening  140 . Backing plate  245  also includes a structural member  310  positioned directly behind contacts  235 , which in the embodiment depicted in  FIG. 3  includes four contacts, to provide support during engagement of mating connector  145  (see  FIG. 2 ). 
     As discussed above, contacts  235  can be formed on flexible circuitry  250  and the flexible circuit can include electrical traces that couple signals between circuitry within the electronic device  100  and contacts  235 . Flexible circuit  250  can include one or more routing portions  315   a ,  315   b  that route signals from plurality of contacts  235  to circuitry within electronic device  100 . In some embodiments each individual contact  235  can have a diameter between 0.1 to 4.0 millimeters and in other embodiments between 0.3 to 2.0 millimeters and in various embodiments between 0.7 to 1.3 millimeters. 
     In some embodiments a concealed electrical connector as described herein can be positioned in an opening within an electronic device wherein the opening is not a speaker opening but is used for a different purpose. For example, in some embodiments speaker opening  140  (see  FIGS. 1 and 2 ) can be used for a different purpose including but not limited to a microphone, an air vent, a sensor (e.g., barometric, temperature, humidity, etc.) or it may only be used to house the concealed connector. As an illustrative example, the configuration illustrated in  FIG. 3  can be used to show such embodiments. For example, one or more openings  305  can be used as air vents for electronic device  100 , and structural member  310  can be used as shown to hold contacts  235  in place so they can be coupled with a mating connector as shown in  FIG. 1 . In other embodiments one or more openings  305  can be used as apertures for a microphone and/or a sensor that are disposed within electronic device  100 , enabling them to communicate with the external environment. In another embodiment speaker opening  140  may have no other function than to house the hidden connector that includes contacts  235 . 
       FIG. 4  illustrates a magnified portion of a plan view looking into speaker opening  140  (see  FIG. 1 ) of another embodiment that uses insert-molded studs  440  to form a plurality of contacts  450  and selectively conductive acoustic mesh in place of the flexible circuit discussed above in  FIGS. 2 and 3 . As shown in  FIG. 4 , acoustically permeable layer  430  is formed from a woven acoustic mesh including individual woven fibers  435 . A plurality of studs  440  that are made from an electrically conductive material such as metal, are insert-molded within a connector plate  445  that can also be formed around a portion of acoustically permeable layer  430 . Signals are coupled from plurality of contacts  450  to circuitry within electronic device  100  using one or more traces  455  formed by selectively metallizing portions of acoustically permeable layer  430 , as discussed in more detail below. 
     The size of connector plate  445  can be small relative to speaker opening  140  (see  FIG. 1 ) such that a majority of acoustically permeable layer  430  is available to pass acoustic energy from speaker assembly  205  (see  FIG. 2 ) to speaker opening  140 . In some embodiments connector plate  445  can be formed separately from or integrally with backing plate  245  (see  FIG. 3 ). More specifically, in some embodiments connector plate  445  and backing plate  245  can be simultaneously formed with an insert molding process, however in other embodiments they may be formed separately. 
       FIG. 5  illustrates a simplified partial cross-sectional view B-B formed through a portion of connector plate  445  and acoustically permeable layer  430  illustrated in  FIG. 4 . As shown in  FIG. 5 , studs  440  can include mold-lock features  505  that secure the studs within connector plate  445 . Acoustically permeable layer  430  includes a mold portion  510  that can be insert-molded within connector plate  445 . 
     One or more traces  455  can be formed from each of studs  440  and routed along connector plate  445 , across acoustically permeable layer  430  and coupled with circuitry within electronic device  100  (see  FIG. 2 ). More specifically, in some embodiments one or more traces  455  can be formed with a selective metallization process such as, but not limited to, laser-direct structuring (LDS), physical vapor deposition, selective photolithography, ion-beam deposition, or other process. As shown in  FIG. 5 , in some embodiments a metallized trace can be formed along one or more fibers  515  of an acoustic mesh  520 . In other embodiments, one or more fibers  515  of acoustic mesh  520  can be formed from an electrically conductive metal, or at least partially from a metal and used as a conductor to route the one or more signals. 
     In some embodiments connector plate  445  has a thickness  525  that is between 0.1 and 0.5 millimeters while in other embodiments the thickness is between 0.2 and 0.4 millimeters and in various embodiments the thickness is between 0.25 and 0.35 millimeters. 
     In some embodiments acoustically permeable layer  430  has a thickness  530  that is between 0.025 and 0.2 millimeters while in other embodiments the thickness is between 0.5 and 0.15 millimeters and in various embodiments the thickness is between 0.075 and 0.125 millimeters. 
       FIG. 6  illustrates an alternative embodiment of a partial cross-sectional view B-B formed through a portion of a connector plate  645  and an acoustically permeable layer  630  illustrated in  FIG. 4 . Compared to the embodiment illustrated in  FIG. 5 , in  FIG. 6  a flexible circuit  605  is used to electrically couple studs  640  to circuitry within the electronic device. More specifically, flexible circuit  605  includes one or more pads  610  that are attached to studs  640  with solder or other conductive means such as electrically conductive epoxy. Flexible circuit  605  then routes signals from contacts  615  to circuitry within the electronic device. 
       FIG. 7  illustrates an alternative internal construction of an embodiment of an electronic device as compared to the electronic device illustrated in  FIG. 2 .  FIG. 7  illustrates a simplified cross-sectional view similar to the view shown in  FIG. 2 , however in  FIG. 7  electronic device  700  employs a conductive metal pin  705  to route signals past speaker assembly  710 , as compared to the embodiment illustrated in  FIG. 2  that used a flexible circuit board. As shown in  FIG. 7 , speaker assembly  710  includes a diaphragm  715  disposed within a speaker housing  720  that is positioned within enclosure  725 . Similar to the embodiment illustrated in  FIG. 2 , a flexible circuit board  730  is used to form plurality of contacts  735  and route signals across acoustically permeable layer  740 . However, in this embodiment a portion of speaker housing  720  includes one or more channels  745  that accommodate one or more conductive metal pins  705  that couple signals from flexible circuit board  730  to routing structure  755  positioned behind seal  760  and used to route signals to circuitry within electronic device  700 . In some embodiments one or more conductive metal pins  705  are attached to flexible circuit board  730  and routing structure  755  by soldering the pin into vias  760   a ,  760   b , however other embodiments can use a different method of connection. In various embodiments one or more metal pins  705  can be insert-molded or stitched within housing  720  forming a liquid-tight interface to the housing. 
     In some embodiments, instead of one or more metal pins  705 , an alternative electrical interconnect can be used and can include an anisotropic conductive elastomer (ACE) including electrically conductive regions separated by electrically insulating regions within an elastomeric panel, a plurality of aligned conductive wires inserted within an elastomeric panel, pogo pins, a wire or any other type of electrical interconnect. 
       FIG. 8  illustrates a simplified cross-sectional view A-A formed through a portion of an electronic device  800  that is similar to electronic device  100  illustrated in  FIG. 1 . However,  FIG. 8  shows an alternative internal construction of electronic device  800  as compared to the embodiments shown in  FIGS. 2 and 7 , and employs an acoustically permeable layer  805  comprising a perforated plate  810  and a connector plate  815  that includes a mating connector guide  820 . As shown in  FIG. 8 , a flexible circuit board  825  is used to couple plurality of contacts  830  to circuitry within electronic device  800 . However, in this embodiment acoustically permeable layer  805  includes connector plate  810  with a plurality of perforations  835  that allow acoustic energy from diaphragm  840  to pass through the acoustically permeable layer and exit speaker opening  843 . In this embodiment, flexible circuit board  825  includes a plurality of openings  845  that align with plurality of perforations  835  to allow sound to pass through the flexible circuit board. In this way, flexible circuit board  825  can cover a significant portion of acoustically permeable layer  805  and not restrict the acoustic performance of electronic device  800 . 
     As further illustrated in  FIG. 8 , connector plate  810  includes mating connector guide  820  that is formed to interface with mating connector  850  such that a plurality of pins  855  on the mating connector are aligned with plurality of contacts  830 . In this embodiment guide  820  can include raised portions  860   a ,  860   b  that can be rounded and/or tapered to align bulkhead  865  of mating connector  850  before plurality of pins  855  come into contact with plurality of contacts  830 . Other alignment features can be used and are within the scope of this disclosure. Because the relatively small dimensions of the concealed connector, alignment features such as guide  820  and one or more alignment features  150  (see  FIG. 1 ) can be useful to assist in the proper and reliable mating of mating connector  850  with electronic device  800 . 
     For simplicity, various internal components, such as the circuitry, processor, graphics circuitry, bus, memory, storage device and other components of electronic devices  100 ,  700  and  800  (see  FIGS. 1, 7 and 8 , respectively) are not shown in the figures. The embodiments described above have been illustrated in a smart watch, however similar concealed connectors can be implemented in any electronic device. Further, the embodiments above have illustrated a hidden connector disposed within a speaker aperture of the electronic device, however a hidden connector can be disposed in any aperture including, but not limited to, a barometric vent, a sensor aperture, or a non-functional aperture that is only used to conceal the connector. 
     In the foregoing specification, embodiments of the invention have been described with reference to numerous specific details that may vary from implementation to implementation. The specification and drawings are, accordingly, to be regarded in an illustrative rather than a restrictive sense. The sole and exclusive indicator of the scope of the invention, and what is intended by the applicants to be the scope of the invention, is the literal and equivalent scope of the set of claims that issue from this application, in the specific form in which such claims issue, including any subsequent correction. The specific details of particular embodiments may be combined in any suitable manner without departing from the spirit and scope of embodiments of the invention. 
     Additionally, spatially relative terms, such as “bottom” or “top” and the like may be used to describe an element and/or feature&#39;s relationship to another element(s) and/or feature(s) as, for example, illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use and/or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as a “bottom” surface may then be oriented “above” other elements or features. The device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

Metadata:
Filing Date: 20180524
Publication Date: 20200121
Grant Date: 20200121
Priority Date: 20170925
Inventors: ELY, COLIN M.
BOOZER, BRAD G.
KALLMAN, BENJAMIN J.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R12/81", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2420/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R13/22", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01R13/631", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2420/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01R12/81", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01R13/631", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2420/09", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 65806931