PATENT DOCUMENT

Publication Number: US-9872094-B2
Application Number: US-201514975508-A
Country: US
Kind Code: B2

Title: Speaker coupling and bracket

Abstract:
This application relates to an audio assembly that includes both a speaker assembly and a microphone. By mounting both the microphone and the speaker assembly to a unitary audio bracket, space savings can be achieved over a configuration that relies on separate brackets for each component. In some embodiments, an acoustic mesh can be embedded within the audio bracket and extending across an audio channel defined by the audio bracket. The microphone can be aligned with an opening in the audio bracket by an alignment clip that is coupled with the microphone. The alignment clip helps to achieve alignment of a sensor opening of the microphone with a channel defined by the audio bracket.

Claims:
What is claimed is: 
     
       1. A portable media device, comprising:
 a device housing including a wall defining multiple audio openings; 
 an audio bracket comprising a first end and a second end opposite the first end, the audio bracket defining multiple audio channels extending from the first end to the second ends of the audio bracket, the first end being coupled with a portion of the wall that defines the audio openings; 
 a speaker housing defining an opening configured to emit audio and comprising a laterally protruding arm, wherein a portion of the speaker housing defining the opening is coupled with the second end of the audio bracket so that audio emitted by the speaker housing is transmitted through an audio channel and then out of the device housing by one of the audio openings; and 
 a microphone coupled with the laterally protruding arm and the second end of the audio bracket, the microphone being positioned to receive audio entering the device housing through one of the audio openings by way of one of the audio channels. 
 
     
     
       2. The portable media device as recited in  claim 1 , wherein the audio bracket further comprises an acoustic mesh embedded within the audio bracket and extending across one of the audio channels. 
     
     
       3. The portable media device as recited in  claim 2 , further comprising:
 a cosmetic mesh positioned between the first end of the audio bracket and the portion of the wall that defines the audio openings, the cosmetic mesh having a mesh pattern defining openings substantially larger than the openings defined by the acoustic mesh. 
 
     
     
       4. The portable media device as recited in  claim 3 , wherein the cosmetic mesh comprises protrusions that extend into the audio openings defined by the device housing. 
     
     
       5. The portable media device as recited in  claim 1 , further comprising:
 an alignment clip coupled with the microphone and engaged with recesses defined by the audio bracket that align the microphone with at least one of the audio channels defined by the audio bracket. 
 
     
     
       6. The portable media device as recited in  claim 5 , further comprising:
 a flexible circuit, comprising 
 a first surface electrically and mechanically coupled with the microphone, 
 a second surface opposite the first surface and mechanically coupled with the alignment clip, 
 wherein the flexible circuit defines an opening that is aligned with the audio channel of the audio bracket. 
 
     
     
       7. The portable media device as recited in  claim 5 , further comprising:
 a processor disposed within the device housing, 
 wherein the flexible circuit electrically couples the microphone with the processor. 
 
     
     
       8. The portable media device as recited in  claim 1 , further comprising a foam adhesive layer that mechanically couples the microphone to the laterally protruding arm of the speaker housing and reduces the transmission of vibration between the microphone and the speaker housing. 
     
     
       9. A portable electronic device, comprising:
 a device housing including a wall defining multiple audio openings; 
 a speaker housing disposed within the device housing and defining an opening configured to emit audio, the speaker housing comprising a laterally protruding arm; 
 an audio bracket defining audio channels through which the speaker assembly transmits audio, the audio bracket comprising a first side coupled to a portion of the speaker housing that defines the opening and a second side coupled to the wall, one or more of the audio channels being configured to transmit audio emitted from the opening defined by the speaker housing to the audio openings defined by the wall; and 
 a microphone coupled with the laterally protruding arm and the first side of the audio bracket, the microphone being configured to receive audio through one or more of the audio channels. 
 
     
     
       10. The audio assembly as recited in  claim 9 , further comprising a flexible circuit comprising a first surface and a second surface opposite the first surface, the first surface being electrically and mechanically coupled to the microphone. 
     
     
       11. The audio assembly as recited in  claim 10 , further comprising:
 an alignment clip including multiple arms that couple the alignment clip with the audio bracket by engaging alignment recesses defined by the audio bracket, 
 wherein the alignment clip is mechanically coupled to the second surface of the flexible circuit. 
 
     
     
       12. The audio assembly as recited in  claim 10 , wherein at least a portion of the audio received by the microphone passes through an opening defined by the flexible circuit. 
     
     
       13. The audio assembly as recited in  claim 9 , further comprising an acoustic mesh including a peripheral portion embedded within the audio bracket and a central portion extending across one of the audio channels defined by the audio bracket. 
     
     
       14. The audio assembly as recited in  claim 13 , wherein the acoustic mesh extends across the audio channel aligned with the microphone.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority under 35 USC 119(e) to U.S. Provisional Patent Application No. 62/214,797 filed on Sep. 4, 2015, and entitled “SPEAKER COUPLING AND BRACKET,” the disclosure of which is incorporated by reference in its entirety and for all purposes. 
    
    
     FIELD 
     The described embodiments relate generally to the efficient integration of audio components within an electronic device. In particular, a bracket for guiding audio into and out of the electronic device is described herein. 
     BACKGROUND 
     In an effort to progressively reduce the size of and concurrently improve the functionality of a portable electronic device, novel ways of optimizing space within the portable electronic device become increasingly important. Increased and improved functionality often come in the form of additional components and/or sensors. The additional components or sensors tend to take up space in a device housing of the portable electronic device that may not be available. While reducing a size of other components can help to produce additional space, such methods can unfortunately result in reduced functionality or performance. Consequently, additional methods for optimizing space within the device housing are desired. 
     SUMMARY 
     This disclosure describes various embodiments that relate to ways for securing a speaker assembly and a microphone assembly within a device housing. 
     An audio bracket is disclosed. The audio bracket is suitable for conducting audio between audio components and audio openings defined by a housing of a portable media device. The audio bracket can include at least the following: a polymeric substrate defining an audio channel therethrough; and an acoustic mesh embedded within the polymeric substrate and extending across the audio channel, the acoustic mesh preventing particulates from passing through the audio channel. 
     A portable media device is disclosed and can include the following: a device housing including a wall defining multiple audio openings; an audio bracket including a first end and a second end opposite the first end, the audio bracket defining multiple audio channels extending from the first end to the second ends of the audio bracket, the first end being coupled with a portion of the wall that defines the audio openings; a speaker housing defining an opening configured to emit audio and including a laterally protruding arm. A portion of the speaker housing defining the opening is coupled with the second end of the audio bracket so that audio emitted by the speaker housing is transmitted through one of the audio channels and then out of the device housing by one of the audio openings. The audio bracket also includes a microphone coupled with the laterally protruding arm and the second end of the audio bracket, the microphone being positioned to receive audio entering the device housing through one of the audio openings by way of one of the audio channels. 
     An audio assembly is disclosed and can include the following: a speaker assembly, comprising a speaker housing that includes a laterally protruding arm; a microphone coupled with the laterally protruding arm; an audio bracket defining multiple audio channels through which the microphone receives audio and the speaker assembly transmits audio. The audio bracket is coupled with both the microphone and the speaker assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure 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  shows an exemplary device suitable for use with the described embodiments; 
         FIG. 2  shows an interior perspective view of one corner of the exemplary device depicted in  FIG. 1 ; 
         FIG. 3A  shows a cross-sectional view of the portion of the exemplary device depicted in  FIG. 2 ; 
         FIGS. 3B-3C  show cross-sectional view of the exemplary device in accordance with section lines depicted in  FIG. 3A ; 
         FIG. 4  shows an exploded view of audio bracket and parts associated with mounting a microphone adjacent to a speaker; 
         FIG. 5  shows a close up perspective view of the audio bracket depicted in  FIG. 4 ; 
         FIG. 6A  shows an alternate embodiment in which multiple microphones are arranged within a speaker housing; 
         FIG. 6B  shows a block diagram depicting communication between a processor and multiple audio devices; and 
         FIG. 7  shows a flow chart depicting a method for embedding an acoustic mesh within an audio bracket. 
     
    
    
     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 described embodiments. 
     DETAILED DESCRIPTION 
     Representative applications of methods and apparatus according to the present application are described in this section. These examples are being provided solely to add context and aid in the understanding of the described embodiments. It will thus be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the described embodiments. Other applications are possible, such that the following examples should not be taken as limiting. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     Modern portable media devices are capable of carrying out a wide variety of functions. To accomplish these varied functions, many cutting edge components and sensors are packaged into a portable media device. While developing the portable media device with numerous discrete off the shelf components can result in a lower development cost, packaging these components together can be challenging and often result in many inefficiencies that cause the portable media device to be much larger than desired. One solution to this problem is to combine one or more components together so that the combined components can share common electrical and/or structural features, thereby saving space by reducing the number of redundant parts. 
     One function common to many portable media devices is the ability to provide a two-way link over which a conversation between at least two people can be conducted. At minimum, the portable media device includes both a speaker and a microphone so that each person can be both heard and listen during the conversation. While a conversation can be carried on with just one microphone, often times equipping the portable media device with multiple microphones can help to improve the voice quality and/or increase the number of orientations in which the device can be held while maintaining the capability to receive and transmit high quality audio. Unfortunately, both microphones and speakers often need to be positioned by an opening that allows audio to pass into and out of a device housing of the portable media device. Microphones and speakers also generally need to be oriented in a way that optimizes transmission of the audio. Orientation of these devices in this way can require various mounting hardware that can take up a substantial amount of space within the portable media device. 
     One way to reduce an amount of space taken up within the portable media device is to use a single piece of mounting hardware to secure multiple audio devices. In some embodiments, both a microphone and a speaker can be coupled within an interior surface of a device housing of the portable media device by a unitary audio bracket. The unitary audio bracket can include discrete openings for transmitting audio between each of the audio devices and the exterior environment. In some embodiments, the audio bracket can include mechanisms for preventing undesirable particulates from entering the portable media device by way of the numerous audio ports. In some embodiments, an acoustic mesh can be embedded within the audio bracket, thereby saving space that would otherwise be taken up by a discrete audio mesh assembly. The acoustic mesh can be embedded within the audio bracket during an insert molding operation, during which molten polymeric material solidifies, causing peripheral portions of the acoustic mesh to be embedded within a polymeric substrate. Although this description describes numerous cases in which the audio bracket takes the form of a polymeric substrate, it should be noted that any material suitable for use during an injection molding operation is possible and deemed to be within the scope of this description. 
     These and other embodiments are discussed below with reference to  FIGS. 1-7 ; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIG. 1  shows a portable media device  100  suitable for use with embodiments disclosed herein. Portable media device  100  can include a device housing  102  configured to protect various electrical components and sensors of portable media device  100 . Portable media device  100  can also include touch sensitive display  104  configured to provide a touch sensitive user interface for controlling portable media device  100 . A protective cover associated with touch sensitive display  104  can also cooperate with device housing  102  to substantially enclose operational and structural components of portable media device  100 . In some embodiments, portable media device  100  can include additional controls such as, for example, button  106 . Multiple hard-wired input/output (I/O) ports that include analog I/O port  108  and digital I/O port  110 . Audio devices within device housing  102  can receive and transmit audio by way of audio openings. For example, audio opening  112  can be defined by device housing  102  and configured to allow audio to enter portable media device  100  and be detected by a microphone positioned within device housing  102 . In some embodiments, audio opening  114  can also be associated with a microphone. A spatial interval between microphones associated with audio openings  112  and  114  can be used to perform a certain amount of beam forming that can filter unwanted audio out of the audio received by the two microphones. Device housing  102  also defines multiple audio opening  116 , which can be associated with a speaker along the lines of a speaker phone suitable for allowing a user to monitor an audio conversation without having the user&#39;s ear positioned directly against portable media device  100  at speaker opening  118 . Portable media device  100  can include numerous other operational components, such as for example, a processor, one or more wireless transceivers, a non-transitory computer readable memory device and a battery. 
       FIG. 2  shows an internal perspective view of a portion of device housing  102  that defines audio openings  114  and  116  (not depicted). Speaker housing  202  is depicted being positioned proximate a sidewall of device housing  102 . In some embodiments, speaker housing  202  can be secured to a device housing  102  by way of a fastener  204 , although it should be noted that speaker housing  202  can be attached to device housing  102  in any number of ways. Speaker housing  202  includes a laterally protruding arm  206 , which provides a mounting surface upon which microphone  208  can be mounted. Microphone  208  can be mounted to laterally protruding arm  206  by way of a foam adhesive layer  210  made up of a layer of foam and a layer of adhesive on opposing sides of the layer of foam. A compressibility of foam adhesive layer  210  can allow a certain amount of motion of microphone  208  with respect to laterally protruding arm  206  in the event of a drop event or other impact being applied to portable media device  100 . Foam adhesive layer  210  can also attenuate any vibratory impulses being transmitted through speaker housing  202 . Microphone  208  can be electrically coupled with other components within device housing  102  by way of flexible circuit  212 . Microphone  208  can be surface mounted to one side of flexible circuit  212 . An opposite side of flexible circuit  212  can then be adhesively coupled or soldered to a clip  214  that includes multiple arms for aligning microphone  208  and flexible circuit  212  with audio bracket  216 . Each of the arms of clip  214  can engage a recess  218  defined by audio bracket  216 . Each of recesses  218  can be substantially complementary to the arms of clip  214 , so that alignment of the arms with the channels provides a predictable alignment of clip  214  with audio bracket  216 . By engaging recesses  218  defined by audio bracket  216  the arms of clip  214  can provide precise alignment of an opening of microphone  208  and a channel defined by audio bracket  216 . Audio bracket  216  is secured to an interior facing surface of a sidewall of device housing  102 . In this way, microphone  208  is secured between laterally protruding arm  206  and audio bracket  216 . Audio bracket  216  can take the form of a polymeric substrate defining multiple openings through which audio signals can be routed. 
       FIG. 3A  shows a cross-sectional view of the corner of portable media device  100  shown in  FIG. 2  and depicts how speaker housing  202  interacts with audio bracket  216  and microphone  208 . In particular, the compression of microphone  208  between laterally protruding arm  206  and audio bracket  216  is depicted. An opening in flexible circuit  212  and channel  302  of audio bracket  216  allow audio to reach and be detected by microphone  208  through audio opening  114 . In some embodiments, channel  302  represents an audio channel of about 1 mm in diameter. Acoustic mesh  304  extends across a central portion of channel  302  and operates to prevent small particles from passing through channel  302 . Acoustic mesh  304  can be insert molded within audio bracket  216 . In this way, peripheral portions of acoustic mesh  304  become permanently lodged within the portions of audio bracket  216  that define channel  302 . As part of a production process, openings in acoustic mesh  304  can be inspected to ascertain whether the openings remained clear and well-suited for passing audio. This inspection process helps to remove bad parts that could have included incidences of partial or complete melting of acoustic mesh  304  or incidences of injection molding material clogging the openings of acoustic mesh  304 . 
       FIG. 3A  also shows cosmetic mesh assembly  306 . Cosmetic mesh assembly  306  acts as an interface between audio bracket  216  and an interior surface of a sidewall of device housing  102 . Cosmetic mesh assembly  306  includes a cosmetic mesh layer  308  having protrusions formed of a cosmetic mesh, which prevents the passage of relatively large objects into microphone channel  302  or any of speaker channels  310 . It should be noted that in some embodiments cosmetic mesh can be darkened to make cosmetic mesh less visually noticeable. A size of the openings in cosmetic mesh layer  308  can be substantially larger than the openings of acoustic mesh  304 . In addition to operating as a block for relatively larger foreign objects, cosmetic mesh can also be substantially more structurally robust than acoustic mesh  304 . The structural integrity of this layer is important on account of there being no screening element in front of it, which allows all objects capable of passing through audio openings  114  and  116  to come in contact with it. In some embodiments, cosmetic mesh layer  308  can be constructed from a steel mesh having a strength suitable for deflecting small objects without being prone to puncture. In some embodiments, each of speaker channels  310  and microphone channel  302  can be made of multiple smaller audio channels or in some embodiments the depicted audio channels be combined into a unitary audio channel transmitting audio to and from all of the audio openings defined by device housing  102 . Speaker housing  202  can also include acoustic mesh  312  that prevents small particulates from entering into speaker housing  202 . Acoustic mesh  312  can be held in place between a forward portion  314  of speaker housing  202  and a remaining portion of speaker housing  202 . 
       FIG. 3B  shows a cross-sectional view of portable media device in accordance with section line A-A of  FIG. 3A .  FIG. 3B  depicts a path audio takes in reaching microphone  208 . In particular, cosmetic mesh layer  308  is depicted. Cosmetic mesh layer  308  masks views of an internal portion of portable media device  100  and also prevents objects from passing through and into portable media device  100 . Cosmetic mesh layer  308  can take the form of a layer of steel mesh that is adhered to device housing  102  and audio bracket  216  by double sided adhesive layers  316 . In some embodiments, the steel mesh can be darkened to create the appearance of a dark audio opening. As depicted, cosmetic mesh layer  308  has openings well-suited for allowing audio signals to pass through. Once audio passes through cosmetic mesh layer  308  it enters audio channel  302 . Audio channel  302  includes an acoustic mesh  304 . Acoustic mesh  304  keeps particularly small particles such as dust from entering any farther into portable media device  100 , while allowing acoustic waves to pass substantially unattenuated. As can be seen in this view, acoustic mesh  304  is embedded within material of audio bracket  216  that defines audio channel  302 . Because acoustic mesh  304  is embedded within audio bracket  216  it doesn&#39;t require any adhesive layers to keep it in position. Clip  214  is shown being coupled with audio bracket  216  by adhesive layer  316 .  FIG. 3B  also depicts how arms of clip  215  engage audio bracket  216 , which causes an opening  318  defined by clip  214  to be precisely aligned with audio channel  302 . Flexible circuit  212  is in turn coupled with clip  214  by another adhesive layer  316 , although it should be noted that when clip  214  is formed from metal it can be soldered to flexible circuit  212 . Flexible circuit  212  and adhesive layers  316  also include openings for accommodating the passage of audio to microphone  208 . In this way, this stackup of audio components allows audio to enter portable media device and be detected by microphone  208 . 
       FIG. 3C  shows a cross-sectional view of portable media device  100  in accordance with section line B-B of  FIG. 3A . Speaker housing  202  is depicted which includes a forward portion  314  detachably coupled to speaker housing  202 . In this way, acoustic mesh  312  can be secured between speaker housing  202  and forward portion  314 . Once acoustic mesh  312  is installed within speaker housing  202 , forward portion  314  can be permanently coupled with speaker housing  202  by, for example, an amount of adhesive. Acoustic mesh  312  allows audio in the form of acoustic waves to travel substantially unattenuated and then through an opening defined by forward portion  314 . Forward portion  314  can be coupled with audio bracket  216  by another foam adhesive layer  210  as depicted. Foam adhesive layer  210  can define an opening through which the acoustic waves can travel. Once within audio channel  310 , the audio can then pass through cosmetic mesh layer  308  and audio opening  116  to exit device housing  102 . It should be noted that while microphone  208  is depicted being positioned external to speaker housing  202 , in some embodiments, microphone  208  can be positioned within speaker housing  202 . 
       FIG. 4  shows an exploded view of speaker housing  202 , audio bracket  216 , cosmetic mesh assembly  306  and parts associated with mounting microphone  208 . Speaker housing  202 , in addition to having laterally offset arm  206  can optionally include a fastening feature  402 . Fastening feature  402  defines a fastener opening configured to receive a fastener that secures speaker housing  202  to at least one portion of device housing  102 . Speaker housing  202  also defines an opening  404  through which audio can exit speaker housing  202 . Laterally offset arm  206  provides a flat surface that supports foam adhesive layer  210 . Foam adhesive layer  210  has a shape and size that corresponds with a surface of microphone  208 , which is in turn mounted to flexible circuit  212 . It should be noted that only a small portion of flexible circuit  212  is shown for clarity sake and it should be understood that flexible circuit  212  can extend to other locations such as a main logic board and/or a power source of portable media device  100 . In this way, flexible circuit  212  places microphone in communication with other components within device housing  102  and also provides power to microphone  802 . Flexible circuit  212  also defines an opening through which audio can propagate to microphone  208 . Clip  214  is also depicted and shows how clip  214  can include two arms. While not depicted in this view, it should be understood that audio bracket  216  also defines a channel for receiving the lower one of the arms. Once the arms of clip  214  are engaged with the channels of audio bracket  216  and clip  214  is compressed against audio bracket  216  a double sided adhesive layer  408  keeps clip  214  and audio bracket  216  from separating from each other again. Opening  406  can be surrounded by another foam adhesive layer  410 . Foam adhesive layer  410  can be configured to form a tight seal with audio bracket  216  without obstructing any audio exiting speaker housing  202  through opening  406 .  FIG. 4  also depicts cosmetic mesh assembly  306 . Portions of cosmetic mesh  308  disposed between the protruding portions can be coupled to adhesive layers  410  arranged across a surface of cosmetic mesh  308  that faces device housing  102  and across a surface of cosmetic mesh  308  that faces audio bracket  216 . In this way, adhesive layers  410  effectively secure cosmetic mesh assembly  306  between audio bracket  216  and device housing  102 . 
       FIG. 5  shows a close up view of audio bracket  216  and various internal features of audio bracket  216 . This view of audio bracket  216  depicts a tapered geometry  502  of audio channel  310 . By including tapering geometry within audio channel  310  as depicted, audio exiting audio bracket  216  can expand and use all of the audio openings defined by device housing  102 . Structural support  504  can be formed between audio channels  310  to make audio bracket  216  more robust. For example, in some embodiments, the material used to form audio bracket  216  may not be robust enough to maintain a unitary opening that encompassed both audio channels  310 . Audio bracket  216  can also include various recesses, along the lines of recess  506  to prevent sink conditions during formation of audio bracket  216 . It should also be noted that while audio bracket  216  has been consistently discussed with regards to it being an injection molded part, in some embodiments, audio bracket  216  can be a part formed of other materials along the lines of metals and ceramics. While the use of another material could preclude the insert molding of the acoustic mesh, other functions and aspects of audio bracket  216  can remain unchanged. For example, in some embodiments, the portion of audio bracket  216  that defines audio channel  302  could be thinned to provide additional space for arranging audio mesh  304  behind audio bracket  216 . 
       FIG. 6A  shows an alternative embodiment in which microphones are placed within speaker housing  202  instead of being placed next to or adjacent speaker housing  202 . Microphones  602  and  604  can be secured to interior surfaces of speaker housing  202 . By offsetting microphones  602  to one side of speaker housing  202 , microphones  602  and  604  can remain substantially out of the path of audio being emitted from speaker housing  202 . Microphones  602  and  604  can be configured to provide an associated device with different types of information. For example, microphone  602  can be configured to receive externally generated audio through audio channel  606 . A sensor opening in microphone  602  configured to receive audio can be aligned with audio channel  606  and a portion of audio bracket  608  that extends nearly up to or comes in direct contact with acoustic mesh  610  can help to isolate audio received by microphone  602  to audio transmitted through audio opening  114 . In some embodiments, microphone  602  can be configured with a sensitivity and diaphragm well-suited for recording audio consistent with the spoken voice entering device housing  102  through audio opening  114 . Microphone  604  can be tuned to a sensitivity and have a diaphragm consistent with a range of audio output emitted by speaker housing  202 . In some embodiments, microphones  602  and  604  can concurrently detect audio. In other embodiments, only one of microphones  602  and  604  can be active at any given time. For example, microphone  602  can be activated and detecting audio when a phone call is in progress or when an application designed to record audio is placed in a recording state. In some embodiments, microphone  602  can be activated when a proximity sensor indicates an ear of a user is in close proximity to a particular surface of portable media device  100  before activating microphone  602  to listen for acoustic waves consistent with a voice of the user. In such an embodiment, microphone  602  can be tuned to record only audio coming from a direction consistent with audio being generated from the mouth of the user holding the phone to the ear. In some embodiments, when speaker housing  202  is emitting audio, microphone  602  can be deactivated and microphone  604  can be activated. It should be noted that while microphones  602  and  604  are depicted in a particular location within speaker housing  202  other locations are also possible. For example, microphones  602  and  604  could be positioned on opposing sides of housing  202  and/or be oriented in different directions. 
       FIG. 6B  shows communication pathways between a processor  612 , microphone  602 , microphone  604  and speaker assembly  614  of portable media device  100 . The described communications are fully compatible with the embodiment depicted and described in connection with  FIG. 6A . Audio generated by speaker assembly  614  and emitted from speaker housing  202  can be detected by a microphone and characterized by processor  612  of portable media device  100 . By monitoring the audio emitted from speaker housing  202  with microphone  604  the processor can determine when speaker assembly  614  begins to start producing distorted audio. This type of monitoring can be used to generate a closed loop control system capable of setting a dynamic threshold for audio output by speaker assembly  614 . This can be particularly useful when an audio track being played back doesn&#39;t reach the volume normally reached by the speaker assembly due to improper audio encoding or any other number of reasons. In such a case, a user would be able to continuously raise the volume as long as speaker assembly  614  did not begin to distort. Once distortion was detected, the volume could be automatically lowered until distortion ceased to be detected. In this way, an amount of volume produced by speaker assembly  614  can be maximized without concern for causing distortion or damage to speaker assembly  614 . In some embodiments, signals received from microphone  604  could be utilized to limit the audio volume below a preset threshold. For example, a user could choose to limit the output of a white noise application to below 30 dB. For a speaker with potentially dangerous amounts of audio output, another application could allow the audio to be limited below 85 dB where a user could be in danger of hearing loss. In some embodiments, microphone  604  could allow a user to set the output volume by an average number of decibels rather than by a preset volume level. In still other embodiments, a user could request the volume of an audio stream to be normalized so that any audio fell within a preselected volume range. Communication between microphone  602  and processor  612  can also produce beneficial outcomes. For example, inputs from both microphone  602  and other microphones situated around portable media device  100  can be used to perform beam forming which helps to filter out audio being received from undesirable sources. For example, the beam forming could assist in receiving audio only from a user of portable media device  100  while filtering interference such as ambient noises out. 
       FIG. 7  shows a flow chart illustrating a method  700  for insert molding a layer of acoustic mesh within an audio bracket. At block  702 , a layer of acoustic mesh is picked up by a pick and place with a suction head that arranges the acoustic mesh within an insert molding cavity. The layer of acoustic mesh can have a pitch and opening suitable for allowing acoustic waves to pass through substantially unattenuated while stopping foreign debris along the lines of dust particles from entering into and inhibiting operation of internal components of a portable media device to which the audio bracket is attached. At block  704 , the location in which the layer of acoustic mesh includes a holder for holding the layer of acoustic mesh in place within the cavity. For example, the injection molding cavity can include its own suction system designed to keep the acoustic mesh in place during an injection molding operation. Alternatively or additionally, the layer of acoustic mesh can be compressed between two rods that define an audio channel during the insert molding operation. In some embodiments, the audio channel formed by the rods can have a narrow diameter (e.g., about 0.8 mm). At block  706 , injection molding material is injected into the cavity and engages and comingles with a periphery of the layer of acoustic mesh. The injection molding material can take many forms including for example plastics/polymers, glass fiber, silicone and metals. After the rods are removed and the resulting acoustic bracket is removed from the cavity, only the portion of the layer of acoustic mesh extending across the acoustic channel remains exposed, while the portion of the acoustic mesh embedded within the molded audio bracket is retained firmly in place by the molding material. At block  708 , subsequent to the audio bracket cooling an inspection can be conducted to verify the openings in the acoustic mesh remain open. In some embodiments, a camera can be used to carry out the inspection, which can take the form of a CCD (charge-coupled device) that can be placed at one opening of the audio channel while a light can be directed through an opening at an opposite end of the audio channel. In this way, the openings in the acoustic mesh can be counted and characterized by the CCD. In situations where too many of the openings are filled with injection molding material or melted together, the part can be rejected. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20151218
Publication Date: 20180116
Grant Date: 20180116
Priority Date: 20150904
Inventors: MEYER ROBERT F.
JARVIS DANIEL W.
DINH RICHARD HUNG MINH
HRISTOV STOYAN
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/023", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/023", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 58190846