PATENT DOCUMENT

Publication Number: US-9467761-B2
Application Number: US-201414318436-A
Country: US
Kind Code: B2

Title: In-ear earphone with articulating nozzle and integrated boot

Abstract:
Intra-canal earphones and methods of manufacturing intra-canal earphones are disclosed. In an embodiment, an intra-canal earphone includes a rigid housing in which a driver is located, a rigid nozzle, and a resilient joint that physically couples the housing with the nozzle and acoustically couples the driver with the nozzle. Other embodiments are also described and claimed.

Claims:
What is claimed is: 
     
       1. An intra-canal earphone, comprising:
 a housing having a chamber, wherein the housing is rigid; 
 a nozzle having a nozzle lumen, wherein the nozzle is rigid; 
 a driver located in the chamber and having a driver port, the driver being configured to receive an electrical audio signal and to emit sound from the driver port; and 
 a resilient joint having an elastomeric body and a joint channel, wherein the nozzle is pivotally coupled with the housing through the elastomeric body, wherein the elastomeric body is elastomeric to allow the nozzle to pivot relative to the housing from an initial state when an external load is applied to the nozzle and to return to the initial state when the external load is removed, wherein the resilient joint is attached to a housing inner surface of the housing, wherein the resilient joint is attached to the nozzle, and wherein the nozzle lumen is acoustically coupled with the driver port through the joint channel. 
 
     
     
       2. The intra-canal earphone of  claim 1 , wherein the resilient joint fills a space between the housing inner surface and the nozzle. 
     
     
       3. The intra-canal earphone of  claim 2 , wherein the resilient joint is frictionally held by the housing inner surface, and wherein the nozzle is frictionally held by the resilient joint. 
     
     
       4. The intra-canal earphone of  claim 3 , wherein the housing includes a protrusion extending radially inward from the housing inner surface, and wherein the resilient joint covers the protrusion. 
     
     
       5. The intra-canal earphone of  claim 3 , wherein the nozzle includes one or more nozzle holes extending through a nozzle wall, and wherein the resilient joint fills the one or more nozzle holes. 
     
     
       6. The intra-canal earphone of  claim 5 , wherein the nozzle wall spreads outward along a flared portion of the nozzle from the nozzle lumen toward the housing, and wherein the one or more nozzle holes are located in the flared portion. 
     
     
       7. The intra-canal earphone of  claim 6 , wherein the one or more nozzle holes define a rib of the nozzle, and wherein the resilient joint surrounds at least a portion of the rib. 
     
     
       8. The intra-canal earphone of  claim 1 , wherein the resilient joint includes a driver receptacle, and wherein a driver outer surface of the driver is located within the driver receptacle. 
     
     
       9. The intra-canal earphone of  claim 8 , wherein the resilient joint seals against the driver outer surface at a proximal end of the joint channel and the resilient joint seals against the nozzle at a distal end of the joint channel such that the driver port is acoustically coupled with the nozzle lumen through the joint channel. 
     
     
       10. The intra-canal earphone of  claim 9 , wherein the resilient joint fills a space between a housing inner surface and the driver outer surface between the driver port and the chamber such that the driver port is acoustically isolated from the chamber. 
     
     
       11. The intra-canal earphone of  claim 1 , wherein the elastomeric body comprises a thermoplastic elastomer. 
     
     
       12. The intra-canal earphone of  claim 11 , wherein the driver includes a balanced armature transducer. 
     
     
       13. The intra-canal earphone of  claim 12  further comprising a compliant tip having a tip lumen acoustically coupled with the driver port through the nozzle lumen, wherein a tip outer surface is configured to seal against an ear canal. 
     
     
       14. The intra-canal earphone of  claim 13  further comprising:
 an audio jack; and 
 a cable electrically connected to the audio jack and to the driver, the cable being configured to transmit the electrical audio signal from the audio jack to the driver. 
 
     
     
       15. A method, comprising:
 forming a housing having a chamber, wherein the housing is rigid; 
 forming a nozzle having a nozzle lumen, wherein the nozzle is rigid; and 
 molding a resilient joint having an elastomeric body and a joint channel over at least a portion of the housing and the nozzle, such that the nozzle is pivotally coupled with the housing through the elastomeric body and the nozzle lumen is acoustically coupled with the chamber through the joint channel, wherein the resilient joint includes a driver receptacle in fluid communication with the joint channel; and 
 installing a driver in the driver receptacle such that a driver port of the driver is acoustically coupled with the nozzle lumen through the joint channel. 
 
     
     
       16. The method of  claim 15 , wherein the resilient joint fills a portion of the chamber between a housing inner surface and a driver outer surface axially between the driver port and the chamber such that the driver port is acoustically isolated from the chamber. 
     
     
       17. The method of  claim 16  further comprising disposing a compliant tip over a nozzle outer surface such that a tip lumen is acoustically coupled with the driver port through the nozzle lumen, wherein a tip outer surface is configured to seal against an ear canal. 
     
     
       18. An intra-canal earphone, comprising:
 a housing having a chamber and a housing inner surface, wherein the housing is rigid; 
 a nozzle having a nozzle lumen, wherein the nozzle is rigid; 
 a driver located in the chamber and having a driver port, the driver being configured to receive an electrical audio signal and to emit sound from the driver port; and 
 a resilient joint having an elastomeric body and a joint channel, wherein the nozzle is pivotally coupled with the housing through the elastomeric body, wherein the resilient joint fills a space between the housing inner surface and the nozzle, and wherein the nozzle lumen is acoustically coupled with the driver port through the joint channel. 
 
     
     
       19. The intra-canal earphone of  claim 18 , wherein the resilient joint includes a driver receptacle, and wherein a driver outer surface of the driver is located within the driver receptacle.

Description:
BACKGROUND 
     1. Field 
     Embodiments related to headphones are disclosed. More particularly, an embodiment related to an intra-canal earphone having a rigid housing in which a driver is located, a rigid nozzle, and a resilient joint that physically couples the housing with the nozzle and acoustically couples the driver with the nozzle, is disclosed. 
     2. Background Information 
     Intra-canal earphones, also known as in-ear earphones, are headphones that are placed in the ear canal during use. Some intra-canal earphones can seal against the ear canal to isolate the ear canal from the surrounding environment and buffer environmental noise. Sealing between the earphone and the ear canal can be achieved using a custom molded flexible tip. The flexible tip may fill a space between the ear canal and a portion of a tube that is inserted into the ear canal. The tube may include a permanent bend, a custom shape, or may flex along the tube length to provide for an acceptable seal and a comfortable fit within a wide range of ear anatomies. Sound may be delivered through the tube into the ear canal. 
     SUMMARY 
     Embodiments of intra-canal earphones are disclosed. In an embodiment, an intra-canal earphone includes a rigid housing and a rigid nozzle pivotally connected by a resilient joint. More particularly, an elastomeric body of the resilient joint may attach to both the housing and the nozzle to join the housing and the nozzle together. The housing may include a chamber that encloses at least a portion of a driver, e.g., a balanced armature transducer, having a driver port. The driver can receive an externally generated electrical audio signal and convert the electrical signal to sound that is emitted from the driver port. A joint channel in the resilient joint may acoustically connect the driver port with a nozzle lumen of the nozzle. Thus, when the earphone is placed in a user&#39;s ear, the sound emitted from the driver port may be transmitted through the joint channel and the nozzle lumen into an ear canal. 
     The resilient joint may include an elastomeric body formed from an elastomeric material, such as a thermoplastic elastomer. Thus, the elastomeric body may flex to allow the nozzle to pivot relative to the housing from an initial state, when an external load is applied to the nozzle, and to return to the initial state, when the external load is removed. For example, when the earphone is inserted into a user&#39;s ear, the nozzle may pivot relative to the housing to align with the ear canal, while the housing may remain outside of the ear canal and comfortably fit within a concha of the outer ear. 
     The resilient joint may fill a space between an inner surface of the housing and a surface of the nozzle. As a result, the resilient joint may be frictionally held by the housing inner surface, and the nozzle may be frictionally held by the resilient joint. The housing and nozzle may include features to enhance retention of the resilient joint therebetween. For example, the housing may include a protrusion extending radially inward from the housing inner surface and the resilient joint may overlay, or cover, the protrusion. As a further example, the nozzle may include one or more nozzle holes extending through a nozzle wall, and the resilient joint may fill the one or more nozzle holes. A wall of the housing or the nozzle may taper, e.g., a nozzle wall may spread outward along a flared portion of the nozzle from the nozzle lumen toward the housing, to resist axial loading applied to the resilient joint. In an embodiment, retention features, such as the one or more nozzle holes, may be located in the tapered or flared portions of housing or nozzle. For example, the one or more nozzle holes in the flared portion may define a rib of the nozzle, and the resilient joint may surround and retain at least a portion of the rib. 
     The resilient joint may include various receptacles to receive, support, and or seal against other components of the earphone. For example, a driver receptacle in the resilient joint may receive the driver such that a driver outer surface is located within the driver receptacle. Accordingly, the driver may be cantilevered from the driver receptacle into the chamber of the housing. In an embodiment, a portion of the resilient joint, e.g., the elastomeric body of the resilient joint, may seal against the driver outer surface at a proximal end of the joint channel and may seal against the nozzle at a distal end of the joint channel such that the driver port is acoustically coupled with the nozzle lumen through the joint channel. Furthermore, the elastomeric body may fill a space between an inner surface of the housing and an outer surface of the driver axially between the driver port and the chamber such that the driver port is acoustically isolated from the chamber. 
     The intra-canal earphone may also include a compliant tip having a tip lumen that is acoustically coupled with the driver port through the nozzle lumen. The intra-canal earphone may be of the sealed-type earphone, and thus, an outer surface of the tip may be configured to seal against an ear canal. Accordingly, the externally generated audio signal may be transmitted from a portable media player through an audio jack and a cable to the driver and the driver may play sound through the nozzle lumen and the tip lumen into the user&#39;s ear canal. 
     Numerous methods may be used to build an intra-canal earphone. In an embodiment, a method includes forming a rigid housing having a chamber and forming a rigid nozzle having a nozzle lumen. The method may also include molding a resilient joint having an elastomeric body and a joint channel over at least a portion of the pre-formed housing and nozzle. Thus, the nozzle may become pivotally coupled with the housing through the overmolded elastomeric body. Furthermore, the nozzle lumen may be acoustically coupled with the chamber through the joint channel. A driver receptacle may be formed in the resilient joint, and the driver receptacle may be in fluid communication with the joint channel. Accordingly, a driver may be installed in the driver receptacle such that a driver port becomes acoustically coupled with the nozzle lumen through the joint channel. By contrast, the overmolded elastomeric body may fill a portion of the chamber between an inner surface of the housing and an outer surface of the driver between the driver port and the chamber such that the driver port is acoustically isolated from the chamber. In an embodiment, a compliant tip may be disposed over an outer surface of the nozzle such that a tip lumen is acoustically coupled with the driver port through the nozzle lumen. Furthermore, an outer surface of the tip may be configured to seal against an ear canal to deliver sound from the driver port through the nozzle lumen and tip lumen into the ear canal. 
     The above summary does not include an exhaustive list of all aspects of the present invention. It is contemplated that the invention includes all systems and methods that can be practiced from all suitable combinations of the various aspects summarized above, as well as those disclosed in the Detailed Description below and particularly pointed out in the claims filed with the application. Such combinations have particular advantages not specifically recited in the above summary. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portable media player connected with headphones in accordance with an embodiment of the invention. 
         FIG. 2  is a side view of an intra-canal earphone in accordance with an embodiment of the invention. 
         FIG. 3  is an exploded cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone in accordance with an embodiment of the invention. 
         FIG. 4  is a cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone having a resilient joint between a housing and a nozzle in accordance with an embodiment of the invention. 
         FIG. 5  is a cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone having a resilient joint between a housing and a nozzle in accordance with another embodiment of the invention. 
         FIG. 6  is a perspective view of a nozzle of an intra-canal earphone in accordance with an embodiment of the invention. 
         FIG. 7  is a pictorial view of an intra-canal earphone placed in an ear canal in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the invention describe headphones for use in playing externally generated audio signals received from an external audio source. However, while some embodiments are described with specific regard to intra-canal earphones, the embodiments are not so limited, and certain embodiments may also be applicable to other uses. For example, one or more of the embodiments described below may be integrated within other devices or apparatuses that direct sound into the ear, such as intra-concha earphones that fit loosely in the outer ear, or hearing aids. 
     In various embodiments, description is made with reference to the figures. However, certain embodiments may be practiced without one or more of these specific details, or in combination with other known methods and configurations. In the following description, numerous specific details are set forth, such as specific configurations, dimensions, and processes, in order to provide a thorough understanding of the embodiments. In other instances, well-known processes and manufacturing techniques have not been described in particular detail in order to not unnecessarily obscure the description. Reference throughout this specification to “one embodiment,” “an embodiment”, or the like, means that a particular feature, structure, configuration, or characteristic described is included in at least one embodiment. Thus, the appearance of the phrase “one embodiment,” “an embodiment”, or the like, in various places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, configurations, or characteristics may be combined in any suitable manner in one or more embodiments. 
     In an aspect, an embodiment of an intra-canal earphone includes a rigid housing, a rigid nozzle, and a resilient joint that pivotally couples the housing with the nozzle. For example, the resilient joint may include an elastomeric body that joins the housing with the nozzle and flexes to allow the nozzle to articulate relative to the housing when the earphone is inserted into an ear canal. Thus, the nozzle and housing may pivot relative to one another from an initial state to fit comfortably within the anatomy of a variety of ear anatomies, and may recover to the initial state after being removed from the ear canal. 
     In an aspect, an embodiment of the intra-canal earphone includes a resilient joint having a joint channel that acoustically couples a driver located in a housing with a nozzle lumen of a nozzle. The resilient joint may seal around the driver at a proximal end of the joint channel and may seal around the nozzle at a distal end of the joint channel such that sound emitted by the driver is transmitted through the joint channel into the nozzle lumen. The resilient joint may fill a space between the housing and the driver to acoustically isolate a housing chamber from the sound emitted by the driver. Thus, the resilient joint may provide an integrated boot to direct sound through the nozzle and reduce the likelihood of sound leaking into the chamber. 
     In an aspect, the resilient joint may include a driver receptacle to receive the driver and support the driver within the chamber. That is, the resilient joint may hold the driver and be located between the driver, the housing, and the nozzle such that the elastomeric body of the resilient joint absorbs mechanical shock transmitted through the housing or the nozzle. Thus, in the event that the intra-canal earphone impacts an external object, e.g., when the earphone is accidentally dropped to the ground, the elastomeric body may absorb the shock and protect the driver from damage. 
     In an aspect, the resilient joint may fill voids or spaces between the housing, the nozzle, and the driver, such that the resilient joint is frictionally fit between the earphone components. For example, the resilient joint may overlay a portion of the housing and the nozzle, as in the case where the resilient joint comprises a thermoplastic elastomer that is overmolded directly between the housing and the nozzle. Furthermore, the driver may fill the driver receptacle in the resilient joint. Thus, empty space between components of the earphone may be minimized to create a compact earphone assembly. More specifically, an intra-canal earphone having a rigid housing pivotally coupled with a rigid nozzle by an intermediate resilient joint may minimize tolerance stack-ups and reduce earphone size. 
       FIG. 1  is a perspective view of a portable media player connected with headphones in accordance with an embodiment of the invention. An electronic device  100 , such as a portable media player or another device capable of playing audio, video, or other media, may be connected to an external speaker system, such as a pair of headphones  102 . For example, the headphones  102  may include an audio jack  104  or other electrical connector that electrically connects the electronic device  100  with a headphones cable  106 . That is, the cable  106  may receive an electrical signal from the electronic device  100  through the audio jack  104 . Thus, an electrical audio signal may be externally generated by the electronic device  100  and transmitted through the audio jack  104  and the cable  106  toward one or more earphones  108 . In an alternative embodiment, the headphones  102  incorporate a wireless interface to receive the externally generated audio signal via a wireless connection with an external amplifier. Other embodiments may include an earphone incorporated in a hearing aid, but by way of contrast, a hearing aid produces an electrical audio signal from a built-in pickup and then converts the electrical signal to sound waves, rather than receiving an externally generated signal from an electronic device  100 . 
     Turning now to  FIG. 2 , a side view of an intra-canal earphone is shown in accordance with an embodiment of the invention. An assembled earphone  108  may include several components. More particularly, earphone  108  may include a housing  202  connected with cable  106 . Housing  202  may be physically connected to a nozzle  204  that extends distally away from housing  202 . For example, housing  202  may be pivotally connected to nozzle  204  by a joint, such as a resilient joint, that may be located at the housing  202  itself. That is, the resilient joint may be located between housing  202  and nozzle  204 , rather than being located along the nozzle  204  length, i.e., at a location between a proximal and distal end of the nozzle  204 . Earphone  108  may also include a tip  206  disposed over nozzle  204 . For example, tip  206  may surround a distal end of nozzle  204  and be distally spaced apart from housing  202  along nozzle  204 . During use, tip  206  may be placed into an ear canal, while housing  202  may at least partially reside in a concha of the ear. Thus, during use, nozzle  204  may traverse a distance between a housing  202  located outside of the ear canal and a tip  206  located inside of the ear canal. 
       FIG. 3  is an exploded cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone in accordance with an embodiment of the invention. In an embodiment, housing  202  includes a shell structure having one or more components that may be integrally formed or assembled. For example, housing  202  may include two halves that are bonded together to form a whole. The assembled housing  202  may include a housing inner surface  302  separated from a housing outer surface  304  by a housing wall  306 . A space within housing inner surface  302  may define a chamber of the assembled earphone  108 , as will be described further below. Furthermore, housing  202  may include one or more features, such as one or more ribbed supports  308  protruding in a radially inward direction from housing inner surface  302 . Housing outer surface  304  may provide a grip for a user to handle during insertion or removal of earphone  108  in an ear canal. Housing inner surface  302  and/or one or more supports  308  may hold a driver  320 , or may limit movement of a driver  320  during use, as will be explained further below. 
     In an embodiment, housing  202  may be rigid. That is, housing  202  may have sufficient stiffness to resist deformation under loading typically experienced during headphone use, such as due to sound waves produced by driver  320  or physical loads applied to housing  202  during handling. The rigidity of the housing  202  may also be described in terms of the material, or the typical elastic modulus of the material, used to form housing  202 . For example, housing  202  may be formed from polymers including high-density polyethylene or polycarbonate. Accordingly, housing  202  material may have an elastic modulus in the range of 0.5 to 20 GPa, by way of example only. For example, housing  202  material may have an elastic modulus in the range of 0.5 GPa to 2.5 GPa. However, many other rigid materials having corresponding elastic moduli may be used to form housing  202 , including metals and ceramics. 
     In an embodiment, driver  320  may be located within a chamber of the assembled earphone  108 , and more particularly, may be at least partially disposed radially inward from housing inner surface  302 . Driver  320  may include one of various known transducers used to receive the externally generated audio signal from cable  106  and to convert the signal into sound. For example, driver  320  may include a balanced armature, moving-coil, electrostatic, electret, or thermoacoustic transducer. In an embodiment, driver  320  includes a balanced armature transducer that drives a diaphragm to generate sound. Driver  320  may emit the sound from a driver port  322  in a distal direction away from the housing chamber. 
     In an embodiment, nozzle  204  includes a shell structure having one or more components that may be integrally formed or assembled. For example, nozzle  204  may be injection molded as a single part having a nozzle inner surface  330  separated from a nozzle outer surface  332  by a nozzle wall  334 . A space within nozzle inner surface  330  may define a nozzle lumen of the assembled earphone  108 , as will be described further below. The nozzle lumen may extend between a nozzle proximal end  336  and a nozzle distal end  338  to provide an acoustic channel for sound emitted by driver  320  to emanate from earphone  108 . 
     In an embodiment, nozzle  204  may be rigid. That is, nozzle  204  may have sufficient stiffness to resist deformation under loading typically experienced during headphone use, such as due to sound waves produced by driver  320  or physical loads applied to nozzle  204  during insertion of earphone  108  into an ear canal. The rigidity of the nozzle  204  may also be described in terms of the material, or the typical elastic modulus of the material, used to form nozzle  204 . For example, nozzle  204  may be formed from polymers including high-density polyethylene or polycarbonate. Accordingly, nozzle  204  material may have an elastic modulus in the range of 0.5 to 20 GPa, by way of example only. For example, housing  202  material may have an elastic modulus in the range of 0.5 GPa to 2.5 GPa. However, many other rigid materials having corresponding elastic moduli may be used to form nozzle  204 , including metals or ceramics. 
     Resilient joint  350  may be installed, injected, or otherwise disposed between nozzle  204  and housing  202  so as to form a joint that physically couples nozzle  204  with housing  202 . For example, resilient joint  350  may include an elastomeric body  352  having a nozzle receptacle  354  that conforms to at least a portion of nozzle  204 . For example, nozzle receptacle  354  may include a counterbore, in elastomeric body  352 , which is sized and configured to receive nozzle  204 . The nozzle receptacle  354  may be distal from a housing receptacle  356  that conforms to at least a portion of housing  202 . For example, housing receptacle  356  may include a boss, extending from elastomeric body  352 , which is sized and configured to fit into a distal opening of housing inner surface  302 . Thus, it will be appreciated that one or more receptacles of resilient joint  350  may be sized and configured to receive another earphone component, or to be received by, e.g., to fit into, another earphone component. Furthermore, the structure of resilient joint  350  is not intended to be limited to prefabricated features that are then assembled with other components, but rather, resilient joint  350  may be integrally formed with the other components. For example, resilient joint  350  may be overmolded on or around nozzle  204  and housing  202  to result in a uniform whole made of several components having varying respective rigidities. 
     Resilient joint  350  may also include a driver receptacle  358  that conforms to at least a portion of driver  320 . For example, driver receptacle  358  may include a counterbore in elastomeric body  352  that is sized and configured to receive driver  320 . Driver receptacle  358  may receive driver  320  loosely, or in an embodiment, driver receptacle  358  may physically support driver  320 , e.g., a distal portion of driver  320  may be located in driver receptacle  358  and a proximal portion of driver  320  may cantilever away from driver receptacle  358 . 
     In an embodiment, resilient joint  350  may be installed, injected, or otherwise disposed between nozzle  204  and driver  320  so as to acoustically couple driver port  322  with a nozzle lumen within nozzle inner surface  330 . For example, a joint channel  360  may be formed through elastomeric body  352  between driver receptacle  358  and nozzle receptacle  354 . Thus, driver port  322 , which may be disposed in driver receptacle  358 , may emit sound distally through joint channel  360  and into the nozzle lumen. The sound may propagate toward nozzle distal end  338  and outward away from earphone  108 . 
     At least a portion of resilient joint  350  may be compliant or resilient. For example, a portion of resilient joint  350  may exhibit one or both of elasticity or viscosity. In an embodiment, forming the compliant portion of resilient joint  350  from a viscoelastic material may be beneficial to shock performance, as the material can lose energy when a load or impact is applied. However, in other embodiments, chemical resistance requirements may supersede the requirement for shock performance, and the compliant portion of resilient joint  350  may include a material with elastic and chemical resistance properties, but with limited or no viscous properties. In an embodiment, the compliant portion of resilient joint  350  may be elastomeric body  352 , which may be elastomeric. That is, elastomeric body  352  may include an elastomer, e.g., silicone, having elasticity and/or some viscosity, such that the assembled components of earphone  108  may exhibit freedom of movement relative to one another. For example, when housing receptacle  356  is engaged with housing inner surface  302  and nozzle receptacle  354  is engaged with nozzle outer surface  332 , nozzle  204  may be pivoted relative to housing  202  from an initial state. Such articulation may occur, for example, when nozzle  204  is inserted into an ear canal while housing  202  remains in the concha of the ear. The articulation may be expressed in terms of a pivot angle that an axis passing through nozzle  204  subtends when it is flexed from an initial orientation. For example, a nozzle axis may be parallel to an axis passing through a chamber in the initial orientation. However, in a pivoted orientation, the nozzle axis may subtend an angle relative to the chamber axis to align with an ear canal. For example, the elastic body  352  may incorporate a material that has sufficient flexibility to allow the subtended angle to be at least about 5 to 10 degrees. Furthermore, the elastomeric body  352  may be elastomeric such that, when the nozzle  204  is removed from the ear canal, the nozzle may pivot back to the initial orientation. Numerous materials having elastomeric characteristics may be used to form elastomeric body  352 , which may form all or part of the mass of resilient joint  350 . For example, elastomeric body  352  may include unsaturated rubbers or saturated rubbers. Elastomeric body may include silicone. In an embodiment, elastomeric body  352  may include thermoplastic elastomers, which are suited to injection molding. Thus, elastomeric body  352  may be injected on or around nozzle  204  and housing  202  in an overmolding process. Suitable thermoplastic elastomers include styrenic block copolymers, polyolefin blends, elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyester, and thermoplastic polyamides. In terms of hardness, elastomeric body  352  may incorporate a material having a durometer of between about 5-70 on the Shore A scale. For example, a durometer of elastomeric body  352  may be between about 20-60 on the Shore A scale. Elastomeric body  352  may also include a stiffness. More particularly, both the durometer and geometry of elastomeric body  352  may affect the overall system stiffness, which may be described in terms of the force required to displace nozzle  204  relative to housing  202 . In an embodiment, a transverse load on nozzle  204  of about 0.25 to 1.0 N may result in articulation between nozzle  204  and housing  202  of between about 5 to 10 degrees. 
     In an embodiment, only a portion of resilient joint  350  may be elastomeric. That is, elastomeric body  352  may form only a portion of resilient joint  350 . For example, resilient joint  350  may have a shell and core structure, in which the core comprises elastomeric body  352 , and elastomeric body  352  is surrounded by an outer shell. For example, an outer 1 to 5 mm thickness of resilient joint  350  may be occupied by the shell, and the shell may be formed from a same or different material as elastomeric body  352 . The shell may be coated, overmolded, or otherwise disposed over elastomeric body  352 . Alternatively, an outer portion of resilient joint  350  may be treated, e.g., cross-linked or heat-treated, to create a resilient joint  350  formed from a material that varies in hardness across its volume. The outer shell may be more rigid than elastomeric body  352 . For example, the outer shell may include a rigid polymer, metal, or ceramic. In another embodiment, the outer shell may be more flexible than the core, and thus, the flexibility of resilient joint may be at least partially due to the outer shell, i.e., the shell may be elastomeric and the core may be rigid. Such a layered structure may be advantageous in that the layers may be tuned to fit their purpose in earphone. For example, an outer layer may be made from a material that is more easily bonded to the material used to form housing  202  or nozzle  204 , while the inner core may be formed from a material that provides flexibility to pivotally couple housing  202  with nozzle  204 , and allow articulation therebetween. 
       FIG. 4  is a cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone having a resilient joint between a housing and a nozzle in accordance with an embodiment of the invention. In an embodiment, elastomeric body  352  forms an entire mass of resilient joint  350  and is attached to housing  202  at housing inner surface  302 . For example, a proximally extending boss of elastomeric body  352 , e.g., housing receptacle  356 , may be inserted into a distal opening of housing  202  to form a press fit against housing inner surface  302 . Furthermore, elastomeric body  352  may be attached to nozzle  204 , e.g., at nozzle outer surface  332 . For example, a proximal portion of nozzle  204  may be inserted into a counterbore in a distal face of elastomeric body  352 , e.g., nozzle receptacle  354 . Thus, the elastomeric body  352  may fill a gap between the housing inner surface  302  and the nozzle  204 , and may apply friction at the mating surfaces to frictionally hold housing  202 , resilient joint  350 , and nozzle  204 , together. Alternatively or additionally, an adhesive, e.g., acrylic resin, may be applied to the mating surfaces to further enhance the attachment between one or more of housing  202 , resilient joint  350 , or nozzle  204 . 
     In the assembled earphone  108 , a nozzle lumen  402  within nozzle inner surface  330  may be acoustically coupled with driver port  322 . A counterbore in a proximal face of resilient joint  350  may form driver receptacle  358 . Prior to integration of driver  320  into earphone  108 , the counterbore may be acoustically coupled with nozzle lumen  402  through joint channel  360 . That is, driver receptacle  358 , joint channel  360 , and nozzle lumen  402  may be coaxially aligned such that nozzle lumen  402  is in fluid communication with a chamber  404  within housing inner surface  302 . During assembly of earphone  108 , driver  320  may be installed in driver receptacle  358  such that driver port  322  is coaxially aligned with joint channel  360 . Thus, driver port  322  may be acoustically coupled with nozzle lumen  402 , since sound emitted from driver port  322  can propagate distally toward nozzle distal end  338  through joint channel  360  and nozzle lumen  402 . 
     In an embodiment, acoustic coupling of driver port  322  and nozzle lumen  402  may be further enhanced by providing a seal between resilient joint  350  and at least some portion of driver  320  to promote propagation of sound through joint channel  360  toward nozzle lumen  402 . A driver outer surface  406  may extend to a distal end of driver  320 . For example, driver  320  may have a cylindrical profile with a diametric surface defining driver outer surface  406 . Furthermore, driver  320  may have a cylindrical boss extending from a larger cylindrical body, i.e., a stepped cylindrical surface, and driver port  322  may be located at a distal end of the cylindrical boss. In such case, driver outer surface  406  may also extend over the diametrical surface defining the cylindrical boss. However, in other cases, driver  320  may have a variety of shapes, and thus, driver outer surface  406  may be any transversely located surface along a length of driver  320 . 
     When driver  320  is disposed within driver receptacle  358 , at least a portion of an inward surface of resilient joint  350  may press and/or seal against a portion of driver outer surface  406 . For example, an inner surface of a counterbore forming driver receptacle  358  may form a press fit around the larger cylindrical body of driver  320 . Alternatively, an inner surface of joint channel  360  through resilient joint  350  may form a press fit around the cylindrical boss of driver  320 . The seal between resilient joint  350  and driver  320  may be formed proximal to driver port  322 , i.e., in a direction opposite to the direction of sound emission from driver port  322 . Furthermore, an inner surface defining joint channel  360  may seal against nozzle proximal end  336 , such that joint channel  360  spans a distance between and seals against driver  320  and nozzle  204 . Accordingly, substantially all of the sound emitted from driver port  322  can propagate through joint channel  360  into nozzle lumen  402 . 
     Sealing between components may be created by pressure between component surfaces, as described above. Sealing may also be enhanced by additional components. For example, a gasket, such as an O-ring, may be located between resilient joint  350  and driver  320  or nozzle  204  to create a hermetic and/or acoustic seal between those components. Similarly, an adhesive or a lubricant film may be located between components, e.g., between resilient joint  350  and driver  320  or nozzle  204 , to create an acoustic seal between those components. 
     Acoustic coupling between driver port  322  and nozzle lumen  402  may be enhanced by preventing sound leakage from driver port  322  into chamber  404 . Resilient joint  350  may seal against a portion of driver outer surface  406  between driver port  322  and chamber  404 , e.g., proximal to driver port  322 . More particularly, resilient joint  350  may fill a space between housing inner surface  302  and the driver outer surface  406  such that sound emitted from driver port  322  is less likely to propagate along driver outer surface  406  into chamber  404 . In an embodiment, sealing may be over a substantial length of driver outer surface  406 , e.g., at least about one third of the driver  320  length. However, in another embodiment, sealing may be over a lesser length of a distal portion of driver  320  that is directly adjacent to driver port  322 , e.g., over the cylindrical boss surrounding driver port  322  (see  FIG. 5 ). In any case, driver port  322  and chamber  404  may be acoustically isolated. Furthermore, since making a seal between resilient joint  350  and driver  320  makes sound leakage toward chamber  404  less likely, sound may propagate toward nozzle lumen  402 , enhancing acoustic coupling between driver port  322  and nozzle lumen  402 . 
     Driver  320  may be supported in chamber  404  in several ways. In an embodiment, driver  320  may be cantilevered from resilient joint  350 . That is, a distal portion of driver  320 , such as driver outer surface  406  surrounding driver port  322  and/or driver outer surface  406  proximal from driver port  322  may fit within driver receptacle  358  such that resilient joint  350  grips and holds driver  320 . Thus, a proximal portion of driver  320 , such as a proximal end that receives cable  106 , may be freely supported within chamber  404 . 
     Whereas resilient joint  350  may exhibit some degree of compliance and flexibility due to elastomeric body  352 , a cantilevered driver  320  may experience some pivoting or lateral motion within chamber  404  during use. In an embodiment, one or more supports  308  extend inward from housing inner surface  302 , effectively reducing the minimum diameter of housing inner surface  302 . As a result, support  308  may limit lateral movement of driver  320  because as the driver pivots within chamber  404 , it may contact support  308 , which can prevent further lateral motion. The geometry of support  308  may be altered as required to distribute pressure applied to driver outer surface  406  when driver  320  contacts support  308 . That is, support  308  may make a point contact or include an axial ribbing to make contact over an axial length of driver  320 . The geometry of support  308  may also be altered as required to provide for more or less lateral movement of driver  320 . For example, in an embodiment, support  308  may contact driver  320  in all configurations, i.e., even in an initial state, such that support  308  forms a cradle that holds a portion of driver  320  within chamber  404  (see  FIG. 5 ). Support  308  may be rigid or flexible, e.g., elastomeric. Accordingly, support  308  may be injection molded in a same shot with housing  202 , or may be separately formed as a compliant support  308  that is overmolded or bonded on housing inner surface  302 . Thus, support  308  may absorb shock between housing  202  and driver  320  in the event of an impact on the housing. 
     A compliant tip  206  may be disposed on nozzle  204  to acoustically couple the nozzle with a user&#39;s ear. For example, a tip hub  408  may include a counterbore in a proximal end of tip  206  that is sized and configured to receive nozzle  204 , e.g., to form a press fit against nozzle outer surface  332 . Tip  206  may include a tip lumen  410  that can be axially aligned with nozzle lumen  402  in the assembled earphone  108 . Thus, tip lumen  410  may be acoustically coupled with nozzle lumen  402 . Accordingly, sound emitted by driver port  322  may propagate through joint channel  360  and nozzle lumen  402  into tip lumen  410 . Furthermore, since tip lumen  410  may extend from a proximal end to a distal end of tip  206 , sound may be emitted into an ear canal from the tip when it is located within a user&#39;s ear. 
     Acoustic coupling between nozzle lumen  402  and the ear canal may be further enhanced by forming a seal against the ear canal. That is, earphone  108  may be a sealed-type earphone  108 . Tip outer surface  412  may have a diameter that is larger than a diameter of the ear canal at the desired sealing location. Furthermore, to facilitate sealing as well as comfort, tip  206  may be formed from a compliant or flexible material. For example, tip  206  may be formed from a foam, an elastomer, or another soft and resilient material that flexes inwardly when pressed into the ear canal, but also applies a resilient outward force to form a seal against the ear canal. 
       FIG. 5  is a cross-sectional view, taken about line A-A of  FIG. 2 , of an intra-canal earphone having a resilient joint between a housing and a nozzle in accordance with another embodiment of the invention. In addition to relying on friction fits or adhesive bonding between flat surfaces to maintain housing  202 , resilient joint  350 , and nozzle  204  in an assembled state, each of the components may include retention features to enhance physical coupling. For example, housing  202  or nozzle  204  may include tapered surfaces that slope at least partially in a radial direction such that axial loading on resilient joint  350  is resisted. As shown in  FIG. 5 , a distal region of housing inner surface  302  may taper radially inward toward nozzle  204 , creating a sloped surface that engages with a mating surface of resilient joint  350 . Relative movement between housing  202  and resilient joint  350  may be resisted by the contacting surfaces, because any distal loading on resilient joint  350 , e.g., transmitted through nozzle  204 , may be resisted by a proximal reaction load applied to resilient joint  350  by the tapered surface of housing  202 . Similar surface contours, such as waves, undulations, spiraled threads, etc., may similarly resist movement of resilient joint  350  relative to housing  202  or nozzle  204 . 
     In an embodiment, retention features on nozzle  204  or housing  202  may include projections extending from a surface that contacts resilient joint  350 . For example, housing  202  may include one or more protrusions  502  extending radially inward from housing inner surface  302  to facilitate bonding between housing  202  and resilient joint  350 . Protrusion  502  may be a nub, bulge, projection, spike, or any other feature having a height and width dimension such that when resilient joint  350  overlays protrusion  502 , a retaining force is applied to resilient joint  350  by protrusion  502  to resist removal of resilient joint  350  from housing  202 . 
     Other retention features may be added to housing  202  or nozzle  204  to retain resilient joint  350 . For example, a lip  504  may be formed along a portion of a distal opening of housing  202 . Like protrusion  502 , lip  504  may be inwardly directed in one embodiment. However, lip  504  may also project outward from housing  202  in an embodiment in which resilient joint  350  extends around an outer surface of housing  202 . Accordingly, lip  504  may have a height and width dimension such that when resilient joint  350  overlays lip  504 , a retaining force is applied to resilient joint  350  by lip  504  to resist removal from housing  202 . 
     Nozzle  204  and housing  202  may also include retention features that may be filled, encapsulated, or surrounded by resilient joint  350  to enhance physical coupling. For example, resilient joint  350  may be overmolded on or around a retention feature to capture and retain nozzle  204  or housing  202 . In an embodiment, nozzle  204  includes one or more nozzle holes  506  formed through nozzle wall  334 . The nozzle holes  506  may extend circumferentially, e.g., around a flared proximal portion of nozzle  204 , such that one or more ribs  508  is defined between the nozzle holes  506 . Resilient joint  350  may fill at least one of the nozzle holes  506  and/or surround at least a portion of one of the ribs  508 . Thus, if a dislodgement force is applied to nozzle  204 , resilient joint  350  may retain nozzle  204  relative to housing  202  because resilient joint  350  may also be attached to housing  202  via a friction fit, adhesive bond, or other attachment mechanism. Thus, distal loading on nozzle  204  may be resisted by a proximal reaction load applied to resilient joint  350  by housing  202 . 
     Referring to  FIG. 6 , a perspective view of a nozzle of an intra-canal earphone is shown in accordance with an embodiment of the invention. In an embodiment, nozzle wall  334  spreads outward over a proximal region of nozzle  204 . More particularly, nozzle outer surface  332  may have a generally conical shape along a flared portion  602 . As shown in  FIG. 5 , the flared portion  602  may extend away from nozzle lumen  402  in the direction of a distal opening of housing  202 . Resilient joint  350  may be overmolded on flared portion  602 , and thus, flared portion  602  may provide some rigidity to earphone  108  along a tapered region between housing  202  and nozzle  204 . Flared portion may incorporate one or more retention features, such as protrusions  502  similar to the projecting features described above. Furthermore, one or more nozzle holes  506  may be formed through nozzle wall  334  in the flared portion  602  to define one or more ribs  508 . Accordingly, resilient joint  350  may be overmolded over flared portion  602  to overlay, fill, or otherwise grip one or more retention features of nozzle  204 . 
     It will be appreciated that features similar to any of the retention features described above, such as holes  506 , protrusions  502 , lips  504 , and ribs  508 , may be formed in housing  202  or nozzle  204  to allow resilient joint  350  to overlay, fill, or otherwise grip and retain a component. Thus, housing  202  and nozzle  204  may be physically coupled by resilient joint  350  and the compliance and flexibility of elastomeric body  352  may allow for the retained housing  202  and nozzle  204  to pivot relative to each other. 
     Earphone  108  may be assembled or fabricated using numerous manufacturing methods. For example, in an embodiment, each component of earphone  108 , e.g., driver  320 , housing  202 , resilient joint  350 , and nozzle  204 , may be formed separately using known molding, machining, or other fabrication techniques. The individually formed components may then be assembled, and optionally, bonded together. For example, housing  202  may be inserted over or into housing receptacle  356 , nozzle  204  may be inserted over or into nozzle receptacle  354 , and driver  320  may be inserted over or into driver receptacle  358 . An adhesive or thermal bond may be formed between respective components using, e.g., chemical adhesives, welding processes including ultrasonic welding, etc., to enhance physical coupling between components. Sealants, such as gaskets, adhesives, lubricants, etc., may be applied between components to enhance acoustic coupling therebetween. In an embodiment, tip  206  may be located over nozzle  204 . Thus, the individual components may be assembled to build earphone  108 . 
     In an embodiment, one or more components may be integrally fabricated with one or more other components to build earphone  108 . For example, one or more pieces may be molded, cast, machined, etc., and optionally assembled to form housing  202 . The assembled housing  202  may include a hollow region within housing inner surface  302  to define chamber  404 . Nozzle  204  may be similarly formed, e.g., by molding, casting, machining, etc., and a tubular nozzle wall  334  may be fabricated to form nozzle lumen  402  within nozzle inner surface  330 . In an embodiment, housing  202  and nozzle  204  may be injection molded from a rigid polymer. After forming housing  202  and nozzle  204  separately, each of the parts may be located within a mold. The mold may be separate from the mold in which they were formed, or it may be the same mold in which they were formed. Resilient joint  350  may then be formed around the pre-fabricated housing  202  and nozzle  204 , e.g., as a second shot within the same injection mold or as an overmold within a separate injection mold. In either case, at least a portion of resilient joint  350  may be flowed into the mold to overlay some portion of housing  202  and nozzle  204  surfaces, e.g., protrusions  502 , and cooled to fill some portion of housing  202  and nozzle  204  features, e.g., chamber  404  or nozzle holes  506 . Accordingly, a unified whole may be formed having an essentially solid region filled by some portion of housing  202 , resilient joint  350 , and nozzle  204  material. The monolithic subassembly of earphone  108  may further include receptacles, e.g., driver receptacle  358  and nozzle outer surface  332 , to receive other components such as driver  320  and tip  206 . Furthermore, as the overmolded material fills a portion of the mold around housing  202  and nozzle  204 , joint lumen may be formed during or after the molding to provide a passage between chamber  404  and nozzle lumen  402 . As described above, upon installation of driver  320  into driver receptacle  358 , chamber  404  may become acoustically isolated from driver port  322  and nozzle lumen  402 , while nozzle lumen  402  may become acoustically coupled with driver port  322 . 
     Turning now to  FIG. 7 , a pictorial view of an intra-canal earphone placed in an ear canal is shown in accordance with an embodiment of the invention. Assembled earphone  108  may be inserted into an ear canal  702 . More particularly, tip  206  may be inserted within and sealed against ear canal  702 , while housing  202  may remain substantially outside of the ear canal  702 , e.g., within a concha of the user&#39;s ear. Furthermore, nozzle  204  may extend between housing  202  and tip  206 , and thus, may occupy a portion of both the concha and ear canal  702 . A housing axis  704  may pass through housing  202 , e.g., through chamber  404  and a distal opening of housing  202 , and define a direction distally away from housing  202 . Similarly, a nozzle axis  706  may pass through nozzle  204 , e.g., through nozzle lumen  402 , and define a direction distally away from nozzle  204 . 
     In an initial state, such as after assembly and prior to insertion into ear canal  702 , housing axis  704  and nozzle axis  706  may be parallel and/or aligned with one another. After nozzle  204  is inserted into ear canal  702 , lateral loading on tip  206  may be transmitted to nozzle  204 , causing a bending moment about resilient joint  350  that results in deflection of elastomeric body  352 . Flexing of elastomeric body  352  allows articulation between rigid housing  202  and rigid nozzle  204 . More particularly, nozzle  204  may deflect to align with ear canal  702  while housing  202  may remain in an orientation that aligns with the concha or the outer region of ear canal  702 . In a typical case where the ear canal  702  is angled, e.g., downward, from the concha, nozzle axis  706  may deflect away from the initial state. That is, nozzle axis  706  may deflect away from housing axis  704  by an ear canal angle  708 . In an embodiment, articulation of nozzle  204  relative to housing  202  is facilitated by the flexibility of elastomeric body  352 , which may allow nozzle axis  706  to pivot relative to housing axis  704  by at least 5-10 degrees. As described above, this articulation may depend on both the hardness and geometry of elastomeric body  352 , which contributes to the overall system stiffness. Accordingly, earphone  108  may be comfortably fit into the user&#39;s ear, since the housing  202  may remain comfortably aligned with the concha of the ear while the nozzle  204  may angulate to conform to ear canal  702 . Furthermore, since driver  320  may be cantilevered from joint channel  360 , driver  320  may also experience some pivoting relative to housing  202  to maintain alignment with nozzle axis  706  and thus further enhance acoustic coupling between driver port  322  and nozzle lumen  402 . Thus, an externally generated audio signal may be transmitted to driver  320  and converted to sound that is emitted from driver port  322  through joint channel  360  and nozzle lumen  402  into ear canal  702 . Furthermore, leakage of sound into chamber  404  may be less likely since resilient joint  350  may both support driver  320  and seal against driver  320  to block sound from traveling between driver port  322  and chamber  404 . Upon removal of earphone  108  from ear canal  702 , elastomeric body  352  may apply a resilient force to cause nozzle  204  to pivot back toward the initial state and bring nozzle axis  706  back into alignment with housing axis  704 . 
     In the foregoing specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications may be made thereto without departing from the broader spirit and scope of the invention as set forth in the following claims. The specification and drawings are, accordingly, to be regarded in an illustrative sense rather than a restrictive sense.

Metadata:
Filing Date: 20140627
Publication Date: 20161011
Grant Date: 20161011
Priority Date: 20140627
Inventors: GRINKER SCOTT C.
TRAINER GLENN K.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 54932042