PATENT DOCUMENT

Publication Number: US-9414141-B2
Application Number: US-201213343645-A
Country: US
Kind Code: B2

Title: Mesh structure providing enhanced acoustic coupling

Abstract:
A portable electronic device that provides compact configurations for audio elements are disclosed. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). According to one aspect, mesh structures, such as mesh barriers, are formed to facilitate improved acoustic sealing in a space efficient manner. In one embodiment, a mesh barrier for an audio port can be reliably acoustically sealed (or coupled) with an audio chamber and/or outer device housing in a space efficient manner. A mesh barrier can serve to block undesired foreign substances from entry or further entry into an audio port and/or serve as a cosmetic barrier which obscures vision into an audio port. In one embodiment, a portion of a mesh structure can be provided with a substantially planar surface that facilitates improved acoustic sealing.

Claims:
What is claimed is: 
     
       1. A mesh structure for an acoustic port opening of an outer surface of a housing of a portable electronic device, the mesh structure comprising:
 a mesh article positioned above an audio element of the portable electronic device, the mesh article having a weave configuration of overlapping elements, the mesh article having a central portion and an outer peripheral portion, wherein the outer peripheral portion is: 
 processed to integrate a material interstitially with the weave configuration thereby reducing the porosity of the peripheral portion with respect to the central portion; and 
 configured to receive an adhesive after being processed, the adhesive facilitating acoustic sealing of the mesh article within the acoustic port. 
 
     
     
       2. A mesh structure as recited in  claim 1 , wherein the processed outer peripheral portion provides a frame for the mesh article. 
     
     
       3. A mesh structure as recited in  claim 2 , wherein the frame is configured to form an acoustic seal between the mesh article and the housing of the portable electronic device. 
     
     
       4. A mesh structure as recited in  claim 1 , wherein the processed outer peripheral portion has a more planer surface as compared to the central portion. 
     
     
       5. A mesh structure as recited in  claim 1 , wherein the mesh structure is a mesh barrier that prevents debris from entering the acoustic port. 
     
     
       6. A mesh structure as recited in  claim 1 , wherein the material integrated into the outer peripheral portion includes an adhesive. 
     
     
       7. A mesh structure as recited in  claim 1 , wherein the material integrated into the outer peripheral portion includes a light cured material. 
     
     
       8. A mesh structure as recited in  claim 1 , wherein the material integrated into the outer peripheral portion includes an ink. 
     
     
       9. A mesh structure as recited in  claim 1 , wherein the material integrated into the outer peripheral portion includes a metal deposited using an electroforming process. 
     
     
       10. A mesh structure as recited in  claim 1 , wherein the material integrated into the outer peripheral portion includes a thermoplastic material. 
     
     
       11. A mesh structure as recited in  claim 1 , wherein the processed outer peripheral portion is compressed with respect to the central portion. 
     
     
       12. A mesh structure for an acoustic port opening of a portable electronic device, the mesh structure comprising:
 a middle portion; and 
 an outer portion having a material interstitially integrated within the mesh structure, wherein the outer portion is:
 less porous than the middle portion; and 
 configured to receive an adhesive layer that facilitates acoustic sealing of the mesh structure within the acoustic port after the material is integrated into the outer portion. 
 
 
     
     
       13. A mesh structure as recited in  claim 12 , wherein the outer portion provides a frame for the mesh structure. 
     
     
       14. A mesh structure as recited in  claim 13 , wherein the frame is configured to form an acoustic seal between the mesh article and the housing of the portable electronic device. 
     
     
       15. A mesh structure as recited in  claim 12 , wherein the outer portion is substantially more planer than the middle portion. 
     
     
       16. A mesh structure as recited in  claim 12 , wherein the material integrated into the outer portion includes a silicone materials. 
     
     
       17. A mesh structure as recited in  claim 12 , wherein the material integrated into the outer portion includes a light-cured adhesive. 
     
     
       18. A mesh structure as recited in  claim 12 , wherein at least a portion of the mesh structure is hydrophobic. 
     
     
       19. A mesh structure for an acoustic port of an electronic device, comprising:
 a woven mesh article having an inner region having a first thickness and a peripheral region having a second thickness that is less than the first thickness, wherein:
 the peripheral region includes a material embedded within the woven mesh; 
 the peripheral region is less porous than the inner region; and 
 the woven mesh is configured to be positioned relative to an acoustic port formed in a housing of a portable electronic device. 
 
 
     
     
       20. The mesh structure of  claim 19 , wherein the peripheral region comprises a recess disposed on at least one of a top surface of the peripheral region and a bottom surface of the peripheral region. 
     
     
       21. The mesh structure of  claim 19 , wherein the peripheral region is compressed with respect to the inner region.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to audio ports for electronic devices and, more particularly, for audio port configurations for compact electronic devices. 
     2. Description of the Related Art 
     Portable electronic devices often provide audio jacks (i.e., audio connectors) that facilitate connection with headsets or headphones which provide personal external speakers for their users. Portable electronic devices can provide one or more internal speakers that are able to be utilized for producing audio sound. Similarly, portable electronic devices can have a microphone jack that facilitates connection with a microphone which can be externally provided for a user. Portable electronic device can also provide one or more internal microphones that are able to be used to pickup (i.e., receive) audio sound. 
     There is, however, an ongoing need to make portable electronic devices smaller and thinner. As portable electronic devices get smaller and thinner, there are increased difficulties in providing the same or greater functionality in a smaller area. With respect to audio sound, a portable electronic device can utilize one or more speakers and one or more microphones provided internal to the housing of the portable electronic device. Unfortunately, given the area constraints imposed on many portable electronic devices, it is increasingly difficult to provide high-quality audio sound output and pickup without hindering the ability to make portable electronic devices smaller and thinner. Consequently, there is a need for improved approaches to provide high-quality audio sound output and/or pickup from portable electronic devices as they get smaller and thinner. 
     One or more audio ports are usually provided with portable electronic device to support the audio sound output and pickup. Typically, the one or more audio ports have a barrier, such as a mesh barrier, so that undesired foreign substances can be blocked from entry or further entry into the audio port. 
     Unfortunately, however, a mesh barrier, is typically an interwoven structure that present difficulties in sealing such against an outer housing or audio port components. Hence, there remains a need to reliably seal to mesh barriers in a space efficient manner (e.g., with minimum thickness). 
     SUMMARY 
     The invention pertains to a portable electronic device that provides compact configurations for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). According to one aspect, mesh structures, such as mesh barriers, are formed to facilitate improved acoustic sealing in a space efficient manner. In one embodiment, a mesh barrier for an audio port can be reliably acoustically sealed (or coupled) with an audio chamber and/or outer device housing in a space efficient manner. A mesh barrier can serve to block undesired foreign substances from entry or further entry into an audio port and/or serve as a cosmetic barrier which obscures vision into an audio port. In one embodiment, a portion of a mesh structure can be provided with a substantially planar surface that facilitates improved acoustic sealing. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     As a mesh structure for an acoustic port opening of an outer surface of a housing of a portable electronic device, where the acoustic port opening pertains to an acoustic port provided within the housing of the portable electronic device, one embodiment can, for example, include at least a mesh article having a weave configuration of overlapping elements. The mesh article can have a central portion and an outer peripheral portion. The outer peripheral portion can have a more reliable sealing surface that facilitates acoustic sealing of the mesh article within the acoustic port. 
     As a portable electronic device, one embodiment can, for example, include at least: a housing having an inner surface and an outer surface, the housing having an audio port opening; an audio component provided internal to the housing; an acoustic chamber provided internal to the housing, the acoustic chamber having an internal audio channel through the acoustic chamber from a first end to a second end; and a mesh barrier having a peripheral frame. The peripheral frame can have a first side and a second side. The first side of the peripheral frame can be acoustically sealed adjacent to the second end of the acoustic chamber, and the second side of the peripheral frame can be acoustically sealed adjacent to the inner surface of the housing adjacent the audio port opening. The first end of the acoustic chamber can be acoustically sealed adjacent to the audio port component. 
     As a mesh structure for an acoustic port opening of an outer surface of a housing of a portable electronic device, where an acoustic port provided internal to the housing is acoustically coupled to the acoustic port opening, one embodiment can, for example, include at least a plurality of interweaved elements configured to provide an inner mesh region and an outer sealing region. The outer sealing region of the mesh structure can be modified to facilitate sealing against counterpart structures proximate to the acoustic port opening of the housing. 
     As a method for sealing a mesh structure within an acoustical port of an electronic product, one embodiment can, for example, include at least: obtaining a mesh sheet; processing the mesh sheet to provide modified outer regions for a plurality of mesh instances; and singulating the mesh instances from the processed mesh sheet to provide a plurality of mesh structures. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  is a perspective diagram of a portable electronic device according to one embodiment. 
         FIG. 2  is a flow diagram of a mesh assembly process according to one embodiment. 
         FIG. 3A  is a cross-sectional view of a mesh structure according to one embodiment. 
         FIG. 3B  is a cross-sectional view of a mesh structure according to another embodiment. 
         FIG. 3C  is a cross-sectional view of a mesh structure according to another embodiment. 
         FIG. 4  is a cross-sectional view of a mesh structure according to still another embodiment. 
         FIG. 5  is a partial cross-sectional diagram of a portion of a portable electronic device according to one embodiment. 
         FIG. 6  is a partial cross-sectional diagram of a portion of a portable electronic device according to another embodiment. 
         FIG. 7  is a flow diagram of a mesh assembly process according to one embodiment. 
         FIG. 8  is a flow diagram of a mesh assembly process according to another embodiment. 
         FIG. 9  is a flow diagram of a mesh assembly process according to another embodiment. 
         FIG. 10  is a flow diagram of a mesh assembly process according to still another embodiment. 
     
    
    
     It should be noted that  FIGS. 1-10  are not necessarily drawn to scale. Instead, these figures are enlarged so that features are more readily visible. 
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The invention pertains to a portable electronic device that provides compact configurations for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). According to one aspect, mesh structures, such as mesh barriers, are formed to facilitate improved acoustic sealing in a space efficient manner. In one embodiment, a mesh barrier for an audio port can be reliably acoustically sealed (or coupled) with an audio chamber and/or outer device housing in a space efficient manner. A mesh barrier can serve to block undesired foreign substances from entry or further entry into an audio port and/or serve as a cosmetic barrier which obscures vision into an audio port. In one embodiment, a portion of a mesh structure can be provided with a substantially planar surface that facilitates improved acoustic sealing. 
     Exemplary embodiments of the invention are discussed below with reference to  FIGS. 1-10 . However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes as the invention extends beyond these limited embodiments. 
       FIG. 1  is a perspective diagram of a portable electronic device  100  according to one embodiment. The portable electronic device  100  is a representative illustration for a portable electronic device. However, it should be understood that, in other embodiments, the size, scale, shape, configuration and/or appearance of the portable electronic device  100  can vary widely. 
     The portable electronic device  100  includes a housing  102  that provides an exterior surface for the portable electronic device  100 . The portable electronic device  100  provides one or more functional capabilities that can be utilized by its user. In so doing, the portable electronic device can include at least one input/output component  104 . 
     The user input/output component  104  typically includes one or more user input devices and/or one or more output device. The one or more user input devices can allow the user to interact with the portable electronic device. The one or more output devices can provide outputs from the portable electronic device to the user or another device. The input/output component  104  can, for example, pertain to one or more of a display, a touch screen, a touchpad, a keypad, a button, a dial, and etc. For example, the input/output component  104  can provide a display and a touch screen combination, with the display providing output capability and the touch screen providing input capability. 
     The portable electronic device  100  can also include an audio circuit  106 . The audio circuit  106  is typically provided internal to the housing  102  of the portable electronic device  100 . The audio circuit  106  can operate to produce audio signals that can be supplied to one or more speakers internal to the housing  102  of the portable electronic device  100 . The one or more speakers, in response to the audio signals, can produce audio sound that can be directed (e.g., by way of one or more acoustic chambers) to one or more audio output openings  108  in the housing  102  of the portable electronic device  100 . In one embodiment, each of the one or more audio output openings  108  can include a mesh cover  110  that serves to protect foreign matter from entering into the housing  102  of the portable electronic device  100  by way of the audio output opening  108 . 
     The audio circuit  106  can also operate to receive audio signals that are picked-up by one or more microphones internal to the housing  102  of the portable electronic device  100 . The one or more microphones can pick-up audio sounds that are received (e.g., directly or by way of one or more acoustic chambers) via an audio input opening  112  in the housing  102  of the portable electronic device  100 . In general, the portable electronic device  100  can place the audio input opening  112  in any of various location. However, in this embodiment, the audio input opening  112  is provided on a side of the housing  102 . In one embodiment, the audio input opening  112  can also include a mesh cover (not shown) that serves to protect foreign matter from entering into the housing  102  of the portable electronic device  100  by way of the audio input opening  112 . 
     The housing  102  of the portable electronic device  100  can also include an external connection port  114 . The external connection port  114  allows the portable electronic device  100  to be directly or indirectly connected to a host device (e.g., personal computer) or other electronic devices (e.g., docking station), so as to exchange data or to charge a battery (not shown) utilized by the portable electronic device  100 . 
     The portable electronic device  100  can also include a receiver opening  116  and a button opening  118 . The receiver opening  116  can be provided adjacent an internal receiver (e.g., speaker) that can provide audio output to a user of the portable electronic device  100 . The button opening  118  can be provided adjacent a button that allows the user to interact with the portable electronic device  100 . Although the receiver opening  116  and the button opening can be provided in the translucent face  105 , it should be understood that these components could be provided elsewhere in the portable electronic device  100 . For example, these components could be provided at the side of the portable electronic device  100 . The translucent face  105  can be a glass sheet or a plastic sheet. The translucent face  105  provides a front face for the housing. The translucent face can also be thin, such as having a thickness of less than 1 millimeter. 
     The portable electronic device  100  can include any suitable type of electronic device having a display. For example, the portable electronic device  100  can be a laptop, tablet computer, media player, phone, GPS unit, remote control, personal digital assistant (PDA), and the like, and devices combining some or all of this functionality. Depending on the capabilities of the portable electronic device  100 , internal to the portable electronic device  100  are various electrical components that serve support the device capabilities. The electronic components include one or more of integrated circuit(s), electronic substrate(s) (flex circuits, printed circuit boards), wireless transceiver(s), battery(s), microphone(s), speaker(s), display circuitry(s), touch circuitry(s), and connectors (e.g., ports), user input devices (button, switches, etc.). 
     According to one embodiment, the portable electronic device  100  can be provided with a compact configuration for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). An audio element can be mounted on or coupled to an acoustic chamber having an opening therein to allow audio sound to pass there through. The acoustic chamber can assist in directing audio sound between the audio output opening  108  and the audio element. As noted above, the audio output opening  108  can include the mesh cover  110  to protect foreign matter from entering into the housing  102  and thus the acoustic chamber of the portable electronic device  100  by way of the audio output opening  108 . The mesh cover  110  can be formed or modified to improve its acoustic sealing with respect to the acoustic chamber. For example, the mesh cover  110  can be reliably sealed to the audio output openings  108  of the housing  102  (and/or some other structure within the housing  102 ). 
       FIG. 2  is a flow diagram of a mesh assembly process  200  according to one embodiment. The mesh assembly process  200  can serve to produce mesh structures that can be used with electronic device housings. A mesh structure can pertain to a barrier (or mesh barrier). In one implementation, the mesh structure can serve to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing. In another implementation, the mesh structure can serve as a cosmetic mesh that is provided at or near an opening at outer surface of an electronic device housing. For example, the cosmetic mesh can obscure vision into an opening, e.g., audio opening, of the electronic device housing. 
     The mesh assembly process  200  can initially obtain  202  a mesh sheet. The mesh sheet can be processed  204  to provide modified outer regions for a plurality of mesh instances. The processing of the mesh sheet to provide the modified outer regions can vary depending upon implementation. In one example, an electroforming technique can be utilized to form the modified outer regions for the plurality of mesh instances. For example, Nickel can be electroformed at outer regions of the plurality of mesh instances. In another embodiment, a photo-curing technique can be utilized to form the modified outer regions for the plurality of mesh instances. In another embodiment, a thermoplastic film can be utilized to form the modified outer regions for the plurality of mesh instances. In another embodiment, an adhesive or silicone buildup can be utilized to form the modified outer regions for the plurality of mesh instances. In yet another embodiment, a compressive technique can be utilized to form the modified outer regions for the plurality of mesh instances. 
     After the mesh sheet has been processed  204  to provide the modified outer regions for the plurality of mesh instances, the processed mesh sheet can then be singulated  206  into a plurality of mesh structures. By using a mesh sheet, processing can concurrently form a plurality of mesh instances, which provided for efficient manufacture of the mesh structures. In assembling a given electronic device, or its housings, one or more of the mesh structures can, for example, be used as a barrier, such as a mesh barrier, for an opening, such as an audio port opening, in an electronic device housing. For example, the resulting mesh structures can serve as mesh barriers, such as cosmetic meshes, for audio ports of electronic device housings. Typically, the mesh structures can be visible to users of the electronic device housings and can serve to provide a cosmetic appearance and/or can serve to block undesired foreign substances from entry or further entry into an exposed audio port of an electronic device housing. Thereafter, as desired, the resulting mesh structures can be installed  208  into electronic products. 
     In one embodiment, a mesh structure can pertain to a barrier, or mesh barrier, that serves to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing. In the same or another embodiment, a mesh structure can serve as a cosmetic mesh (or cosmetic barrier) that is provided at or near an audio opening in an outer surface for an electronic device housing. The cosmetic mesh can provide a cosmetic appearance to the audio opening. 
       FIG. 3A  is a cross-sectional view of a mesh structure  300  according to one embodiment. The mesh structure  300  can be used as a mesh barrier, such as an actual particle barrier or a cosmetic barrier. The mesh structure  300  has an inner region  304  (or central region) and an outer region  306 . In one embodiment, the mesh structure  300  can have a circular structure and the outer region  306  can represent a circular outer peripheral region. In one embodiment, the mesh structure  300 , both the inner region  304  and the outer region  306 , can be a woven structure formed from metal wires (e.g., stainless steel wire). The outer region  306  is also processed or formed to provide a sealed area  308 . In this embodiment, the sealed area  308  can be processed or formed by adhering or binding (e.g., through electroforming, embedding, painting, or pressing) material into the mesh structure  300  at the outer region  306 . The sealed area  308  of the outer region  306  can operate to render the mesh structure  300  at the outer region  306  able to be acoustically sealable within an acoustic chamber (port) in a more reliable manner. In one embodiment, material being adhered (e.g., bonded, printed, electroformed or embedded) to the outer region  306  to form the sealed region  308 . The material may require pressure, curing, drying, optical energy or electrical energy before being adhered to the mesh structure  300 . As compared to the inner region  304 , the outer region  306  is typically substantially less porous to air flow therethrough. 
       FIG. 3B  is a cross-sectional view of a mesh structure  320  according to another embodiment. The mesh structure  320  can be used as a mesh barrier, such as an actual particle barrier or a cosmetic barrier. The mesh structure  320  has an inner region  324  (or central region) and an outer region  326 . In one embodiment, the mesh structure  320  can have a circular structure and the outer region  326  can represent a circular outer peripheral region. In one embodiment, the mesh structure  320 , both the inner region  324  and the outer region  326 , can be a woven structure formed from metal wires (e.g., stainless steel wire). The outer region  326  is also processed or formed to provide a sealed area  328 . In this embodiment, the sealed area  328  can be processed or formed by adhering or binding (e.g., through electroforming, embedding, painting, or pressing) material into the mesh structure  320  at the outer region  326 . 
     As shown in  FIG. 3B , a top layer of material  330  can be adhered to the top portion of the outer region  326 , and a bottom layer of material  332  can be adhered to the bottom portion of the outer region  326 . In one embodiment, material can be adhered into the outer region  326  from one or both a top side and a bottom side of the mesh structure  320 . As shown in  FIG. 3B , the material being adhered may only partially embed, bind or form into the outer region  326 . In one embodiment, the result of the application of the top layer of material  330  and/or the bottom layer of material  332  can provide a planar surface at the outer region  326 . Accordingly, as a result of the forming of the sealed region  328 , the outer region  320  can become more planar (or flatter) which allows easier sealing (e.g., acoustically sealing) with other surfaces (such as with a thin layer of adhesive). The sealed area  328  can be referred to as having a fame that facilitates sealing to other surfaces (such as with a thin layer of adhesive). As compared to the inner region  324 , the outer region  326  is typically substantially less porous to air flow therethrough. 
       FIG. 3C  is a cross-sectional view of a mesh structure  340  according to another embodiment. The mesh structure  340  illustrated in  FIG. 3C  is generally similar to the mesh structure  320 , except that sealed area is configured differently. The mesh structure  340  can be used as a mesh barrier, such as a cosmetic mesh. The mesh structure  340  has an inner region  344  (or central region) and an outer region  346 . In one embodiment, the mesh structure  340 , both the inner region  344  and the outer region  346 , can be a woven structure formed from metal wires (e.g., stainless steel wire). The outer region  346  is also processed or formed to provide a sealed area  348 . In this embodiment, the sealed area  348  is processed or formed by adhering material into the mesh structure  340  at the outer region  346 . For example, material can be adhered to the outer region  346  from one or both a top side, a bottom side and a side of the mesh structure  340 . As shown in  FIG. 3C , a top layer of material  348   a  can be adhered to the top portion of the outer region  346 , a bottom layer of material  358   b  can be adhered to the bottom portion of the outer region  346 , and a side layer of material  348   c  can be adhered to the side portion of the outer region  346 . In one embodiment, the result of sealed area  348  can provide a planar surface at the outer region  346 . As a result of the forming of the sealed region  348 , the outer region  346  can become more planar (or flatter) which allows easier sealing (e.g., acoustically sealing) with other surfaces (such as with a thin layer of adhesive). The sealed area  348  can be referred to as having a fame that facilitates sealing to other surfaces (such as with a thin layer of adhesive). As compared to the inner region  344 , the outer region  346  is typically substantially less porous to air flow therethrough. 
       FIG. 4  is a cross-sectional view of a mesh structure  400  according to still another embodiment. The mesh structure  400  can be used as a barrier, such as an actual particle barrier or a cosmetic barrier. The mesh structure  400  has an inner region  404  (or central region) and an outer region  406 . In one embodiment, the mesh structure  400  can have a circular structure and the outer region  406  can represent a circular outer peripheral region. In one embodiment, the mesh structure  400 , both the inner region  404  and the outer region  406 , can be a woven structure formed from metal wires (e.g., stainless steel wire). The outer region  406  is also processed or formed to provide a compressed area  407 . In this embodiment, the sealed area  407  is processed or formed by compressing the mesh structure  400  at the outer region  406 . As compared to the inner region  404 , the outer region  406  (as a result of the compressing) is substantially less porous to air flow therethrough. As shown in  FIG. 4 , the compressed area  407  can have both top and bottom sides compressed at the outer region  406 , which provides a top outer recess  408  and a bottom outer recess  410 . The sealed area  407  of the outer region  406  can operate to render the mesh structure  400  at the outer region  406  more reliably acoustically sealable within an acoustic chamber (port). The recesses  408 ,  410  can also facilitate low profile assembly with or for an electronic device housing. 
     Embodiments described herein provide a low-profile audio port arrangement. The audio port arrangement can include an acoustic chamber as well as a barrier that can block foreign matter from an audio channel while not blocking the audio sound from passing through the acoustic chamber. The barrier, which is typically woven metal, can be modified to enhanced sealing of the barrier to the acoustic chamber and/or to an audio port region of an electronic device housing. 
       FIG. 5  is a partial cross-sectional diagram of a portion of a portable electronic device  500  according to one embodiment. The portable electronic device  500  includes a housing  502  for the portable electronic device  500 . The housing  502  has an opening  504  that allows audio sound to enter or be emitted from the portable electronic device  500 . The portable electronic device  500  includes an audio element  506  provided internal to the housing  502  for the portable electronic device  500 . The audio element  506  can represent a speaker driver (e.g., speaker) and/or a receiver (e.g., microphone). 
     When the audio element  506  serves as a receiver, audio sound can be picked-up via the opening  504  in the housing  502 . The sound, in this example, can be environment or can be audio sound (e.g., voice communications) associated with a user. 
     Alternatively, when the audio element  506  serves as a speaker driver, the speaker driver  506  upon controlled activation can produce audio sound that can be directed out of the opening  504  of the housing  502 . For example, the audio sound can be associated with playback of digital media asset, such as a video file (e.g., movie), an audio file (e.g., music, e-book or podcast), etc., by the portable electronic device  500 . As another example, the audio sound can be associated with a user, such as a voice conversation, using the portable electronic device  500  as a wireless telephone. 
     In the low-profile design for the portable electronic device  500 , the compactness of the portable electronic device  500  is of importance. Consequently, placement of the audio element  506  within the housing  502  for the portable electronic device  500  is managed such that the overall size and/or thickness of the portable electronic device  500  is able to remain compact (e.g., thin). 
     As shown in  FIG. 5 , an audio channel can be established between the audio element  506  and the opening  504 . The audio element  506  can be acoustically coupled to the opening  504  in the housing  502  by or via various components that participate in providing the audio channel. In the embodiment illustrated in  FIG. 5 , the audio channel can extend from the audio element  506  proximate to the opening  504  in the housing  502 . 
     To further support the audio channel, the portable electronic device  500  can include an acoustic chamber  508  (or audio boot). The acoustic chamber  508  can include an internal audio channel  510  that extends through the acoustic chamber  508  from a first end to a second end. In one embodiment, the acoustic chamber  508  can be a single structure that can be formed with a molding process. For example, the acoustic chamber can be formed of an elastomer (e.g., plastic (including thermoplastic elastomer), rubber or foam), such as nylon, silicone, Acrylonitrile Butadiene Styrene (ABS), or polypropylene. 
     The first end of the acoustic chamber  508  can abut against the audio element  506 . The first end of the acoustic chamber  508  can be secured and/or acoustically sealed to the audio element  506  by any of a variety of ways, including a mechanical feature, a gasket, adhesive and the like, or some combination thereof. The second end of the acoustic chamber  508  can be acoustically coupled to a cosmetic barrier  512  (e.g., cosmetic mesh barrier). The cosmetic barrier  512  has an outer portion  514  (e.g., peripheral portion) that has been modified to facilitate sealing with the acoustic chamber  508  and/or the housing  502 . Various approaches to modify the outer portion  514  of the cosmetic barrier  512  are described herein. An adhesive layer  516  can be provided to couple the second end of the acoustic chamber  508  to a first side of the cosmetic barrier  512 . A second side of the cosmetic barrier  512  can be acoustically coupled to the housing  502  around the opening  504  in the housing  502 . An adhesive layer  518  can be provided to couple a second side of the cosmetic barrier  512  to the inner surface of the housing  502 . Since the outer portion  514  of the cosmetic barrier  512  has been modified, the ability to reliably seal the cosmetic barrier  512  to the acoustic chamber  508  or the inner surface of the housing  502  is improved. For example, the outer portion  514  can be rendered more planar (e.g., flatter) and less porous, so that sealing thereto is easier to achieve. Advantageously, the thickness of the adhesive layer  516  and/or the adhesive layer  518  can typically be significantly reduced (as compared to conventional thicknesses) since reliable sealing has been made easier. For example, in one embodiment, if a prior adhesive layer thickness was 1 mm, then the invention can enable the adhesive layer thickness to be reduced to about 0.4 mm. 
       FIG. 6  is a partial cross-sectional diagram of a portion of a portable electronic device  600  according to another embodiment. The portable electronic device  600  shown in  FIG. 6  is similar to the portable electronic device  500  shown in  FIG. 5 , except that its outer portions are modified differently. 
     The portable electronic device  600  includes a housing  602  for the portable electronic device  600 . The housing  602  has an opening  604  that allows audio sound to enter or be emitted from the portable electronic device  600 . The portable electronic device  600  includes an audio element  606  provided internal to the housing  602  for the portable electronic device  600 . The audio element  606  can represent a speaker driver (e.g., speaker) and/or a receiver (e.g., microphone). 
     When the audio element  606  serves as a receiver, audio sound can be picked-up via the opening  604  in the housing  602 . The sound, in this example, can be environment or can be audio sound (e.g., voice communications) associated with a user. 
     Alternatively, when the audio element  606  serves as a speaker driver, the speaker driver  606  upon controlled activation can produce audio sound that can be directed out of the opening  604  of the housing  602 . For example, the audio sound can be associated with playback of digital media asset, such as a video file (e.g., movie), an audio file (e.g., music, e-book or podcast), etc., by the portable electronic device  600 . As another example, the audio sound can be associated with a user, such as a voice conversation, using the portable electronic device  600  as a wireless telephone. 
     In the low-profile design for the portable electronic device  600 , the compactness of the portable electronic device  600  is of importance. Consequently, placement of the audio element  606  within the housing  602  for the portable electronic device  600  is managed such that the overall size and/or thickness of the portable electronic device  600  is able to remain compact (e.g., thin). 
     As shown in  FIG. 6 , an audio channel can be established between the audio element  606  and the opening  604 . The audio element  606  can be acoustically coupled to the opening  604  in the housing  602  by or via various components that participate in providing the audio channel. In the embodiment illustrated in  FIG. 6 , the audio channel can extend from the audio element  606  proximate to the opening  604  in the housing  602 . 
     To further support the audio channel, the portable electronic device  600  can include an acoustic chamber  608  (or audio boot). The acoustic chamber  608  can include an internal audio channel  610  that extends through the acoustic chamber  608  from a first end to a second end. In one embodiment, the acoustic chamber  608  can be a single structure that can be formed with a molding process. For example, the acoustic chamber can be formed of an elastomer (e.g., plastic (including thermoplastic elastomer), rubber or foam), such as nylon, silicone, Acrylonitrile Butadiene Styrene (ABS), or polypropylene. 
     The first end of the acoustic chamber  608  can abut against the audio element  606 . The first end of the acoustic chamber  608  can be secured and/or acoustically sealed to the audio element  606  by any of a variety of ways, including a mechanical feature, a gasket, adhesive and the like, or some combination thereof. The second end of the acoustic chamber  608  can be acoustically coupled to a cosmetic barrier  612  (e.g., cosmetic mesh barrier). The cosmetic barrier  612  has an outer portion  614  (e.g., peripheral portion) that has been modified to facilitate sealing with the acoustic chamber  608  and/or the housing  602 . In this embodiment, the outer portion  614  of the cosmetic barrier  612  has a reduced thickness as compared to an inner portion. For example, the outer portion  614  can be compressed to provide the reduced thickness. An adhesive layer  616  can be provided to couple the second end of the acoustic chamber  608  to a first side of the cosmetic barrier  612 . A second side of the cosmetic barrier  612  can be acoustically coupled to the housing  602  around the opening  604  in the housing  602 . An adhesive layer  618  can be provided to couple a second side of the cosmetic barrier  612  to the inner surface of the housing  602 . Since the outer portion  614  of the cosmetic barrier  612  has been modified, the ability to reliably seal the cosmetic barrier  612  to the acoustic chamber  608  or the inner surface of the housing  602  is improved. Specifically, the compression of the cosmetic barrier  612 , which is often a woven wire structure, can render the outer portion  614  less porous so that less air is able to pass therethrough. The outer portion  614  can also be more planar (e.g., flatter) so that sealing thereto is easier to achieve. Further, due to the modification to the outer portion  614 , such as through compression, the thickness of the outer portion  614  is reduce which further assists in providing a compact audio port. Advantageously, the thickness of the adhesive layer  616  and/or the adhesive layer  618  can typically be significantly reduced (as compared to conventional thicknesses) since reliable sealing has been made easier by the use of the outer portion  614 . For example, in one embodiment, if a prior adhesive layer thickness was 1 mm, then the invention can enable the adhesive layer thickness to be reduced to about 0.4 mm. 
     Although  FIGS. 5 and 6  indicate use of a single mesh structure, or barrier, it should be noted that multiple mesh structures can be provided for an audio opening of an electronic device. For example, the multiple mesh structures can be stacked on one another, directly or separated by intermediate structures or materials. In one embodiment, one mesh can primarily serve as a cosmetic mesh and another mesh can serve primarily to block foreign substances. For example, in a mesh stack, one mesh can be a stainless steel mesh and another mesh can be a polymer hydrophobic mesh. 
       FIGS. 7-10  pertain to additional examples of processing to form improved cosmetic meshes as discussed above and installing them. 
       FIG. 7  is a flow diagram of a mesh assembly process  700  according to one embodiment. The mesh assembly process  700  can serve to produce mesh structures that can be used with electronic device housings. As previously noted, a mesh structure can pertain to a barrier, or mesh barrier, that serves to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing and/or serves to block vision into an audio opening (or the internal audio chamber) of the electronic device housing. For example, a mesh structure can provided at or near an opening at outer surface of an electronic device housing and serve a cosmetic purpose, and in such case be referred to as a cosmetic mesh. 
     The mesh assembly process  700  can initially obtain  702  a mesh sheet. Typically, the mesh sheet is formed from a series of interwoven wire elements. As an example, the wire elements can be stainless steel, and the wire elements can be interwoven to form the mesh. In addition, a patterned thermoplastic film can also be obtained  704 . The thermoplastic film can be patterned (or can be patterned) to correspond to outer regions of a plurality of mesh instances to be formed. 
     Next, the patterned thermoplastic film can be applied  706  over the mesh sheet. For example, the patterned thermoplastic film can be placed adjacent top and/or bottom surfaces of the mesh sheet. After the patterned thermoplastic film has been applied  706  over the mesh sheet, the patterned thermoplastic film can be heated and pressed  708  into the mesh sheet to thereby provide modified outer regions for a plurality of the mesh instances. For example, the result of the thermoplastic film being heated and pressed  708  into the mesh sheet is that the thermoplastic film is deposited, bonded or embedded at outer regions (but not inner regions) of a plurality of mesh instances that are being formed. As a result, the outer regions of each of the plurality of mesh instances are able to more reliably seal with an audio port or chamber, so that enhanced audio sound quality can be offered by the corresponding electronic products, particularly compact portable electronic devices. 
     The processed mesh sheet can be singulated  710  into a plurality of mesh structures. Subsequently, as desired, the mesh structures can be installed  712  into electronic products. Typically, a mesh structure produced by the mesh assembly process  700  can be secured at or proximate to an audio port opening in an electronic device housing. By processing the mesh sheet to form the modified outer regions, the resulting individual mesh barriers are able to more reliably acoustically seal (or couple) with (i) an audio port or chamber and/or (ii) an opening in an outer device housing (proximate to the audio port or chamber) in a space efficient manner. 
       FIG. 8  is a flow diagram of a mesh assembly process  800  according to another embodiment. The mesh assembly process  800  can serve to produce mesh structures that can be used with electronic device housings. As previously noted, a mesh structure can pertain to a barrier, or mesh barrier, that serves to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing and/or serves to block vision into an audio opening (or the internal audio chamber) of the electronic device housing. For example, a mesh structure can provided at or near an opening at outer surface of an electronic device housing and serve a cosmetic purpose, and in such case be referred to as a cosmetic mesh. 
     The mesh assembly process  800  can initially obtain  802  a mesh sheet. Typically, the mesh sheet is formed from a series of interwoven wire elements. As an example, the wire elements can be stainless steel, and the wire elements can be interwoven to form the mesh. In addition, an emulsion can be applied  804  to the mesh sheet. 
     After the emulsion has been applied  804  to the mesh sheet, the portions of the emulsion can be selectively cured  806 . Upon being cured  806  the selective portions bind to the mesh sheet. Next, remaining uncured emulsion can be rinsed  808  away from the mesh sheet. Following the rinse  808 , those selective portions that were the emulsion was cured remain bound to the mesh sheet. The selective portions can serve as modified outer regions for a plurality of the mesh instances. For example, the result of the cured emulsion is bound to the mesh sheet at outer regions (but not inner regions) of a plurality of mesh instances that are being formed. As a result, the outer regions of each of the plurality of mesh instances are able to more reliably seal with an audio port or chamber, so that enhanced audio sound quality can be offered by the corresponding electronic products, particularly compact portable electronic devices. 
     The processed mesh sheet can then be singulated  810  into a plurality of mesh structures. Subsequently, as desired, the mesh structures can be installed  812  into electronic products. Typically, a mesh structure produced by the mesh assembly process  800  can be secured at or proximate to an audio port opening in an electronic device housing. By processing the mesh sheet to form the modified outer regions, the resulting individual mesh barriers are able to more reliably acoustically seal (or couple) with (i) an audio port or chamber and/or (ii) an opening in an outer device housing (proximate to the audio port or chamber) in a space efficient manner. 
       FIG. 9  is a flow diagram of a mesh assembly process  900  according to another embodiment. The mesh assembly process  900  can serve to produce mesh structures that can be used with electronic device housings. As previously noted, a mesh structure can pertain to a barrier, or mesh barrier, that serves to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing and/or serves to block vision into an audio opening (or the internal audio chamber) of the electronic device housing. For example, a mesh structure can provided at or near an opening at outer surface of an electronic device housing and serve a cosmetic purpose, and in such case be referred to as a cosmetic mesh. 
     The mesh assembly process  900  can initially obtain  902  a mesh sheet. Typically, the mesh sheet is formed from a series of interwoven wire elements. As an example, the wire elements can be stainless steel, and the wire elements can be interwoven to form the mesh. 
     Next, material can be printed  904  onto selective portions of the mesh sheet. The printing can be by any of a variety of techniques, including inkjet printing, pad printing or silkscreen printing. The material being printed can be a silicone-based ink or paint. As the material printed dries, the material binds to the selective portions. The printing can be performed on one side or multiple sides of the mesh sheet. The printing can also be performed multiple times so as to accumulate the printed material at the selective portions of the mesh sheet. 
     The selective portions being printed  904  can serve as modified outer regions for a plurality of the mesh instances. For example, the result of the material printed to the mesh sheet at outer regions (but not inner regions) of a plurality of mesh instances that are being formed is that the outer regions become filled or solid (or at least significantly more filled or solid than previously), in that less air can pass through the outer regions. As a result, the outer regions of each of the plurality of mesh instances are able to more reliably seal with an audio port or chamber, so that enhanced audio sound quality can be offered by the corresponding electronic products, particularly compact portable electronic devices. 
     The processed mesh sheet can then be singulated  906  into a plurality of mesh structures. Subsequently, as desired, the mesh structures can be installed  908  into electronic products. Typically, a mesh structure produced by the mesh assembly process  900  can be secured at or proximate to an audio port opening in an electronic device housing. By processing the mesh sheet to form the modified outer regions, the resulting individual mesh barriers are able to more reliably acoustically seal (or couple) with (i) an audio port or chamber and/or (ii) an opening in an outer device housing (proximate to the audio port or chamber) in a space efficient manner. 
       FIG. 10  is a flow diagram of a mesh assembly process  1000  according to still another embodiment. The mesh assembly process  1000  can serve to produce mesh structures that can be used with electronic device housings. As previously noted, a mesh structure can pertain to a barrier, or mesh barrier, that serves to block undesired foreign substances from entry or further entry into an audio chamber provided internal to an electronic device housing and/or serves to block vision into an audio opening (or the internal audio chamber) of the electronic device housing. For example, a mesh structure can provided at or near an opening at outer surface of an electronic device housing and serve a cosmetic purpose, and in such case be referred to as a cosmetic mesh. 
     The mesh assembly process  1000  can initially obtain  1002  a mesh sheet. Typically, the mesh sheet is formed from a series of interwoven wire elements. As an example, the wire elements can be stainless steel, and the wire elements can be interwoven to form the mesh. 
     Next, selective portions of the mesh sheet can be compressed  1004 . The compression can result from the application of pressure to the selective portions of the mesh sheet. The selective portions being compressed  1004  can serve as modified outer regions for a plurality of the mesh instances. For example, the result of the compression  1004  to the mesh sheet at outer regions (but not inner regions) of a plurality of mesh instances is that the outer regions become flattened (or at least significantly more flattened than previously) so that less air can pass through the outer regions. As a result, the outer regions of each of the plurality of mesh instances are able to more reliably seal with an audio port or chamber, so that enhanced audio sound quality can be offered by the corresponding electronic products, particularly compact portable electronic devices. 
     The processed mesh sheet can then be singulated  1006  into a plurality of mesh structures. Subsequently, as desired, the mesh structures can be installed  1008  into electronic products. Typically, a mesh structure produced by the mesh assembly process  1000  can be secured at or proximate to an audio port opening in an electronic device housing. By processing the mesh sheet to form the modified outer regions, the resulting individual mesh barriers are able to more reliably acoustically seal (or couple) with (i) an audio port or chamber and/or (ii) an opening in an outer device housing (proximate to the audio port or chamber) in a space efficient manner. 
     Additional details on speaker arrangements can be found in: (1) U.S. patent application Ser. No. 12/794,561, filed Jun. 4, 2010 and entitled “AUDIO PORT CONFIGURATION FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference; and (2) U.S. patent application Ser. No. 12/698,957, filed Feb. 2, 2010 and entitled “LOW-PROFILE SPEAKER ARRANGEMENTS FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference. 
     Additional details on audio port configurations can be found in: (1) U.S. Provisional Application No. 61/325,803, filed Apr. 19, 2010 and entitled “AUDIO PORT CONFIGURATION FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference; (2) U.S. application Ser. No. 12/794,561, filed Jun. 4, 2010 and entitled “AUDIO PORT CONFIGURATION FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference; and (3) U.S. application Ser. No. 13/163,308, filed Jun. 17, 2011 and entitled “AUDIO PORT CONFIGURATION FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference. 
     Embodiments of the invention are well suited for portable, battery-powered electronic devices, and more particularly handheld battery-powered electronic devices. Examples of portable, battery-powered electronic devices can include laptops, tablet computers, media players, phones, GPS units, remote controls, personal digital assistant (PDAs), and the like. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20120104
Publication Date: 20160809
Grant Date: 20160809
Priority Date: 20120104
Inventors: COHEN SAWYER I.
KOLE JARED M.
WITTENBERG MICHAEL B.
MERZ NICHOLAS
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R7/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/023", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/035", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/086", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R7/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/023", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/086", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/18", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/035", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 48694631