PATENT DOCUMENT

Publication Number: US-9210492-B2
Application Number: US-201113283506-A
Country: US
Kind Code: B2

Title: Microphone assembly having an acoustic coupler

Abstract:
Embodiments of the invention include a microphone assembly having a microphone soldered on a bottom side of a bottom ported microphone flex circuit carrier, and a rigid coupler soldered on the top side of the carrier, opposite to the microphone. The coupler is inserted into and sealed to a microphone boot made out of a soft material. The top of the boot may be sealed to an electronic audio device into which the assembly is integrated. Acoustic openings through the housing, boot, coupler and carrier allow acoustic signals to reach the microphone. However, the seals between the housing, boot, coupler, carrier and microphone provide sound isolation, as well as a moisture and dust seal between the ambient and the inside of the electronic device. Such seals may include rings, grooves, threads, O-rings between the boot and coupler; or a reinforcing ring around the soft material of the boot.

Claims:
What is claimed is:  
     
       1. An electronic device comprising:
 a microphone assembly having:
 a printed circuit carrier having a first opening; 
 a microphone having an acoustic input port aligned with the first opening and that faces a back side of the carrier; 
 a rigid acoustic coupler having a round outer surface formed around an outer perimeter of the rigid coupler and having a second opening that is aligned with the first opening; and 
 
 a compliant boot having a round inner surface formed around an inner perimeter of the compliant boot and installed over the outer surface of the rigid acoustic coupler, wherein a seal is formed between the round inner surface of the compliant boot and the round outer surface of the ridged acoustic coupler. 
 
     
     
       2. The electronic device of  claim 1 , wherein the microphone is bonded to the back side of the carrier; and wherein the coupler is bonded to the front side of the carrier. 
     
     
       3. The electronic device of  claim 1 , wherein the microphone is soldered to the back side of the carrier, the rigid acoustic coupler is soldered to the front side of the carrier, and the carrier is a flex circuit carrier. 
     
     
       4. The apparatus of  claim 1 , wherein the rigid acoustic coupler comprises a metal cap and the compliant boot comprises a soft compression molded material. 
     
     
       5. The apparatus of  claim 4 , wherein the seal comprises at least one of: a ring in the round inner surface of the boot that engages a groove formed in the round outer surface of the coupler, at least one ring in the round inner surface of the boot, at least one thread formed in the round outer surface of the coupler, at least one O-ring between the round inner surface of the boot and the round outer surface of the coupler, a metal ring in the boot and surrounding the round outer surface of the coupler, or a hard material in the boot and surrounding the round outer surface of the coupler. 
     
     
       6. The electronic device of  claim 1 , further comprising:
 a mobile housing in which the microphone assembly is installed, wherein the second opening faces an acoustic aperture through a bottom or side of the mobile housing. 
 
     
     
       7. The electronic device of  claim 6 , wherein the microphone assembly is attached to a support structure within the mobile housing; and wherein the boot is bonded to edges of an aperture of the mobile housing. 
     
     
       8. A mobile device having a microphone assembly, the assembly comprising:
 a printed circuit carrier having a first opening through the printed circuit carrier; 
 a microphone attached to and facing a back side of the carrier, the microphone having an acoustic input port aligned with the first opening; 
 a rigid acoustic coupler attached to and facing a front side of the carrier, the rigid acoustic coupler having a round outer surface formed around an outer perimeter of the rigid coupler and having a second opening through the coupler that is aligned with the first opening; and 
 a compliant boot having a round inner surface formed around an inner perimeter of the compliant boot and installed over the rigid acoustic coupler, wherein a seal is formed between the round inner surface of the compliant boot and the round outer surface of the ridged acoustic coupler. 
 
     
     
       9. The apparatus of  claim 8 , wherein the compliant boot has a third opening through the boot and aligned with the first opening;
 wherein the second opening extends from the front side of the coupler to the first opening; and 
 wherein the third opening extends from the front side of the boot to the second opening. 
 
     
     
       10. The apparatus of  claim 8 , wherein the compliant boot is attached to a device housing with an adhesive;
 wherein the third opening is aligned with an acoustic aperture of the housing; and 
 further comprising:
 a cosmetic mesh over the third opening and attached to the front side of the boot with an adhesive; 
 an acoustic mesh under the cosmetic mesh, over the third opening and attached to the front side of the boot with an adhesive. 
 
 
     
     
       11. The apparatus of  claim 8 , wherein the microphone is soldered to the back side of the carrier, the rigid acoustic coupler is soldered to the front side of the carrier, and the compliant boot is sealed to the rigid acoustic coupler. 
     
     
       12. The apparatus of  claim 8 , wherein the seal comprises at least one of: a ring in the round inner surface of the compliant boot that engages a groove formed in the round outer surface of the coupler, at least one ring in the round inner surface of the boot, at least one thread formed in the round outer surface of the coupler, at least one O-ring between the boot and the round outer surface of the coupler, a metal ring in the boot and surrounding the round outer surface of the coupler, or a hard material in the boot and surrounding the outers surface of the coupler. 
     
     
       13. The apparatus of  claim 8  wherein the rigid acoustic coupler comprises a metal cap, and the compliant boot comprises a soft compression molded material. 
     
     
       14. The apparatus of  claim 8 , wherein the compliant boot does not touch the printed circuit carrier; and wherein audio signals incident upon the front side of the compliant boot are converted by the microphone into analog audio electrical signals transmitted through electrical traces of the printed circuit carrier. 
     
     
       15. The apparatus of  claim 8 , wherein the microphone is secured to and sealed to the back side of the printed circuit carrier by a soldering process or glue; and
 wherein the coupler is secured to and sealed to the front side of the printed circuit carrier by a soldering process or glue. 
 
     
     
       16. The apparatus of  claim 8 , wherein the acoustic input port of the microphone adjoins the first opening, and wherein the microphone is soldered and connected to a through signal contact on the back side of the printed circuit carrier. 
     
     
       17. The apparatus of  claim 8 , wherein the printed circuit carrier is a flexible circuit carrier; and
 wherein the first opening is a through opening from the front side to the back side of the printed circuit carrier. 
 
     
     
       18. The apparatus of  claim 8 , wherein the microphone assembly is mounted in a bottom edge or side edge of a mobile device housing; and wherein the mobile device is a cell phone, tablet computer, notebook computer, or PDA. 
     
     
       19. The apparatus of  claim 8 , wherein the microphone assembly is mounted in a bottom edge or side edge of a device housing;
 and wherein the device is a desktop computer. 
 
     
     
       20. The apparatus of  claim 8 , wherein the microphone is disposed entirely behind a surface of the back side of the printed circuit carrier and not within the first opening of the printed circuit carrier. 
     
     
       21. The apparatus of  claim 8 , wherein the microphone is contained within an encasement or housing, and wherein the encasement or housing is outside and behind the backside of the printed circuit carrier, and external to the first opening of the printed circuit carrier. 
     
     
       22. An electronic audio device comprising:
 a processor coupled to a memory, the processor to execute software instructions to operate the device; 
 RF communications circuitry coupled to an antenna and the processor, the RF communications circuitry to at least communicate a telephone call; 
 a microphone assembly having: a printed circuit carrier having a first opening; 
 a microphone having an acoustic input port aligned with the first opening and that faces a back side of the carrier; 
 a rigid acoustic coupler having a round outer surface formed around an outer perimeter of the rigid coupler and having a second opening that is aligned with the first opening; 
 a compliant boot having a round inner surface formed around an inner perimeter of the compliant boot and installed over the rigid acoustic coupler, wherein a seal is formed between the round inner surface of the compliant boot and the round outer surface of the ridged acoustic coupler; and 
 microphone circuitry coupled to the microphone and to the processor, the microphone circuitry to process the electrical audio signal output of the microphone. 
 
     
     
       23. The electronic audio device of  claim 22  further comprising:
 a device housing including a front face, aback face and sides attaching the front face to the back face; 
 wherein the front face include a touch screen input/output; 
 wherein the third opening of the microphone assembly faces and is open to an aperture through one of the sides.

Description:
Embodiments of the invention relate to microphone assemblies, particularly those that are integrated within an electronic audio device such as a mobile phone, tablet computer, notebook computer or desktop computer. 
     BACKGROUND 
     In the field of electronic audio devices such as personal computers, laptop computers, tablet computers, and smart phones (e.g., a typical mobile phone such as an iPhone™ device by Apple Inc., of Cupertino Calif.), microphones are used to sense speech and other audio signals. The audio signals are converted to electronic signals, such as for communicating by phone, or making audio recordings. The device typically has a housing with an acoustic aperture or opening through which audio signals reach a microphone assembly that includes the microphone. 
     However, ambient moisture and dirt may enter the device through the opening or through the assembly. This may cause problems for the microphone or other circuitry of the device. For example, this may cause the microphone or other circuitry of the device to fail or become unusable. In addition, stray or unwanted sound in the ambient and vibration of the housing can effect the microphone assembly. In some situations, this may cause feedback or cause the microphone circuitry to otherwise become unusable for converting verbal input by the user into electronic audio signals. 
     SUMMARY 
     Embodiments of the invention include a microphone assembly having a microphone bonded to a bottom side of a printed circuit carrier. The microphone&#39;s acoustic input port is aligned with a port thought the carrier and a rigid coupler is bonded to the top side of the carrier, opposite to the microphone. An opening through the coupler is aligned with the other side of the carrier port. The coupler is inserted into and sealed to a microphone boot made out of a soft material. An opening through the boot is aligned with the opening through the coupler. The top of the boot may be bonded to a housing of an electronic audio device such as a mobile phone, tablet computer, notebook computer or desktop computer into which the assembly is integrated. The openings through the housing, boot, coupler and carrier allow acoustic signals in the ambient to reach the microphone. However, seals between the housing, boot, coupler, carrier and microphone provide sound isolation, as well as a dust and moisture-tight seal between the ambient and other components within the electronic device. For example, seals between the boot and coupler may include rings in an inner perimeter of the boot that engage grooves in an outer perimeter of the coupler, one large ring around the upper outer perimeter of the coupler to engage a large groove in the boot inner perimeter, threads around the outer perimeter of the coupler to engage threads in the boot, an O-ring in a groove of the coupler to engage the flat surface of the boot, a metal reinforcing ring around and interlocked to the soft material of the boot, a metal reinforcing ring within and interlocked to the soft material of the boot, or a reinforcing hard material ring around the outer base of the soft material boot. 
     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 
       The embodiments of the invention are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings in which like references indicate similar elements. It should be noted that references to “an” or “one” embodiment of the invention in this disclosure are not necessarily to the same embodiment, and they mean at least one. 
         FIG. 1  is a side view of one type of microphone assembly. 
         FIG. 2  is a side view of another type of microphone assembly, and includes parts of an electronic device the assembly is integrated into. 
         FIG. 3A  is a side view of another type of coupler. 
         FIG. 3B  is a cross-section view of  FIG. 3A . 
         FIG. 4  is a cross-section view of another type of coupler and boot. 
         FIG. 5A  is a perspective view of another type of boot. 
         FIG. 5B  is a cross-section view of  FIG. 5A . 
         FIG. 6A  is a perspective view of another type of boot. 
         FIG. 6B  is a cross-section view of  FIG. 6A . 
         FIG. 7A  is a perspective view of another type of boot. 
         FIG. 7B  is a cross-section view of  FIG. 7A . 
         FIG. 8  depicts an example electronic device into which embodiments of the microphone assembly may be installed. 
     
    
    
     DETAILED DESCRIPTION 
     Several embodiments of the invention with reference to the appended drawings are now explained. Whenever the shapes, relative positions and other aspects of the parts described in the embodiments are not clearly defined, the scope of the invention is not limited only to the parts shown, which are meant merely for the purpose of illustration. Also, while numerous details are set forth, it is understood that some embodiments of the invention may be practiced without these details. In other instances, well-known circuits, structures, and techniques have not been shown in detail so as not to obscure the understanding of this description. 
     Microphone assemblies are often integrated within electronic audio devices such as mobile phones, tablet computers, notebook computers and desktop computers to detect audio signals (e.g., sound). However, ambient moisture and dirt (e.g., dust) may enter the electronic device due to gaps through components of the assembly or through the acoustic apertures (e.g., openings) of the assembly, and may cause the microphone or other circuitry within the device to fail or have reduced functionality. Thus, it can be important to provide a microphone assembly that has sound isolation, and a moisture and dirt tight seal between the ambient and spaces, components and circuitry inside the housing of the electronic device. For example, a microphone assembly may be designed with proper sealing technology between the device housing, components of the assembly and the microphone to provide sound isolation, as well as a moisture, dust and air-tight seal between the ambient and the inside of the electronic device. 
     More specifically,  FIG. 1  shows one type of such a microphone assembly. Microphone assembly  1  includes printed circuit carrier  2  (PCC) having opening  3  (e.g., an acoustic aperture) through the carrier. Microphone  4  is attached to and facing back side  5  of the carrier  2 , such as by having its input acoustic port  7  (or its transducer) facing and open to the surface of back side  5 . The microphone has acoustic input port  7  aligned with the opening  3 , such as by having the axis of port  7  aligned or parallel to the axis of opening  3 . Port  7  may also be described as facing and open to opening  3 . 
       FIG. 1  also shows coupler  8 A attached to and facing front side  6  of the carrier  2 , such as by having its opening  10  facing and open to the surface of front side  6 . The rigid acoustic coupler  8 A has opening  10  through the coupler  8 A and aligned with the opening  3 . The coupler has its opening  10  aligned with the opening  3 , such as by having opening  10  facing and open to opening  3 . Compliant boot  9 A is installed over the rigid acoustic coupler  8 A. Compliant boot  9 A has opening  10  through the boot and aligned with opening  3 . Opening  10  extends from the front side  11  of the coupler to opening  3 , and opening  12  extends from the front side  13  of boot  9 A to opening  10 . 
     Printed circuit carrier  2  may be a “flex” circuit carrier, a microphone flex circuit board, a flexible circuit, a printed circuit board (PCB), and/or a printed circuit carrier. Such a carrier may include signal and other traces on (and possibly in) a flexible material (e.g., PCB material). A “flex” circuit carrier may include a flexible plastic substrate, such as polyimide, PEEK or a transparent conductive polyester film. It may also include screen printed technology, photolithographic technology, metal strips laminated between two layers of PET, and/or technology used to manufacture components of rigid PCBs. It may allow the carrier to conform to a desired shape, or to flex during its use. It may also include solder around a perimeter of opening  3  on sides  5  and  6 , contacts and signal traces for connecting the microphone to audio processing circuitry. 
     Microphone  4  may be a MEMS (MicroElectrical-Mechanical System) microphone, such as a microphone chip or silicon microphone. In some cases, microphone  4  may use a field effect transistor or amplification system to amplify a sensed signal in the audio range, such as from a human voice. 
     Rigid acoustic coupler  8 A may be made of or may include a metal material such nickel, iron, bronze, copper, aluminum, or steel). In some cases, coupler  8 A is a metal cap of one metal plated with another. It is considered that coupler  8 A may be a metal cap of nickel plated steel. 
     Compliant boot  9 A may be made of or may include a soft compression molded material. In some cases, boot  9 A is made of a soft compression molded silicon, rubber, or polymer. 
     Carrier  2 , microphone  4 , coupler  8 A and boot  9 A may be described as components of assembly  1 . Gaps through the components, between the ambient (e.g., moisture, dirt and possibly air) and the inside of a device the assembly is integrated into can be avoided by ensuring appropriate seals and bonds between components. For instance, the assembly may have seals (e.g., moisture, dirt and possibly air) between its acoustic apertures (e.g. holes or openings between the ambient and the microphone input port) and the inside of the device. The assembly may also be sealed to an acoustic aperture of the housing of the device, under which the assembly is located. The components and seals may also provide sound isolation from stray or unwanted sound in the ambient and vibration of the housing. 
     To provide such seals,  FIG. 1  shows an embodiment having microphone  4  bonded to back side  5  of the carrier, such as using glue, adhesive, solder, or by being otherwise joined. In some cases, microphone  4  is soldered to back side  5  of the carrier. For example, a solder seal may be formed between microphone  4  and back side  5  around a perimeter of opening  3  so that the microphone is sealed to carrier  2 . A perimeter may have various shapes such as a circle, oval, square, rectangle, etc. Such a seal may include being sealed with respect to air and dust; and being sound isolated (e.g., providing substantial sound isolation, muffling or deadening) with respect to stray or unwanted sound in the ambient and vibration of the housing. In some cases, the solder may hold the microphone  4  with enough force (e.g., tight enough) against back side  5  to form such a seal, even though the solder may not form a complete perimeter. The acoustic input port of microphone  4  may be described as aligned with and adjoining opening  3 . In some embodiments, microphone  4  is disposed entirely behind or below a surface of back side  5  of carrier  2  and does not extend within opening  3 . It is also considered that microphone  4  may be contained within an encasement or housing that is outside and behind back side  5  of carrier  2 , and external to opening  3 . 
     The seals may also include coupler  8 A being bonded to front side  6  of the carrier, such as using glue, adhesive, solder, or by being otherwise joined. In some cases, coupler  8 A is soldered to front side  6  of the carrier. For example, a solder seal may be formed between coupler  8 A and front side  6  around a perimeter of opening  3  so that the coupler is sealed to carrier  2 . Such a seal may include being sealed with respect to air and dust; and being sound isolated (e.g., providing substantial sound isolation, muffling or deadening) with respect to stray or unwanted sound in the ambient and vibration of the housing. In some cases, the solder holds the coupler  8 A with enough force against front side  6  to form such a seal, even though the solder may not form a complete perimeter. In some embodiments, coupler  8 A is disposed entirely in front of or above a surface of front side  6  of carrier  2  and does not extend within opening  3 . 
     The bonding between microphone  4  and back side  5  and/or the bonding between coupler  8 A and front side  6  may be or include of one or more different or repeated bonding techniques (e.g., overlapping solder joints). In some cases, such bonding includes other material such as signal traces, adhesive, solder, and/or tape between surfaces of microphone  4  and back side  5  and/or between surfaces of coupler  8 A and front side  6 . In some cases, microphone  4  is secured to and sealed to the back side of carrier  2  by a soldering process or glue; and coupler  8 A is secured to and sealed to the front side of carrier  2  by a soldering process or glue. 
     In some embodiments, the solder between microphone  4  and back side  5  and/or the solder between coupler  8 A and front side  6  does not conduct signals to any circuitry of the device. It is considered that the solder may be grounded to help reduce unwanted electronic effects or signals due to the existence of the solder. In some cases, such solder includes at least one bias or signal path, to or from the microphone, in addition to the bonding solder. In some cases, such solder includes exposed metal traces to which microphone  4  and back side  5  and/or coupler  8 A and front side  6  are bonded. 
     Compliant boot  9 A may be sealed (vial seal  22 ) to acoustic coupler  8 A by mechanical friction and/or mechanical structure. This seal may be caused by the material and shape of inner perimeter  23  of boot  9 A nominally interfering with outer perimeter  26  of coupler  8 A along one or more discrete paths to ensure a dirt and moisture tight seal. Such paths may be formed by surfaces of rings nominally interfering with (e.g., causing friction when moved with respect to) with corresponding surfaces of corresponding grooves. In some cases, the seal includes at least one ring in an inner perimeter of the boot that engages at least one groove in an outer perimeter of the coupler (e.g., see  FIGS. 1 and 2 ), at least one large ring around the upper outer perimeter of the coupler boot to engage a large groove in the boot inner perimeter, at least one thread around the outer perimeter of the coupler to engage threads in the boot (e.g., see  FIGS. 3A-B ), at least one O-ring in a groove of the coupler to engage the flat surface of the boot (e.g., see  FIG. 4 ), a metal reinforcing ring around and interlocked to the soft material of the boot (e.g., see  FIGS. 5A-B ), a metal reinforcing ring within and interlocked to the soft material of the boot (e.g., see  FIGS. 6A-B ), or a reinforcing hard material ring around the outer base of the soft material boot (e.g., see  FIGS. 7A-B ). 
     In some embodiments, such as shown in  FIG. 1 , coupler  8 A is or includes a metal cap; boot  9 A is or includes a soft compression molded material; and an inner perimeter of the compliant boot is sealed to an outer perimeter of the coupler, where the seal includes using rings (e.g., in the boot or coupler) that engage (e.g., mate with) grooves (e.g., in the coupler or boot). It can be appreciated that there may be 1, 2, 3, 4, or more rings to provide some of the seal. In some cases only 1 or 2 rings may be needed. 
     For example, as shown in  FIG. 1 , compliant boot  9 A has inner perimeter  23  having rings  24  that engage or mate with corresponding grooves  25  in outer perimeter  26  of the coupler to from a dirt and moisture (an possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). Rings  24  may be ring shaped protrusions that extend outward from the outer perimeter along a ring around the perimeter. They may extend out to form a half circle or semi-circular cross section shape with respect to the path of the ring around the perimeter. It is considered that they may also extend out to form other curved or angled cross section shapes. For example, they may extend out to form an arc, an arch, a half oval, a sine wave bump, a Gaussian curve bump, or other protruding shapes with curved surface and/or flat surfaces shape cross section with respect to the path. Grooves  25  may extend inward along the inner perimeter in a shape that is the same as (e.g., receives) the ring shape (e.g., with respect to the path of the ring around the perimeter). Also, some other embodiments may have grooves in boot  9 A inner perimeter  23 , and corresponding rings in outer perimeter  26  of the coupler to from a dirt and moisture (and possibly air) tight seal between the boot and the coupler. In some embodiments, the rings do not necessarily engage grooves to from a dirt and moisture (and possibly air) tight seal between the boot and the coupler, such as embodiments including the rings in the boot, without the grooves in the coupler to mate into, or embodiments that have rings in the coupler but not grooves in the boot. 
     The compliance of the material of boot  9 A and of coupler  8 A may be selected so to ensure a seal between the boot and the coupler. The number of rings and grooves, thickness and height of the rings, and thickness and height of the grooves may also be selected so to ensure a seal between the boot and the coupler. 
     In some cases, a mechanical friction seal  22  (e.g., by the rings and grooves; or by other similar structure) may be formed between boot  9 A and coupler  8 A around perimeters  23  and  26  so that the boot is sealed to the coupler. Such a seal may include being sealed with respect to air and dust; and being sound isolated (e.g., providing substantial sound isolation, muffling or deadening) with respect to stray or unwanted sound in the ambient and vibration of the housing. In some cases, the mechanical friction holds the boot  9 A with enough force against coupler  8 A to form such a seal. For example, this may occur, even though the rings, thread, and/or grooves do not form (e.g., do not exist, or exist but do not form) a complete seal around a complete perimeter. In some embodiments, glue or adhesive may help the seal between compliant boot  9 A and acoustic coupler  8 A. Similar concepts apply to embodiments described below for  FIGS. 2-7 . 
       FIG. 2  is a side view of another type of microphone assembly, and includes parts of an electronic device the assembly is integrated into. For instance,  FIG. 2  shows a housing  18  and support structure  29  of an electronic device in which assembly  1  is mounted or contained. Although some similar feature numbers are used for  FIGS. 1 and 2 , there is a distinction between the engaging or mating of coupler  8 B and boot  9 B of FIG.  2  as compared to coupler  8 A and boot  9 A of  FIG. 1 . Thus, descriptions above for coupler  8 A and hoot  9 A may apply to coupler  8 B and boot  9 B, such as with the exceptions of the differences described below. For example, as compared to rings  24  and grooves  25  of coupler  8 A and boot  9 A in  FIG. 1 , in embodiments shown in  FIG. 2 , coupler  8 B has an outer perimeter with one large ring or disc shape  30  that engages or mates with one corresponding groove  32  in the inner perimeter of compliant boot  9 B. This may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, groove  32  has at least two flat surfaces that engage and seal to corresponding flat surfaces in ring  30 . More particularly, flat surfaces  33  and  35  of ring  30  may be nominally interfering with (e.g., causing friction when moved with respect to) with corresponding flat surfaces  34  and  36  of groove  32 . 
     In some cases, surfaces  33  and  35  may form a protrusion that extend outward from the outer perimeter along a ring around the perimeter. They may extend out to form an angled edge cross section shape with respect to the path of the ring around the perimeter, such as forming an angle of 45 degrees where they meet. It is considered that ring  30  may also extend out to form other curved or angled cross section shapes, such as noted above for ring  24 . Surfaces  34  and  36  may extend inward along the inner perimeter in a shape that is the same as (e.g., receives) the ring shape (e.g., with respect to the path of the ring around the perimeter). 
       FIG. 2  also shows an embodiment having boot  9 B attached to device housing  18  (e.g., of a device such as device  50  of  FIG. 8 ) with an adhesive  16 , and opening  3  aligned with acoustic aperture  19  (e.g., a hole) of the housing. In some embodiments, cosmetic mesh  17  is disposed over opening  12 , and is attached to front side  13  of the boot with adhesive  16 . Cosmetic mesh  17  may provide a visually appealing look for aperture  19 , such as by providing a noticeable location of the microphone assembly so that a user will know which part of the device to speak at or aim at audio signals the user desired to be picked up by the microphone. 
     Adhesive  16  may hold the boot in place vertically and horizontally so that a seal is formed between the boot front side  13  and the back side of housing  18 . In some cases, the outer side surfaces of the boot are sealed horizontally to inner side surfaces of acoustic aperture  19  of housing  18 , such as by adhesive. Such a seal may include being sealed with respect to air and dust; and being sound isolated (e.g., providing substantial sound isolation, muffling or deadening) with respect to stray or unwanted sound in the ambient and vibration of the housing. In some cases, the adhesive  16  holds the boot  9 B with enough force against housing  18  to form such a seal, even though the adhesive may not form a complete perimeter. Boot may be described as being bonded to edges of aperture  19  of a mobile housing. 
     In accordance with embodiments, compliant boot  9 B may not touch the printed circuit carrier  2 . In some cases, boot  9 B also touches or is attached (e.g., by adhesive and/or mechanical pressure) to support structure  29  within housing  18  or an electronic device. 
     Also, in some cases, acoustic mesh  15  is disposed under cosmetic mesh  17  and over opening  12 , and is attached to front side  13  of the boot with adhesive  14 . Acoustic  15  may provide physical audio filtering to help pass speech audio frequencies but filter out or mute frequency ranges above and below typical human speech. This way, undesired audio signals picked up by the microphone will not interfere with a user&#39;s speech received by the microphone. 
     This design allows audio signals  30  in the ambient or incident upon assembly  1  (e.g., opening  12 ) to be received by microphone  4  and converted into electronic audio signals. In some cases, audio signals incident upon the compliant boot and front side of the carrier are converted by the microphone into electronic signals. For example, assembly  1  (e.g., microphone  4 ) may be used to convert verbal input by a user (or other audio signals) into electronic audio signals. The microphone may be soldered to signal traces and/or circuitry of carrier  2  for processing the electronic signals. In some embodiments, microphone  4  is described as soldered and connected to through signal contacts on back side  5  of printed circuit carrier  2 . Carrier  2  may be attached to housing  18 , support structure  29 , and/or to other internal components of an electronic device containing assembly  1  or into which the assembly is integrated (e.g., device  50  of  FIG. 8 ). In some cases, carrier  2  is attached or bonded to support structure  29  within or inside housing  18  of an electronic device. Thus, analog audio electrical signals transmitted through the electrical traces of the printed circuit carrier may be stored and/or transmitted by an electronic device that includes assembly  1 . 
       FIG. 3A  is a side view of another type of coupler.  FIG. 3B  is a cross-section view of  FIG. 3A . Although some similar feature numbers are used for  FIGS. 1-3 , there is a distinction between the engaging or mating of coupler  8 C of  FIG. 3  (e.g., and the boot) as compared to couplers  8 A-B and boots  9 A-B of  FIGS. 1-2 . Thus, descriptions above for couplers  8 A-B and boots  9 A-B may apply to coupler  8 C and the boot, such as with the exceptions of the differences described below. For example, as compared to rings  24  and grooves  25  of coupler  8 A and boot  9 A in  FIG. 1 , and as compared to disc shape  30  and groove  32  of coupler  8 B and boot  9 B of  FIG. 2 , in embodiments shown in  FIG. 3 , coupler  8 C has an outer perimeter  26  with threads  37  on the coupler that engage or screw into corresponding threads (e.g., grooves) in the inner perimeter of a hard boot (e.g., corresponding to boot  9 A but with threaded grooves instead of rings  24 ). This may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, coupler  8 C has at least two threads around it&#39;s perimeter that engage and seal to corresponding threads of the boot, such as by nominally interfering with (e.g., causing friction when moved with respect to) the corresponding threads. The number of threads, and thickness and height of the threads may be selected so to ensure a seal between the boot and the coupler. 
       FIGS. 3A-B  also show that the bottom side(s)  38  of the coupler may be angled (e.g., forms an angle greater than 90 degrees) with respect to front side  6  of PCC 2 . Such an angle may be 100 degrees or some other angle between 95 and 105 degrees. In some cases, bottom side(s)  38  of the coupler may be have knurled surfaces for better bonding or attachment of the coupler with a solder joint to front side  6  of CCA  2 , such as by providing a better solder interlock when soldering the coupler to the CCA. For instance, knurling can be added to the sides of the coupler to add mechanical strength to the joint between the coupler and CCA. Such knurling may be performed in a manufacturing process, such as using a lathe, to cut a diamond-shaped (criss-cross) pattern into the material of sides  38 . The knurling may also be rolled into sides  38 . This allows a better grip on the knurled object than would be provided by a smooth metal surface. In some cases, the knurled pattern is a series of straight ridges or a helix of “straight” ridges rather than a criss-cross pattern. 
       FIG. 4  is a cross-section view of another type of coupler and boot. Although some similar feature numbers are used for  FIGS. 1-4 , there is a distinction between the engaging or mating of coupler  8 D and boot  9 D of  FIG. 4  as compared to couplers and boots of  FIGS. 1-2 . Thus, descriptions above for couplers  8 A-B and boots  9 A-B may apply to coupler  8 D and boot  8 D, such as with the exceptions of the differences described below. For example, as compared to rings  24  and grooves  25  in  FIG. 1 , and as compared to disc shape  30  and groove  32  of  FIG. 2 , in embodiments shown in  FIG. 3 , coupler  8 D has an outer perimeter  26  with groove  25  and O-ring  39  on the coupler that engage or form a friction seal onto the surface (e.g., smooth) of the inner perimeter  23  of a hard boot  9 D. This may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, coupler  8 D has at least one O-ring  39  around it&#39;s perimeter that engages and seals to corresponding surface of the boot, such as by nominally interfering with (e.g., causing friction when moved with respect to) the corresponding surface. 
     Hard boot  9 D may be made of or may include a metal material such as described above for coupler  8 A. The compliance of the material of boot  9 D, O-ring  39 , and of coupler  8 D may be selected so to ensure a seal between the boot and the coupler. The number of O-rings and grooves, thickness and height of the rings, and thickness and height of the grooves may also be selected so to ensure a seal between the boot and the coupler. 
       FIG. 5A  is a perspective view of another type of boot.  FIG. 5B  is a cross-section view of  FIG. 5A . Although some similar feature numbers are used for  FIGS. 1-2 , there is a distinction between the engaging or mating of boot  9 E of  FIGS. 5A-B  (e.g., and the coupler) as compared to couplers and boots of  FIGS. 1-2 . Thus, descriptions above for couplers and boots of  FIGS. 1-2  may apply to boot  9 E and the coupler, such as with the exceptions of the differences described below. For example, as compared to rings  24  and grooves  25  in  FIG. 1 , and as compared to disc shape  30  and groove  32  of  FIG. 2 , in embodiments shown in  FIGS. 5A-B , boot  9 E includes a hard material, metal ring  40  that is overmolded on the inside surface of the ring (e.g., but not the outside surface of the ring) with soft material  41  that engage or form a friction seal onto the surface (e.g., smooth or grooved) of the outer perimeter of a hard coupler (e.g., coupler  8 A). Boot  9 E may also include rings  24 , such as for engaging grooves  25  in a coupler as noted above. Ring  40  may have slots  42  that provide a rubber/metal interlock (e.g., attachment) between ring  40  and material  41  of the boot. Moreover, ring  40  may provide additional support, constriction towards, and resistance against expansion of the coupler, thus causing a tighter or more forceful seal (e.g., friction) between the boot and coupler. This may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, boot  9 E has at least one ring around it&#39;s perimeter that engage and seal to the coupler, such as by increasing the nominal interference with (e.g., causing friction when moved with respect to) the corresponding coupler surface (e.g., smooth or grooved). 
     Ring  40  may be made of or may include a metal material such as described above for coupler  8 A. Soft material  41  may be made of or may include a metal material such as described above for boot  9 A. The compliance of the material of ring  40 , material  41 , and of the coupler may be selected so to ensure a seal between the boot and the coupler. The number of rings, and thickness and height of the rings may be selected so to ensure a seal between the boot and the coupler. 
       FIG. 6A  is a perspective view of another type of boot.  FIG. 6B  is a cross-section view of  FIG. 6A . Although some similar feature numbers are used for  FIGS. 1-2 ,  5 A-B and  6 A-B, there is a distinction between boot  9 E of  FIGS. 5A-B  as compared to boot  9 F of  FIG. 6A-B . Thus, descriptions above for couplers and boots of  FIGS. 1-2  and  5 A-B may apply to boot  9 F and the coupler, such as with the exceptions of the differences described below. For example, as compared to boot  9 E in  FIG. 5A-B , in embodiments shown in  FIGS. 6A-B , boot  9 F includes a hard material, metal ring  43  that is overmolded on the inside surface and on the outside surface of the ring with soft material  44  that engage or form a friction seal onto the surface (e.g., smooth or grooved) of the outer perimeter of a hard coupler (e.g., coupler  8 A). Boot  9 F may also include rings  24 , such as for engaging grooves  25  in a coupler as noted above. Ring  43  may have slots  45  that provide a rubber/metal interlock (e.g., attachment) between ring  43  and material  44  of the boot. Moreover, ring  43  may function similarly to, and may be made of or may include a similar material as ring  40 . In some cases, ring  43  has a smaller diameter than ring  40 , so that the boot  9 F will be the same size and thickness as boot  9 E, including material  44  on the outside surface of ring  43 . Moreover, material  44  may function similarly to, and may be made of or may include a similar material as material  41 . Thus, boot  9 F may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, boot  9 F has at least one ring that engages and seals to the coupler, such as by increasing the nominal interference with (e.g., causing friction when moved with respect to) the corresponding coupler surface (e.g., smooth or grooved). 
     The compliance of the material of ring  43 , material  44 , and of the coupler may be selected so to ensure a seal between the boot and the coupler. The number of rings, and thickness and height of the rings may be selected so to ensure a seal between the boot and the coupler. 
       FIG. 7A  is a perspective view of another type of boot.  FIG. 7B  is a cross-section view of  FIG. 7A . Although some similar feature numbers are used for  FIGS. 1-2 , there is a distinction between the engaging or mating of boot  9 G of  FIGS. 7A-B  (e.g., and the coupler) as compared to couplers and boots of  FIGS. 1-2 . Thus, descriptions above for couplers and boots of  FIGS. 1-2  may apply to boot  9 G and the coupler, such as with the exceptions of the differences described below. For example, as compared to rings  24  and grooves  25  in  FIG. 1 , and as compared to disc shape  30  and groove  32  of  FIG. 2 , in embodiments shown in  FIGS. 7A-B , boot  9 G includes a ring of hard material  46  around a boot of soft material (e.g., overmolded silicon or rubber) on the inside surface of the ring (e.g., but not the outside surface of the ring) that engages or forms a friction seal onto the surface (e.g., smooth or grooved) of the outer perimeter of a hard coupler (e.g., coupler  8 A with our without a groove  25 ). The ring  46  of hard material (example metal) maintains a high hoop stresses around the outer perimeter of the boot of soft material  47 . Boot  9 G may also have upper ring  48  to restrain or maintain the coupler within the boot. Rings  48  may engage a groove  25  in a coupler as noted above. Ring  46  may have a rubber/metal interlock (e.g., attachment) with material  47  of the boot. Moreover, ring  46  may provide additional support, constriction towards, and resistance against expansion of the coupler, thus causing a tighter or more forceful seal (e.g., friction) between the boot and coupler. This may from a dirt and moisture (and possibly air) tight seal between the boot and the coupler (e.g., by sealing inner perimeter  23  to outer perimeter  26 ). In some embodiments, boot  9 G has ring  46  around it&#39;s perimeter that engage and seal to the coupler, such as by increasing the nominal interference with (e.g., causing friction when moved with respect to) the corresponding coupler surface (e.g., smooth or grooved). 
     Ring  46  may be made of or may include a metal material such as described above for coupler  8 A. Soft material  44  may be made of or may include a metal material such as described above for boot  9 A. The compliance of the material of ring  46 , material  44 , and of the coupler may be selected so to ensure a seal between the boot and the coupler. The thickness and height of the ring may be selected so to ensure a seal between the boot and the coupler. 
     In addition, by forming seals between housing  18 , the boot, the coupler, carrier  2  and microphone  4 , assembly  1  provides a seal with respect to air and dust, as well as sound isolation between the ambient, outside of acoustic aperture  19  and spaces, components and circuitry within housing  18  (e.g., within device  50  of  FIG. 8 ). These seals may provide sufficient sound isolation (e.g., muffling or deadening) between stray or unwanted sound in the ambient, outside of acoustic aperture  19  and spaces, components and circuitry within housing  18 . For example, desired sound waves may be directionally detected within an acceptance angle of the axis of the assembly acoustic apertures, but stray or unwanted sound in the ambient outside of the acceptance angle may be isolated. Such isolation may isolate the audio output of a speaker of the device (e.g., within device  50  of  FIG. 8 ), such as to avoid feedback. Similarly, the softness of boot  9 B may (e.g., material may be selected softness) provide audio vibration isolation between the microphone and the housing, such as to isolate device vibration from the audio output of a speaker causing feedback at the microphone. 
     In some cases, the seals between housing  18 , the boot, the coupler, carrier  2  and microphone  4  prevent ambient moisture and dirt (e.g., dust) from entering the device through aperture  19 . For example, these seals may reduce or eliminate gaps between the ambient and inside of the device. Such gaps may include breaks or openings through pairs of components of the assembly, between the ambient and spaces/components inside of the device housing, other than the acoustic apertures of the assembly and the microphone input. Thus, these seals reduce or eliminate the chances that ambient moisture and dirt will cause unwanted signals (e.g., due to buildup causing unwanted increases or decreases in resistance; shorts or open circuits) or other damage to the microphone or other component and circuitry of the device. For example, this helps avoid moisture and dirt causing the microphone or microphone circuitry to fail or become unusable for converting verbal input by a user or other desired audio signals into electronic audio signals. 
     Also, cosmetic mesh  17  may assist in reducing or filtering out incident dust from entering opening  12 , providing a partial or total dust seal between the ambient, outside of acoustic aperture  19  and opening  12 . Acoustic mesh may also provide such a partial seal. Either or both of these meshes may reduce dust buildup within openings  12 ,  10 , and  3 ; and upon microphone  4 . This may reduce an amount of dust that resides on microphone  4 , improving the response and life of the microphone. 
       FIG. 8  shows an example electronic device  50  and circuitry into which embodiments of the microphone assembly can be installed or integrated. Generally, device  50  may represent a personal computer, business computer or other electronic communications device (e.g., a mobile telephone) that allows two-way real-time conversations (generally referred to as calls) between a near-end user and a far-end user. The particular example of  FIG. 8  is a smart phone having an exterior housing  18  that is shaped and sized to be suitable for use as a mobile telephone handset. Thus, device  50  allows two-way real-time conversations (generally referred to as calls) between a near-end user holding the device  50  against her ear, or using speaker mode, and a far-end user. There may be a connection over one or more communications networks between the device  50  and a counterpart device of the far-end user. Such networks may include a wireless cellular network or a wireless local area network as the first segment, and any one or more of several other types of networks such as transmission control protocol/internet protocol (TCP/IP) internetworks and plain old telephone system networks. 
     For example, the housing may include audio electronic circuitry and other components that interface with the speaker  52  and the microphone assembly  1 , such as during a telephone call. The call may include sending video taken with an imaging system that is synchronized with audio received by microphone assembly  1 . The call may be conducted by establishing a connection through a wireless network, with the help of RF communications circuitry coupled to an antenna that are also integrated in the housing of the device  50 . Device  50  may allow two-way calls between a near-end user whose speech is converted by the microphone of the phone, and a far-end user whose speech is converted by a microphone of the far-end user&#39;s phone (e.g., to perform telephone video conferencing or chatting). 
     Device  50  of  FIG. 8  includes housing  18 , touch screen  56 , microphone assembly  1 , and ear-piece  52 . One or more imaging systems may also be installed into device  50 . For example, device  50  is shown having camera  53 , mounted to capture images of objects below the bottom surface of housing  18 . In some cases, device  50  has camera  54  mounted to capture images of objects above the top surface of housing  18 . It is also possible for device  50  to have both, camera  53  and  54 . Housing  18  of device  50  may include front face  60  and opposing back face  62 , which are joined by sides of the device. For example,  FIG. 8  shows them joined by left side  63 , right side  64 , top  65  and bottom  66 . Front face  60  may include touch screen  56  and may include various materials such as rigid plastic, metal and/or glass. Back face  62 , left side  63 , right side  64 , top  65  and bottom  66  may include various materials such as rigid plastic and/or metal. 
     According to embodiments, one or more of microphone assembly  1  may be installed or integrated into device  50 . During a telephone call, the near-end user may listen to the call using an earpiece speaker  52  located within the housing of the device and that is acoustically coupled to an acoustic aperture formed near the top of the housing. The near-end user&#39;s speech and/or other audio signals may be picked up by microphone assembly  1  (e.g., microphone  4 ) whose acoustic port  7  is aligned with aperture  19 , which may be located along a side of housing  18 . In some cases, assembly  1  (e.g., microphone  4  and opening  12 ) may be facing towards left side  63 , right side  64 , top  65  or bottom  66 . This may include having opening  12  aligned with aperture  19  formed in a surface of left side  63 , right side  64 , top  65  or bottom  66 . 
     For example,  FIG. 8  shows device  50  is shown having microphone assembly  1 , such as an assembly having acoustic aperture  19  to allow audio signals  30  to be received by microphone  4  (e.g., mounted below the bottom surface of housing  18 ). As shown in  FIG. 8 , embodiments may include cosmetic mesh  17  exposed within acoustic aperture  19 . The microphone assembly  1  can have its circuitry in a stand-alone component (e.g., a module including assembly  1  and having electronic connectors); or can have its circuitry incorporated into circuitry of other electronic components of the device. Microphone assembly  1  may be an acoustic-to-electric transducer or sensor that converts sound into an electrical signal. The electrical signal may be stored (e.g., in volatile or non-volatile electronic memory within the device) and/or transmitted via SMS, email, or phonecall by device  50 . 
     A user may interact with the device  50  by way of a touch screen  56  that is formed in the front exterior face or surface of the housing. The touch screen may be an input and display output for the device. The touch screen may be a touch sensor (e.g., those used in a typical touch screen display such as found in an iPhone™ device by Apple Inc., of Cupertino Calif.). As an alternative, embodiments may use a physical keyboard may be together with a display-only screen, as used in earlier cellular phone devices. As another alternative, the housing of the device  50  may have a moveable component, such as a sliding and tilting front panel, or a clamshell structure, instead of the chocolate bar type depicted. 
     In some embodiments of the present invention, device  50  may be described in the general context of a “system” or “electronic audio device”, such as a portable electronic device or mobile phone that includes microphone assembly  1 . Device  50  may include a processor and a memory unit operatively connected to the processor, the memory unit including software computer program instructions for operations of the device.  18 . The processor may be able to execute the software instructions to operate the device. The device may also includes RF communications circuitry coupled to an antenna and the processor, such that the RF communications circuitry is able to communicate telephone calls. In this device, the microphone assembly may be coupled to microphone circuitry, which is coupled to the processor and which processes the electrical audio signal output of the microphone. In some cases, the device has a device housing including a front face, a back face and sides attaching the front face to the back face. The front face may have a touch screen input/output. Also, an opening of the microphone assembly may face and be open to an aperture through one of the sides of the housing (e.g., the bottom or a side). 
     Is it considered that embodiments of microphone assembly  1  can be integrated into a wide variety of electronic devices such as desktop computers, personal digital assistants, personal computers, and other mobile and non-mobile devices (e.g., security systems, and mounted microphones). In some embodiments, microphone assembly  1  is mounted in a bottom edge or side edge of a desktop computer housing; or of mobile device housing, such as of a cell phone, tablet computer, notebook computer, or PDA. 
     The microphone assemblies described herein may be designed and/or sold by electronic device manufacturers, such as manufacturers of a computer, a telephone handset, a “source device” or a “host device” that can detect audio signals as described herein. They may also be designed and/or sold by headset manufacturers, such as manufacturers of an audio headset or other headset having a microphone of a “headset” or “headphone” device that can detect audio signals as described herein. 
     While certain embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the invention is not limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those of ordinary skill in the art. For example, although the microphone assembly has been described in connection with the embodiments of  FIG. 8 , a similar microphone assembly can be integrated into other electronic audio devices such as mobile recorders, and video cameras.

Metadata:
Filing Date: 20111027
Publication Date: 20151208
Grant Date: 20151208
Priority Date: 20111027
Inventors: DAVE RUCHIR M.
COHEN SAWYER ISAAC
WILK CHRISTOPHER
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/086", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/086", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 48172480