PATENT DOCUMENT

Publication Number: US-9237389-B2
Application Number: US-201313892906-A
Country: US
Kind Code: B2

Title: Audio port configuration for compact electronic devices

Abstract:
A portable electronic device that provides compact configurations for audio elements are disclosed. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). In one embodiment, an audio element can be mounted on or coupled to an intermediate structure (e.g., a flexible electrical substrate) having an opening therein to allow audio sound to pass there through. In another embodiment, an audio chamber can be formed to assist in directing audio sound between an opening an outer housing and a flexible electronic substrate to which the audio element is mounted or coupled thereto. In still another embodiment, a barrier, such as a mesh barrier, can be provided in an opening of an outer housing so that undesired foreign substances can be blocked from further entry into the opening in the outer housing.

Claims:
What is claimed is: 
     
       1. A portable electronic device, comprising: a housing having an opening;
 an audio element provided internal to the housing, having a rear surface positioned opposite to the opening and attached to a structure, the audio element being disposed between the structure and the opening of the housing; wherein the structure is internal to the housing and forms a back volume for the audio element; 
 an electronic substrate disposed between the audio element and the housing, operably coupled to the audio element, and having an opening there through; and 
 an audio chamber disposed between the audio element and the housing and acoustically coupling the audio element with the opening of the housing. 
 
     
     
       2. The portable electronic device of  claim 1 , wherein the structure is a wall of the housing opposite to a wall having the opening of the housing. 
     
     
       3. The portable electronic device of  claim 2 , wherein the audio element is attached to the structure by a layer of material that acoustically couples the audio element to the structure. 
     
     
       4. The portable electronic device of  claim 3 , wherein the layer of material includes a foam and an adhesive. 
     
     
       5. The portable electronic device of  claim 1 , wherein the audio chamber comprises an audio boot having an upper boot portion and a lower boot portion. 
     
     
       6. The portable electronic device of  claim 5 , wherein the upper boot portion is a more rigid than the lower boot portion, and the lower boot portion is more compliant than the upper boot portion. 
     
     
       7. The portable electronic device of  claim 1 , wherein the electronic substrate is a flexible electronic substrate. 
     
     
       8. The portable electronic device of  claim 1 , wherein the audio element comprises a driver or a receiver. 
     
     
       9. The portable electronic device of  claim 1 , wherein the audio element comprises a speaker driver assembly. 
     
     
       10. The portable electronic device of  claim 1 , wherein the audio element comprises a microphone assembly. 
     
     
       11. A portable electronic device, comprising: a first wall having an opening; a second wall opposite to the first wall;
 an audio element having a rear surface positioned opposite to the opening in the first wall and attached to the second wall, wherein the audio element is disposed between the second wall and the first wall; 
 a flexible electronic substrate disposed between the audio element and first wall and operatively coupled to the audio element, the flexible electronic substrate having an opening there through; an inner structure internal to the housing, wherein the second wall forms a wall of the inner structure and wherein the inner structure forms a back volume for the audio element. 
 
     
     
       12. The portable electronic device of  claim 11 , wherein the flexible electronic substrate is attached to the audio element. 
     
     
       13. The portable electronic device of  claim 11 , further comprising a housing, wherein the first wall forms a wall of the housing. 
     
     
       14. The portable electronic device of  claim 11 , wherein the second wall forms another wall of the housing. 
     
     
       15. The portable electronic device of  claim 11 , further comprising an audio chamber disposed between the flexible electronic substrate and the first wall and acoustically coupling the audio element with the opening in the first wall. 
     
     
       16. The portable electronic device of  claim 15 , wherein the audio chamber comprises an audio boot having an upper boot portion and a lower boot portion. 
     
     
       17. The portable electronic device of  claim 16 , wherein the upper boot portion is a more rigid than the lower boot portion, and the lower boot portion is more compliant than the upper boot portion.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation patent application of U.S. patent application Ser. No. 12/794,561, filed Jun. 4, 2010 and titled “Audio Port Configuration for Compact Electronic Devices,” which claims the benefit of U.S. Provisional Patent Application No. 61/325,803, filed Apr. 19, 2010 and titled “Audio Port Configuration for Compact Electronic Devices,” the disclosures of which are hereby incorporated herein in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to audio ports for electronic devices and, more particularly, for audio port configurations for compact electronic devices. 
     2. Description of the Related Art 
     Today, it is popular for portable electronic devices, such as notebook computers, netbook computers, portable digital assistants (PDAs), smart phones, digital audio players (e.g., MP3 players) and the like, include at least one speaker to produce audio sound output and at least one microphone to receive audio sound input. 
     Portable electronic devices often provide audio jacks (i.e., audio connectors) that facilitate connection with headsets or headphones which provide personal external speakers for their users. Alternatively or additionally, portable electronic devices can provide one or more internal speakers that are able to be utilized for producing audio sound. Similarly, portable electronic devices can have a microphone jack that facilitates connection with a microphone which can be externally provided for a user. Alternatively or additionally, portable electronic device can provide one or more internal microphones that are able to be used to pickup (i.e., receive) audio sound. 
     There is, however, an ongoing need to make portable electronic devices smaller and thinner. As portable electronic devices get smaller and thinner, there are increased difficulties in providing the same or greater functionality in a smaller area. With respect to audio sound, a portable electronic device can utilize at least one or two speakers and one or more microphones provided internal to the housing of the portable electronic device. Unfortunately, given the area constraints imposed on many portable electronic devices, it is increasingly difficult to provide high-quality audio sound output and pickup without hindering the ability to make portable electronic devices smaller and thinner. Consequently, there is a need for improved approaches to provide high-quality audio sound output and/or pickup from portable electronic devices as they get smaller and thinner. 
     SUMMARY 
     The invention pertains to a portable electronic device that provides compact configurations for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). In one embodiment, an audio element can be mounted on or coupled to an intermediate structure (e.g., a flexible electrical substrate) having an opening therein to allow audio sound to pass there through. In another embodiment, an audio chamber can be formed to assist in directing audio sound between an opening an outer housing and a flexible electronic substrate to which the audio element is mounted or coupled thereto. In still another embodiment, a barrier, such as a mesh barrier, can be provided in an opening of an outer housing so that undesired foreign substances can be blocked from further entry into the opening in the outer housing. 
     The invention can be implemented in numerous ways, including as a method, system, device, or apparatus. Several embodiments of the invention are discussed below. 
     According to one embodiment, a portable electronic device can include a housing having an opening. The portable electronic device can also include an intermediate structure provided internal to the housing and having an opening there through. Still further, the portable electronic device can also include an audio element. The audio element can be secured to a first surface of the intermediate structure such that the audio element is acoustically coupled to the opening in the intermediate structure. 
     According to another embodiment, a portable electronic device can include a housing having an opening. The portable electronic device can also include an intermediate structure provided internal to the housing and having an opening there through. In addition, the portable electronic device can include an audio element. The audio element can be secured to a first surface of the intermediate structure such that the audio element is acoustically coupled to the opening in the housing by way of the opening in the intermediate structure. The portable electronic device can further include an audio chamber acoustically coupled to a second surface of the intermediate structure. 
     According to still another embodiment, a portable electronic device can include a housing having an opening. The portable electronic device can also include a flexible electrical substrate having an opening there through. Still further, the portable electronic device can also include an audio assembly. The audio assembly being secured to a first surface of the flexible electrical substrate such that the audio assembly is provided over the opening in the flexible electrical substrate. 
     According to yet still another embodiment, a portable electronic device can include a housing including an opening for emitting audio sound. The portable electronic device can also include a mesh barrier assembly configured to be inserted into the opening of the housing of the portable electronic device. The mesh barrier assembly can include at least a mesh screen and a support structure configured to support the mesh screen. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  is a perspective diagram of a portable electronic device according to one embodiment. 
         FIG. 2A  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIG. 2B  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIG. 3A  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIG. 3B  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIG. 3C  is a partial cross-sectional diagram of a portable electronic device according to another embodiment. 
         FIG. 4A  is a cross-sectional view of a speaker driver according to one embodiment. 
         FIG. 4B  is a cross-sectional view of a receiver according to one embodiment. 
         FIG. 5A  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIG. 5B  is a partial cross-sectional diagram of a portable electronic device according to one embodiment. 
         FIGS. 6A-6C  are diagrams illustrating insertion of a mesh barrier assembly into an opening in a housing of a portable electronic device according to one embodiment. 
         FIG. 7  is a top view of a portion of a flexible substrate according to one embodiment. 
     
    
    
     It should be noted that  FIGS. 2A-7  are not drawn to scale. Instead, these figures are enlarged so that features are more readily visible. 
     DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION 
     The invention pertains to a portable electronic device that provides compact configurations for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). In one embodiment, an audio element can be mounted on or coupled to an intermediate structure (e.g., a flexible electrical substrate) having an opening therein to allow audio sound to pass there through. In another embodiment, an audio chamber can be formed to assist in directing audio sound between an opening an outer housing and a flexible electronic substrate to which the audio element is mounted or coupled thereto. In still another embodiment, a barrier, such as a mesh barrier, can be provided in an opening of an outer housing so that undesired foreign substances can be blocked from further entry into the opening in the outer housing. 
     Exemplary embodiments of the invention 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 as the invention extends beyond these limited embodiments. 
       FIG. 1  is a perspective diagram of a portable electronic device  100  according to one embodiment. The portable electronic device  100  is a representative illustration for a portable electronic device. However, it should be understood that, in other embodiments, the size, scale, shape, configuration and/or appearance of the portable electronic device  100  can vary widely. 
     The portable electronic device  100  includes a housing  102  that provides an exterior surface for the portable electronic device  100 . The portable electronic device  100  provides one or more functional capabilities that can be utilized by its user. In so doing, the portable electronic device can include at least one input/output component  104 . 
     The user input/output component  104  typically includes one or more user input devices and/or one or more output device. The one or more user input devices can allow the user to interact with the portable electronic device. The one or more output devices can provide outputs from the portable electronic device to the user or another device. The input/output component  104  can, for example, pertain to one or more of a display, a touch screen, a touchpad, a keypad, a button, a dial, and etc. For example, the input/output component  104  can provide a display and a touch screen combination, with the display providing output capability and the touch screen providing input capability. 
     The portable electronic device  100  can also include an audio circuit  106 . The audio circuit  106  is typically provided internal to the housing  102  of the portable electronic device  100 . The audio circuit  106  can operate to produce audio signals that can be supplied to one or more speakers internal to the housing  102  of the portable electronic device  100 . The one or more speakers, in response to the audio signals, can produce audio sound that can be directed (e.g., by way of one or more acoustic chambers) to one or more audio output openings  108  in the housing  102  of the portable electronic device  100 . In one embodiment, each of the one or more audio output openings  108  can include a mesh cover  110  that serves to protect foreign matter from entering into the housing  102  of the portable electronic device  100  by way of the audio output opening  108 . 
     The audio circuit  106  can also operate to receive audio signals that are picked-up by one or more microphones internal to the housing  102  of the portable electronic device  100 . The one or more microphones can pick-up audio sounds that are received (e.g., directly or by way of one or more acoustic chambers) via an audio input opening  112  in the housing  102  of the portable electronic device  100 . In general, the portable electronic device  100  can place the audio input opening  112  in any of various location. However, in this embodiment, the audio input opening  112  is provided on a side of the housing  102 . In one embodiment, the audio input opening  112  can also include a mesh cover (not shown) that serves to protect foreign matter from entering into the housing  102  of the portable electronic device  100  by way of the audio input opening  112 . 
     The housing  102  of the portable electronic device  100  can also include an external connection port  114 . The external connection port  114  allows the portable electronic device  100  to be connected to a host device (e.g., personal computer) or other electronic devices (e.g., docking station), so as to exchange data or to charge a battery (not shown) utilized by the portable electronic device  100 . 
     The portable electronic device  100  can also include a receiver opening  116  and a button opening  118 . The receiver opening  116  can be provided adjacent an internal receiver (e.g., speaker) that can provide audio output to a user of the portable electronic device  100 . The button opening  118  can be provided adjacent a button that allows the user to interact with the portable electronic device  100 . Although the receiver opening  116  and the button opening can be provided in the translucent face  105 , it should be understood that these components could be provided elsewhere in the portable electronic device. For example, these components could be provided at the side of the portable electronic device  100 . The translucent face  105  can be a glass sheet or a plastic sheet. The translucent face  105  provides a front face for the housing. The translucent face is also thin, such as having a thickness of less than 1 millimeter. 
     The portable electronic device  100  can include any suitable type of electronic device having a display. For example, the portable electronic device  100  can be a laptop, tablet computer, media player, phone, GPS unit, remote control, personal digital assistant (PDA), and the like, and devices combining some or all of this functionality. Depending on the capabilities of the portable electronic device, internal to the portable electronic device  100  are various electrical components that serve support the device capabilities. The electronic components include one or more of integrated circuit(s), electronic substrate(s) (flex circuits, printed circuit boards), wireless transceiver(s), battery(s), microphone(s), speaker(s), display circuitry(s), touch circuitry(s), and connectors (e.g., ports), user input devices (button, switches, etc.). 
     According to one aspect, a portable electronic device can be provided with a compact configuration for audio elements. The audio elements can be drivers (e.g., speakers) or receivers (e.g., microphones). In one embodiment, an audio element can be mounted on or coupled to an intermediate structure (e.g., a flexible electrical substrate) having an opening therein to allow audio sound to pass there through. In another embodiment, an audio chamber can be formed to assist in directing audio sound between an opening an outer housing and a flexible electronic substrate to which the audio element is mounted or coupled thereto. 
       FIG. 2A  is a partial cross-sectional diagram of a portable electronic device  200  according to one embodiment. The portable electronic device  200  includes a housing  202  for the portable electronic device  300 . The housing  202  has an opening  204  that allows audio sound to be emitted or received from the portable electronic device  200 . The portable electronic device includes an audio element  206  provided internal to the housing  202  for the portable electronic device  200 . The audio element  206  can represent a speaker driver (e.g., speaker) and/or a receiver (e.g., microphone). The speaker driver  206  upon controlled activation produces audio sound that can be directed out of the opening  204  of the housing  202 . For example, the audio sound can be associated with playback of digital media asset, such as a video file (e.g., movie), an audio file (e.g., music or podcast), etc., by the portable electronic device  200 . As another example, in the case of the speaker driver  206 , the audio sound can be associated with a user, such as a voice conversation, using the portable electronic device  200  as a wireless telephone. As an example, in the case of the receiver  206 , the audio sound can be picked-up via the opening  204  if the housing  202 . The sound, in this example, can be environment or can be audio sound (e.g., voice communications) associated with a user. 
     In the low-profile design for the portable electronic device  200 , the compactness of the portable electronic device  200  is of design importance. Consequently, placement of the audio element  206  within the housing  202  for the portable electronic device  200  is managed such that the overall size and/or thickness of the portable electronic device  200  is able to remain compact (e.g., thin). 
     As shown in  FIG. 2A , the audio element  206  can be provided proximate to the opening  204  in the housing  202 . Although the audio element  206  can be provided adjacent to the opening  204 , there may be one or more intermediate structures. An audio chamber can be established at least between the audio element  206  and the opening  204 . In the embodiment illustrated in  FIG. 2A , the audio chamber can extend from the speaker driver  206  to the opening  204  in the housing  202 . As such, the audio chamber passes through an opening  207  within a flexible electronic substrate  208 . The flexible electrical substrate  208  is, for example, a flex circuit. The flexible electrical substrate  208  can provide electrical traces, pads, and the like that support electronic devices and/or electrical interconnections between electronic devices. The portable electronic device  200  can include a printed circuit board (PCB) (not shown) and the flexible electronic substrate  208  can couple to the PCB. The audio element  206  can be coupled to the flexible electrical substrate  208  such that the speaker driver  206  is acoustically coupled to audio chamber that directs audio sound to the opening  204  in the housing  202 . In one implementation, the audio element  206  can be acoustically sealed to a first surface of the flexible electrical substrate  208  by a seal  210 . The seal  210  can, for example, by provided by a layer of adhesive, a compliant gasket (e.g., form gasket), or solder. In the case where a gasket is used, an adhesive can be used to adhere the seal  210  to the first surface of the flexible electrical substrate  208  as well as to the audio element  206 . In addition, in one implementation, a second surface of the flexible electrical substrate  208  can be adhered to the housing  202 . For example, the flexible electrical substrate  208  can be adhered to the housing  202  through use of a thin layer of adhesive  212  provided between the second surface of the flexible electrical substrate  208  and the housing  210 . The opening  207  in the flexible electrical substrate  208  facilitates mounting of the audio element  206  to the flexible electrical substrate  208 , whereby the audio element  206  can emit or receive sound through the opening  207  in the flexible electrical substrate  208  so that the sound being emitted or received can pass through the opening  204  in the housing  202 . 
       FIG. 2B  is a partial cross-sectional diagram of a portable electronic device  250  according to one embodiment. The portable electronic device  250  is generally similar to the portable electronic device  200  illustrated in  FIG. 2A . However, the portable electronic device  250  further includes a mesh screen  252  provided in the opening  204  of the housing  202 . The mesh screen  252  serves as a device that does not substantially impede audio sound through the opening  204 , but does provide a barrier that impedes foreign substances (e.g., dust, dirt) from passing through the opening  207 . The mesh screen  252  can be formed from any of a variety of materials, including fabrics or fibers, either natural or synthetic. As one particular example, the mesh screen  252  can be formed of nylon fibers. Further discussion provided below describes different embodiments by which the mesh screen  252  can be provided and/or retained within the opening  204 . In some embodiments, the mesh screen  252  can also be removable from the opening  204  of the housing  202 . By being removable, the screen mesh  252  and any accumulated foreign substances can be cleaned or removed, and thereafter the screen mesh  252  can be re-inserted. 
       FIG. 3A  is a partial cross-sectional diagram of a portable electronic device  300  according to one embodiment. The portable electronic device  300  includes a housing  302  for the portable electronic device  300 . The housing  302  has an opening  304  that allows audio sound to be emitted from the portable electronic device  300 . The portable electronic device  300  includes an audio element  306  provided internal to the housing  302  for the portable electronic device  300 . The audio element  306  can represent a speaker driver (e.g., speaker) and/or a receiver (e.g., microphone). The speaker driver  306  upon controlled activation produces audio sound that can be directed out of the opening  304  of the housing  302 . For example, the audio sound can be associated with playback of digital media asset, such as a video file (e.g., movie), an audio file (e.g., music or podcast), etc., by the portable electronic device  300 . As another example, in the case of the speaker driver  306 , the audio sound can be associated with a user, such as a voice conversation, using the portable electronic device  300  as a wireless telephone. As an example, in the case of the receiver  306 , the audio sound can be picked-up via the opening  304  if the housing  302 . The sound, in this example, can be environment or can be audio sound (e.g., voice communications) associated with a user. 
     In the low-profile design for the portable electronic device  300 , the compactness of the portable electronic device  300  is of design importance. Consequently, placement of the audio element  306  within the housing  302  for the portable electronic device  300  is managed such that the overall size and/or thickness of the portable electronic device  300  is able to remain compact (e.g., thin). 
     As shown in  FIG. 3A , an audio chamber can be established between the speaker driver  206  and the opening  204 . The audio element  306  can be acoustically coupled to the opening  304  in the housing  302  by the audio chamber. In the embodiment illustrated in  FIG. 3A , the audio chamber can extend from the speaker driver  306  to the opening  304  in the housing  302 . As such, the audio chamber passes through an opening  307  within a flexible electronic substrate  308 . The flexible electrical substrate  308  is, for example, a flex circuit. The flexible electrical substrate  308  can provide electrical traces, pads, vias, and the like that support electronic devices and/or electrical interconnections between electronic devices. The portable electronic device  300  can include a printed circuit board (PCB) (not shown) and the flexible electronic substrate  308  can couple to the PCB. The audio element  306  can be coupled to the flexible electrical substrate  308  such that the speaker driver  306  is acoustically coupled to audio chamber that directs audio sound to the opening  304  in the housing  302 . In one implementation, the audio element  306  can be acoustically sealed to a first surface of the flexible electrical substrate  308  by a seal  310 . The seal  310  can, for example, by provided by a layer of adhesive, a compliant gasket (e.g., form gasket), or solder. In the case where a gasket is used, an adhesive can be used to adhere the seal  310  to the first surface of the flexible electrical substrate  308  as well as to the audio element  306 . 
     To support the audio chamber, the portable electronic device  300  can also include an audio boot  312 . The audio boot  312  can include an upper boot portion  312   a  and a lower boot portion  312   b . In one implementation, the upper boot portion  312   a  is a rigid member, and the lower boot portion  312   b  is a compliant member. The rigidity of the upper boot member  312   a  and the compliance of the lower boot member  312   b  are relative to one another. The audio boot  312  is normally a single structure and can be formed with a molding process with respect to elastomers (e.g., plastics (including thermoplastics elastomers), rubber or foams), such as nylon, silicone, Acrylonitrile Butadiene Styrene (ABS), or polypropylene. For example, a co-molding or overmolding process can be performed to integrally form the audio boot  312  having the upper boot portion  312   a  and the lower boot portion  312   b . The upper boot member  312   a  can be adhered to a second surface of the flexible electronic substrate  308 . For example, an adhesive layer  314  can be provided between a second surface of the flexible electrical substrate  308  and the upper boot member  312   a . The lower boot portion  312   b  can be provided adjacent the opening  304  in the housing  302 . Specifically, the portable electronic device  300  can also include inner structures  316   a ,  316   b . The inner structures  316   a ,  316   b  can be adhered to the housing  302 . Adherence member  318   a ,  318   b  can be provided to adhere the inner structures  316   a ,  316   b  to the housing  302 . The lower boot member  312   b  can also seal against the inner structures  316   a ,  316   b  and/or support the audio boot  312 . 
     The opening  307  in the flexible electrical substrate  308  and the audio boot  312  both facilitate providing the audio chamber. The audio element  306  can emit or receive sound through the opening  307  in the flexible electrical substrate  308  and then through the audio chamber so that the sound being emitted or received by the audio element  306  can pass through the opening  304  in the housing  302 . 
       FIG. 3B  is a partial cross-sectional diagram of a portable electronic device  350  according to one embodiment. The portable electronic device  350  is generally similar to the portable electronic device  300  illustrated in  FIG. 3A . However, the portable electronic device  350  further illustrates a device structure  352 . The device structure  352  can represent an inner structure internal to the portable electronic device  350 . Alternatively, the device structure  352  can represent an outer housing of the portable electronic device  350 . For example, the housing  302  can pertain to a first wall of the outer housing of the portable electronic device  350 , and the device structure  352  can pertain to a second wall of the outer housing of the portable electronic device  350 . A layer of material  354  can couple between the audio element  306  and the device structure  352 . The layer of material  354  can pertain to a layer of adhesive or a foam member. In one implementation, the layer of material  354  can provide structural coupling between a surface of the audio element  306  and a surface of the device structure  352 . In another implementation, the layer of material  354  can provide acoustic coupling between a surface of the audio element  306  and a surface of the device structure  352 . For example, if an acoustic volume (e.g., back volume) is to be provided acoustically coupled to the surface of the audio element (i.e., speaker device)  306 , the layer of material  354  can participate in the acoustic coupling for the acoustic volume. 
       FIG. 3C  is a partial cross-sectional diagram of a portable electronic device  370  according to another embodiment. The portable electronic device  370  is generally similar to the portable electronic device  300  illustrated in  FIG. 3A . However, the portable electronic device  370  further illustrates an internal support structure  372 . The internal support structure  372  can represent an inner structure internal to the portable electronic device  370 . A layer of material  354  can couple between the speaker device  306  and the internal support structure  372 . The layer of material  374  can pertain to a layer of adhesive or a foam member. In one implementation, the layer of material  374  can provide structural coupling between a surface of the audio element  306  and a surface of the internal support structure  372 . In another implementation, the layer of material  374  can provide acoustic coupling between a surface of the audio element  306  and a surface of the internal support structure  372 . For example, if an acoustic volume (e.g., back volume) is to be provided acoustically coupled to the surface of the audio element (i.e., speaker device)  306 , the layer of material  374  can participate in the acoustic coupling for the acoustic volume. 
       FIG. 4A  is a cross-sectional view of a speaker driver  400  according to one embodiment. The speaker driver  400  can pertain to the audio element (operating as a speaker driver)  206 ,  306  in  FIGS. 2A ,  2 B,  3 A,  3 B and  3 C. The speaker driver  400  can pertain to a dynamic speaker. The speaker driver  400  includes a speaker housing  402 . The speaker housing  402  has an opening  404  through which generated sound wave can be expelled from the opening  404 . The internal structure of the speaker driver  400  can include a driver element  406  (e.g., magnet and coil) and a diaphragm  408 . 
     Although the speaker driver  400  includes a speaker housing  402 , it should be noted that in another embodiment, the speaker driver  400  can be mounted internal to an electronic device housing without a dedicated speaker housing, i.e., without the speaker housing  402 . In one implementation, the driver element  406  (e.g., magnet and coil) and the diaphragm  408  can be secured to the electronic device housing (without a dedicated speaker housing). 
       FIG. 4B  is a cross-sectional view of a receiver  450  according to one embodiment. The receiver  450  can pertain to the audio element (operating as a microphone)  206 ,  306  in  FIGS. 2A ,  2 B,  3 A,  3 B and  3 C. The receiver  450  can pertain to a MEMS microphone. The receiver  450  includes a receiver housing  452 . The receiver housing  452  has an opening  454  through which generated sound wave can be expelled from the opening  454 . The internal structure of the receiver  450  can include a receiver element  456  (e.g., magnet and coil) and a diaphragm  458 . 
     Although the receiver  450  includes a receiver housing  452 , it should be noted that in another embodiment, the receiver  450  can be mounted internal to an electronic device housing without a dedicated receiver housing, i.e., without the receiver housing  452 . In one implementation, the receiver element  456  (e.g., magnet and coil) and the diaphragm  458  can be secured to the electronic device housing (without a dedicated receiver housing). 
     According to another aspect, a barrier, such as a mesh barrier, can be provided in an opening of an outer housing so that undesired foreign substances can be blocked from further entry into the opening in the outer housing. 
       FIG. 5A  is a partial cross-sectional diagram of a portable electronic device  500  according to one embodiment. The portable electronic device  500  includes a housing  502  for the portable electronic device  500 . The housing  502  has an opening  504  that allows audio sound to be emitted or received from the portable electronic device  500 . The portable electronic device  500  also includes an audio element  506  provided internal to the housing  502  for the portable electronic device  500 . As shown in  FIG. 5A , the speaker driver  506  can be provided adjacent to the opening  504  in the housing  502 . 
     The audio element  506  can, for example, represent a speaker driver (e.g., speaker) and/or a receiver (e.g., microphone). When the audio element  506  includes a speaker, the speaker driver, upon controlled activation, produces audio sound that can be directed out of the opening  504  of the housing  502 . For example, the audio sound can be associated with playback of digital media asset, such as a video file (e.g., movie), an audio file (e.g., music or podcast), etc., by the portable electronic device  500 . As another example, in the case of the speaker driver, the audio sound can be associated with a user, such as a voice conversation, using the portable electronic device  500  as a wireless telephone. Alternatively, when the audio element  506  includes the receiver, the audio sound can be picked-up via the opening  504  if the housing  502 . The sound, in this example, can be environment or can be audio sound (e.g., voice communications) associated with a user. 
     An intermediate layer  508  can be provided between the audio element  506  and a portion of the housing  502 . The intermediate layer  508  can serve to seal and/or bond the audio element  506  to the housing  502 . When the intermediate layer  508  is providing sealing, the intermediate layer  508  is a compliant member (e.g., foam, rubber, silicone) that can provide an acoustic seal between the audio element  506  and the housing  502 . The complaint member can, for example, be a gasket for the audio element  506 . When the intermediate layer  508  is providing bonding, the intermediate layer  508  can be an adhesive layer or a mechanical structure (e.g., screw, snap, solder, etc.) that serves to bond the audio element  506  with the housing  502 . The intermediate layer  508  can also provide both sealing and bonding (e.g., compliant member as well as adhesive). 
     The portable electronic device  500  can further optionally include a mesh screen  510  provided in the opening  504  of the housing  502 . The mesh screen  510  serves as a device that does not substantially impede audio sound input/output through the opening  204 , but does provide a barrier for foreign substances (e.g., dust, dirt). The mesh screen  510  operates to reduce accumulation of foreign substances within the opening  504 . The mesh screen  510  can be formed from fabrics or fibers, either natural or synthetic. As one particular example, the mesh screen  510  can be formed of nylon fibers. 
       FIG. 5B  is a partial cross-sectional diagram of a portable electronic device  550  according to one embodiment. The portable electronic device  550  is generally similar to the portable electronic device  500  illustrated in  FIG. 5A . However, the portable electronic device  550  further includes a notch  552  in the opening  504  of the housing  502 . The mesh screen  510  can be held in position within the opening  504  by placing the mesh screen  510  in the notch  552 . Alternatively or additionally, a ridge, a detent, a nub, an adhesive, etc. can be used to hold the mesh screen  510  in position within the opening  504  of the housing  502 . 
     In other embodiment, a support structure can assist with insertion into the opening  504  and with retaining the mesh screen  510  at the proper position within the opening  504 . A support structure can be particularly useful when the mesh screen  510  is formed of fabric or fibers. In one embodiment, the diameter of the opening  504  and the mesh screen  510  is ten (10) millimeters or less. In another embodiment, the diameter of the opening  504  and the mesh screen  510  is approximately one (1) millimeter. In any case, the structure support can made insertion and retention of the mesh screen  510  manageable even though the diameter of the opening  504  is very small. 
       FIGS. 6A-6C  are diagrams illustrating insertion of a mesh barrier assembly into an opening in a housing of a portable electronic device according to one embodiment. 
       FIG. 6A  is a cross-sectional diagram of a mesh barrier assembly  600  according to one embodiment. The mesh barrier assembly  600  includes a mesh barrier  602  attached to a support structure  604 . The mesh barrier can be formed, for example, by a die cutting process. The mesh barrier  602  can be rendered integral with the support structure  604 , such as by way of an over-molding or co-molding process. Alternatively, the mesh barrier  602  can be separately formed attached together, e.g., by adhesive, thermal bonding or mechanical means. In one implementation, to facilitate assembly, a plurality of mesh barriers can be partially die cut in a sheet of mesh fabric, then support structures can be attached or formed onto the corresponding mesh barriers, and then finally the mesh barriers can be completely cut from the sheet of mesh fabric. 
       FIG. 6B  is a partial cross-sectional diagram of a portable electronic device  606  according to one embodiment. The portable electronic device  606  includes a housing  608  for the portable electronic device  606 . The housing  608  has an opening  610  that allows audio sound to be emitted from the portable electronic device  606 . The portable electronic device  606  includes a speaker driver  612  provided internal to the housing  606  for the portable electronic device  606 . The speaker driver  612  upon controlled activation produces audio sound that can be directed out of the opening  610  of the housing  606 . As shown in  FIG. 6B , the speaker driver  612  can be provided adjacent to the opening  610  in the housing  606 . A bonding layer  614  can be provided to secure the speaker driver  612  to the housing  606 . The bonding layer  614  can be an adhesive layer or a mechanical structure (e.g., screw, snap, solder, etc.). Additionally, the opening  610  can include a recessed region  616  that facilitates retention of the mesh barrier assembly  600  within the opening  610 . 
       FIG. 6C  is a partial cross-sectional diagram of a portable electronic device  606 ′ according to one embodiment. The portable electronic device  606 ′ is the same as the portable electronic device  606  illustrated in  FIG. 6B  except that the mesh barrier assembly  600  has been inserted into the opening  610 . When inserted, the mesh barrier assembly  600  is retained within the opening  610  with the assistance of the recessed region  616  and/or frictional coupling. The support structure  604  can have a configuration that corresponds to the configuration of the opening  610  or the recessed region  616  of the opening  610 . The support structure  604  can also be used in controlling to placement of the mesh barrier assembly  600  within the opening  610 , such as controlling its depth or recessed amount within the opening  610 . Although the mesh barrier assembly  600  is retained within the opening  610 , the mesh barrier assembly  600  can in some embodiments be thereafter removed for servicing (such as cleaning the mesh barrier  602 ). In an alternative embodiment, the recessed region  616  is not required but the support structure  604  can be retained within the opening by simply fictional coupling. In still another embodiment, an adhesive couple be provided to secure the support structure  604  within the opening  610 , though controlling the location of the adhesive can be difficult and can hinder audio performance if the adhesive misplaced. 
     In an alternative embodiment, the portable electronic device  600 ,  600 ′ can use a microphone instead of the speaker driver. In such case, the block  612  can be considered a microphone. For example, the microphone is small, such as a MEMS microphone. 
     In one embodiment, the scale of the housing  608  and the opening  610  in the housing  608  are rather small. For example, the thickness of the housing  608  can be approximately 2.5 millimeters (mm), and the opening  610  can be approximately 1 mm in diameter. The mesh barrier assembly  600  in such an embodiment would have a width on the order of 1 mm, and a height of approximately 1 mm to 2 mm. 
       FIG. 7  is a top view of a portion of a flexible substrate  700  according to one embodiment. The flexible substrate  700  can, for example, be a flex circuit. The flexible substrate  700  can provide electrical traces  702 , electrical connections  704  and/or electrical pads  706  on one or both primary surfaces of the flexible substrate  700 . The flexible substrate  700  can also include an opening  708  there through for supporting an audio port as discussed above where a speaker driver assembly can be coupled to the flexible substrate  700  over or adjacent the opening  708 . 
     Further, various electronic components can be attached to the flexible substrate  700 . These electrical components can include transistors, capacitors, resistors, inductors, integrated circuits, microphones, sensors, switches, etc. For example, the flexible substrate  700  can include a representative electrical component  710  electrically and mechanically attached to the flexible substrate  700 . 
     Additional details on speaker arrangements can be found in U.S. patent application Ser. No. 12/698,957, filed Feb. 2, 2010 and entitled “LOW-PROFILE SPEAKER ARRANGEMENTS FOR COMPACT ELECTRONIC DEVICES,” which is hereby incorporated herein by reference. 
     Embodiments of the invention are well suited for portable, battery-powered electronic devices, and more particularly handheld battery-powered electronic devices. Examples of portable, battery-powered electronic devices can include laptops, tablet computers, media players, phones, GPS units, remote controls, personal digital assistant (PDAs), and the like. 
     The various aspects, features, embodiments or implementations of the invention described above can be used alone or in various combinations. 
     The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20130513
Publication Date: 20160112
Grant Date: 20160112
Priority Date: 20100419
Inventors: YU MICHELLE
DINH RICHARD HUNG MINH
TAN TANG YEW
CHEN SHAOHAI
Assignee: APPLE INC
CPC Classifications: [{"code": "H04R1/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/15", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/003", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/15", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/025", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 44788226