PATENT DOCUMENT

Publication Number: US-10595112-B2
Application Number: US-201715829415-A
Country: US
Kind Code: B2

Title: Seamless earbud structures and methods for making the same

Abstract:
Seamless earbud structures and methods for making the same are disclosed. Seamless earbud structures can be constructed using an insert molding construction method, which overmolds a cosmetic material over two sub-enclosures that are mated together. The two sub-enclosures form a housing that can encompass a driver assembly (e.g., woofer and tweeter), a conductor bundle, and provide one or more acoustic volumes. The housing has a non-occluding member and a neck member, and has a seamless or nearly seamless construction. The cosmetic material is insert molded around the housing to provide a smooth and seamless surface disposed around the periphery of the housing.

Claims:
What is claimed is: 
     
       1. An earbud comprising:
 a driver assembly for generating sound; 
 a housing encompassing the driver assembly and having a center plane that is vertically oriented, wherein the center plane is perpendicular to the largest cross-section of the housing, and wherein the center plane extends through the center of the largest cross-section of the housing; and 
 a port provided as an opening through a wall of the housing for directing the sound from the driver assembly out from the housing, wherein the port is fixed and is offset with respect to the center plane of the housing. 
 
     
     
       2. The earbud of  claim 1 , wherein:
 the housing comprises:
 a first sub-enclosure; and 
 a second sub-enclosure coupled to the first sub-enclosure; 
 
 the first sub-enclosure and a first portion of the second sub-enclosure provide an internal volume; and 
 the driver assembly is positioned within the internal volume. 
 
     
     
       3. The earbud of  claim 2 , wherein a second portion of the second sub-enclosure provides a neck member that extends away from the internal volume along a neck axis. 
     
     
       4. The earbud of  claim 3 , wherein:
 the port is provided as the opening through the wall of the housing for directing the sound from the driver assembly out from the housing in a direction; and 
 a line comprises the direction. 
 
     
     
       5. The earbud of  claim 3 , wherein:
 the opening lies in a plane; 
 a line is perpendicular to the plane; and 
 the line intersects the opening. 
 
     
     
       6. The earbud of  claim 3 , wherein:
 the center plane is distinct from the neck member; and 
 the center plane is distinct from the opening. 
 
     
     
       7. An earbud comprising:
 a first sub-enclosure structure; and 
 a second sub-enclosure structure that is mated with the first sub-enclosure structure for defining a housing, wherein:
 the first sub-enclosure structure and a first portion of the second sub-enclosure structure define a non-occluding portion of the housing; 
 the non-occluding portion of the housing defines a volume operative to hold a driver assembly; 
 a second portion of the second sub-enclosure structure defines a neck portion of the housing that extends away from the volume along a neck axis; 
 an opening through an external surface of a wall of the first sub-enclosure structure of the non-occluding portion of the housing is fixed and lies in a plane; 
 a line is perpendicular to the plane; 
 the line intersects the opening; and 
 the line is offset from a center plane of the first portion, wherein the center plane is vertically oriented and perpendicular to the largest cross-section of the first portion, and wherein the center plane extends through the center of the largest cross-section of the first portion. 
 
 
     
     
       8. The earbud of  claim 7 , wherein:
 the earbud further comprises a component covering at least a portion of the housing; and 
 the at least a portion of the housing comprises at least a portion of a junction between the mated first and second sub-enclosure structures of the housing. 
 
     
     
       9. The earbud of  claim 8 , wherein the at least a portion of the housing comprises the entirety of the junction between the mated first and second sub-enclosure structures of the housing. 
     
     
       10. The earbud of  claim 7 , wherein the non-occluding portion of the housing defines a shape that is operative to fit in an ear of a user in a non-occluding manner. 
     
     
       11. The earbud of  claim 10 , wherein, when the shape is fit in the ear of the user when the volume holds the driver assembly, the opening is operative to direct sound generated by the driver assembly out from the volume and into an ear canal of the ear of the user. 
     
     
       12. The earbud of  claim 7 , wherein the neck portion is operative to pass a cable into the volume. 
     
     
       13. An earbud comprising:
 a first sub-enclosure structure; and 
 a second sub-enclosure structure that is mated with the first sub-enclosure structure for defining a housing, wherein:
 the first sub-enclosure structure and a first portion of the second sub-enclosure structure define a non-occluding portion of the housing; 
 the non-occluding portion of the housing defines a volume operative to hold a driver assembly; 
 a second portion of the second sub-enclosure structure defines a neck portion of the housing that extends away from the volume; and 
 an opening through an external surface of the first sub-enclosure structure for directing sound from the driver assembly out from the volume, wherein the opening lines in a plane; 
 a line is perpendicular to the plane; 
 the line intersects the opening; and 
 the line is offset from a center plane of the first portion, wherein the center plane is vertically oriented and perpendicular to the largest cross-section of the first portion, and wherein the center plane extends through the center of the largest cross-section of the first portion. 
 
 
     
     
       14. The earbud of  claim 13 , wherein:
 the neck portion of the housing extends away from the volume along a neck axis; and 
 the opening is configured to direct the sound from the driver assembly out from the volume in a direction. 
 
     
     
       15. The earbud of  claim 13 , wherein:
 the neck portion of the housing extends away from the volume along a neck axis.

Description:
This application is a continuation of U.S. patent application Ser. No. 15/006,046, filed Jan. 25, 2016 (now U.S. Pat. No. 9,838,770), which is a continuation of U.S. application Ser. No. 14/626,727, filed Feb. 19, 2015 (now abandoned), which is a continuation of U.S. application Ser. No. 13/251,002, filed Sep. 30, 2011 (now U.S. Pat. No. 8,965,030), which claims the benefit of U.S. Provisional Application No. 61/453,074, filed Mar. 15, 2011. Each of these earlier applications is incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     Wired headsets are commonly used with many portable electronic devices such as portable music players and mobile phones. Headsets can include non-cable components such as a jack, headphones, and/or a microphone and one or more cables that interconnect the non-cable components. The headphones exist in many different form factors such as over-the-ear headphones or as in-the-ear or in-the-canal earbuds. 
     SUMMARY 
     Seamless earbud structures and methods for making the same are disclosed. Seamless earbud structures can be constructed using an insert molding construction method, which overmolds a cosmetic material over two sub-enclosures that are mated together. The two sub-enclosures form a housing that can encompass a driver assembly (e.g., woofer and tweeter), a conductor bundle, and provide one or more acoustic volumes. The housing has a non-occluding member and a neck member, and has a seamless or nearly seamless construction. The cosmetic material is insert molded around the housing to provide a smooth and seamless surface disposed around the periphery of the housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other aspects and advantages of the invention will become more apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  shows an illustrative perspective view of an earbud in accordance with an embodiment of the invention; 
         FIGS. 2-2C  show illustrative cross-sectional views of the earbud of  FIG. 1  in accordance with an embodiment of the invention; 
         FIG. 3  shows several illustrative views of another earbud in accordance with an embodiment of the invention; 
         FIG. 4  shows an illustrative insert molding process for making an earbud in accordance with embodiments of the invention; and 
         FIGS. 5A-H  show different illustrative views of an insert molded earbud at different stages of the process of  FIG. 4  in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Headphones or earbuds for use in headsets are disclosed. Earbuds according to embodiments of this invention include a non-occluding housing having a directional port offset with respect to a center axis of the earbud. The housing can have an asymmetric shape amenable to in-the-ear retention. In addition, the earbuds can be constructed to have a seamless finish even though two or more parts are joined together to form part of the earbud. As will be explained in more detail below, the earbuds can be constructed using an insert molding construction method, which overmolds a cosmetic material over two sub-enclosures that are mated together. Other construction methods for making earbuds include techniques for welding or bonding two halves of an earbud together, and then de-flashing and polishing the earbud to obtain the desired aesthetics. 
       FIG. 1  shows an illustrative perspective view of earbud  100  in accordance with an embodiment of the invention. As shown, earbud  100  can include non-occluding member  110 , directional port  112 , filter  114 , neck member  120 , strain relief member  130 , and conductor bundle  140 . Earbud  100  can also include a driver assembly (not shown) for generating sound. The driver assembly can include, for example, a woofer and a tweeter. 
     Non-occluding member  110  is designed to fit in the ear of a user in a non-occluding manner. Non-occluding earbuds are generally designed not to form an airtight seal between the ear and the outer surface of the earbud. However, depending on the size of the user&#39;s ear, there may be instances when the earbud does form an airtight seal with the user&#39;s ear. By way of contrast, occluding earbuds are generally designed to fit inside of the user&#39;s ear canal and form a substantially perfect airtight seal. 
     Referring now to  FIG. 2 , the shape of non-occluding member  110  is discussed.  FIG. 2  shows two illustrative perspective views of earbud  100 , one shown at zero degrees and the other shown rotated at forty-five degrees.  FIGS. 2A-2C  show illustrative cross-sectional views taken along planes A-A, B-B, and C-C, respectively, of the 0° perspective view and the 45° perspective view of earbud  100 . Each of planes A, B, and C are orthogonal to each other and plane B coincides with a center axis of earbud  100 . The cross-sectional views of  FIGS. 2A-2C  show that that the shape of earbud  100  is irregular or asymmetric along each cross-section. 
     In addition, assuming plane B coincides with a center axis of earbud  100 , directional port  112  is located offset with respect to the center axis. Directional port  112  is offset so that when earbud  100  is placed in a user&#39;s ear, directional port  112  is positioned to direct sound directly into the user&#39;s ear canal. 
       FIG. 3  shows several illustrative views of earbud  300  in accordance with an embodiment of the invention. In particular,  FIG. 3  shows a side, front, top, and perspective views of earbud  300 . As shown, earbud  300  is asymmetrically shaped along at least two orthogonal axes (e.g., at least two of orthogonal axes X, Y, and Z). In addition, directional port  312  is positioned offset with respect to center axis  350 . Earbud  300  includes non-occluding member  310 , directional port  312 , neck member  320 , and strain relief member  330 . 
     The earbud embodiments shown in  FIGS. 1-3  each show earbuds that exhibit desired cosmetic finishes. That is, the earbuds are seamless and appear to have a single piece construction even though they are constructed with multiple parts. Because earbuds according to the invention are irregularly shaped and have varying contours, it is difficult to mass produce such earbuds with the desired cosmetic finish. Referring now to  FIGS. 4 and 5A -H, a process for manufacturing an earbud using an insert molding process according to an embodiment of the invention is discussed. In an insert molding process, a housing (which includes the non-occluding member, neck member, and any components contained therein (e.g., driver assembly)) is overmolded with a cosmetic material. The housing provides the desired shape such as the earbud shape shown in  FIGS. 1-3  and the overmold material provides the seamless cosmetic finish. 
       FIG. 4  shows an illustrative insert molding process  400  for making an earbud according to an embodiment of the invention.  FIGS. 5A-H  show different illustrative views of an earbud at different stages of process  400 . Reference will be made to  FIG. 4  and  FIGS. 5A-H  during discussion of process  400 . Beginning with step  410 , a first sub-enclosure is provided that, when mated with a second sub-enclosure, forms a housing including non-occluding and neck members.  FIG. 5A  shows first sub-enclosure  510 . 
     First sub-enclosure  510  can be constructed using any suitable material such as metal or plastic and is configured to mate with second sub-enclosure  530  (shown in  FIG. 5E ). Second sub-enclosure  530  can also be constructed using any suitable material such as metal or plastic. When enclosures  510  and  530  are mated, they form a housing  540  having non-occluding member  542  and neck member  544 . Housing  540  can contain driver assembly  520  ( FIG. 5D ), a portion of conductor bundle  550  ( FIGS. 5C and 5D ), and other components (not shown). 
     First sub-enclosure  510  can include directional port  512 , filter engagement region  514 , driver assembly engagement region  515 , dampener  516 , other internal structures (not shown). Filter engagement region  514  is operative to receive filter assembly  517  (shown in  FIG. 5B ). Driver assembly engagement region  515  can be a structure that holds driver assembly  520  in place during assembly of the earbud. For example, region  515  can be a groove or slot into which drive assembly  520  can be inserted. Dampener  516  is optional but may be included to dampen low frequency vibrations that can be caused by conductor bundle movement. 
     Although not shown in  FIGS. 5A-H , second sub-enclosure  530  can include internal features such as a driver assembly engagement region or one or more acoustic volume members. Sub-enclosure  510  can also include one or more acoustic volume members (not shown). The acoustic volume members can define the front and back volumes of the earbud. The front volume can be the portion of the earbud existing between driver assembly  520  and port  512  and the back volume can be the portion of the earbud existing behind driver assembly  520 . If desired, a port may exist in the back volume. 
     At step  420 , a conductor bundle is coupled to the first sub-enclosure. Conductor bundle  550  can include any suitable number of conductors for enabling conduction of signals and/or power. Conductor bundle  550  can also include one or more anti-tangle rods such as nitinol that resist plastic deformation. All or a portion of conductor bundle  550  can be coupled to sub-enclosure  510 . In addition, a portion of conductor bundle  550  is coupled to driver assembly  520 . In some embodiments, conductor bundle  550  can be slid through a conductor bundle engagement member  518  of dampener  516 . 
     At step  430 , a driver assembly is coupled to the first sub-enclosure. For example, driver assembly  520  can be inserted into driver retention member  515 , which holds driver assembly  520  in place during assembly. Driver assembly  520  can be welded (e.g., laser welded) or glued to sub-enclosure  510 . If desired, additional structures (e.g., acoustic volume member) or circuitry can be mounted within sub-enclosure  510  before step  440 . 
     At step  440 , the second sub-enclosure is mated to the first sub-enclosure. The first and second sub-enclosures may be secured using an adhesive, weld, or chemical bond. In some embodiments, a hermetic seal may exist between the first and second sub-enclosures. When sub-enclosures  510  and  530  are mated together, they provide housing  540 , which includes non-occluding member  542  and neck member  544 . An advantage of constructing an earbud with first and second sub-enclosures  510  and  530  is that the flushness of the mating fit can be tightly controlled. For example, the fit between sub-enclosures  510  and  530  can be such that any deviation between the two enclosures at any point along the junction is less than 0.04 mm, or more particularly, less than 0.02 mm. Such a tight tolerance fit enables a uniform coating of material to be molded onto the housing (step  450 ) and polished (step  460 ) to provide a smooth and seamless earbud. 
     Material  560  may be injection molded around housing  540 , as shown in  FIG. 5F . In an injection mold, one or more shutoffs are used to limit flow of injected plastic. A shutoff can be placed near the end of port  512  and another can be placed near the base of neck member  544 . The material may be fed near the base of neck member  544  to minimize any potential for cosmetic blemishes of non-occluding member  542 . 
     Any suitable polishing techniques may be used to polish the injection molded material. For example, a vapor polish, a flame polish, or a mechanical polish may be applied to buff the cosmetic material, as shown in  FIG. 5G . In a vapor polish, a boiling solvent etches away a portion of the material applied to the earbud.  FIG. 5H  shows earbud  580  with strain relief member  590  molded around a portion of conductor bundle  550 . 
     It should be understood that steps in  FIG. 4  are merely illustrative. Any of the steps may be removed, modified, or combined, and any additional steps may be added, without departing from the scope of the invention. For example, a step may be added for coupling a filter assembly to the first sub-enclosure. The filter assembly can be added before or after application of the injected material. As another example, polishing step  460  can be replaced with a painting step, which applies a uniform coat of paint to the cosmetic material. 
     The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20171201
Publication Date: 20200317
Grant Date: 20200317
Priority Date: 20110315
Inventors: AASE, JONATHAN S.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1075", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2460/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1075", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2460/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1066", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2460/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1066", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49176", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2460/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2460/09", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1066", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1075", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 46828481