PATENT DOCUMENT

Publication Number: US-10196750-B2
Application Number: US-201514698354-A
Country: US
Kind Code: B2

Title: Electroformed housings and methods for making the same

Abstract:
Electroformed housings for electronic devices and methods for making the same are provided. An electronic device is provided having at least one electronic part and an electroformed housing constructed from a metal that encloses the at least one electronic part.

Claims:
What is claimed is: 
     
       1. A method for making an electroformed housing for an electronic device, the method comprising:
 encapsulating electronic circuitry in a material to form a mandrel, the mandrel encompasses the electronic circuitry and has a first shape; 
 electroforming a metal layer around the mandrel to form the electroformed housing, the electroformed housing encompasses the mandrel and has a second shape that resembles the first shape; 
 removing at least a portion of the mandrel from the electroformed housing such that, after the portion of the mandrel is removed, the electronic circuitry is retained within the electroformed housing and the electroformed housing is on its own a self-supporting structure, that retains the second shape for holding the electronic circuitry in place within the electroformed housing. 
 
     
     
       2. The method of  claim 1 , wherein removing the portion of the mandrel comprises:
 heating the material to cause it to flow from the electroformed housing. 
 
     
     
       3. The method of  claim 1 , wherein the material is aluminum and wherein the removing comprises:
 submersing the electroformed housing in an acid bath to remove the material. 
 
     
     
       4. The method of  claim 1 , wherein the encapsulating further comprises:
 using at least one of injection molding, insert molding, or compression molding to encompass the electronic circuitry. 
 
     
     
       5. The method of  claim 1 , wherein the mandrel has a flexible region, and the electroforming further comprises:
 electroforming the metal layer around the flexible region to form an articulated region of the electroformed housing. 
 
     
     
       6. The method of  claim 1 , the method further comprising:
 coupling a bellows shaped member to the electroformed housing. 
 
     
     
       7. The method of  claim 1 , wherein the mandrel comprises one or more retention forming features, and wherein the electroforming further comprises:
 forming one or more retention features within the electroformed housing based on the one or more retention forming features, wherein the one or more retention features hold the electronic circuitry in place when the mandrel is removed. 
 
     
     
       8. The method of  claim 1 , the method further comprising:
 applying a photomask film to a region of the electroformed housing; and 
 using a laser to create a plurality of holes in the electroformed housing in accordance with the photomask film. 
 
     
     
       9. The method of  claim 1 , the method further comprising:
 prior to the electroforming, applying a photomask film having a plurality of holes to the mandrel, wherein electroforming the metal layer around the mandrel comprises enabling the metal to seep into at least some of the plurality of holes to create a pattern in the electroformed housing; and 
 removing the photomask film to reveal the pattern in the electroformed housing. 
 
     
     
       10. A method for making a housing, the method comprising:
 encapsulating an electronic component in a material to form a mandrel; 
 electroforming metal about the mandrel to form the housing; and 
 removing at least a portion of the mandrel from the housing such that, after the at least the portion of the mandrel is removed, the housing on its own is self-supporting and the electronic component is held in place by the housing. 
 
     
     
       11. The method of  claim 10 , wherein the housing is a unitary structure. 
     
     
       12. The method of  claim 10 , wherein the encapsulating forms the mandrel to have a first shape. 
     
     
       13. The method of  claim 12 , wherein the electroforming forms the housing to have a second shape that resembles the first shape. 
     
     
       14. The method of  claim 13 , wherein, after the removing, the housing retains the second shape. 
     
     
       15. The method of  claim 10 , wherein the electronic component is larger than the size of any opening provided through the housing. 
     
     
       16. The method of  claim 10 , wherein the removing comprises submersing the housing in a bath to remove the at least the portion of the mandrel. 
     
     
       17. The method of  claim 10 , wherein the encapsulating comprises using at least one of injection molding, insert molding, or compression molding to encapsulate the component. 
     
     
       18. A method for making an electronic device, the method comprising:
 encapsulating circuitry in a material that forms a mandrel; 
 electroforming a metal layer around the mandrel to form an electroformed housing; and 
 removing at least a portion of the mandrel from the electroformed housing such that, after the portion of the mandrel is removed, the circuitry is held in place by the electroformed housing and the electroformed housing is on its own a self-supporting structure. 
 
     
     
       19. The method of  claim 18 , the method further comprising:
 applying a photomask film to a region of the electroformed housing; and 
 using a laser to create a plurality of holes in the electroformed housing in accordance with the photomask film. 
 
     
     
       20. The method of  claim 18 , wherein:
 the encapsulating forms the mandrel to have a first shape; and 
 the electroforming forms the housing to have a second shape that resembles the first shape.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional of U.S. patent application Ser. No. 13/708,683 filed Dec. 7, 2012, which is hereby incorporated herein by reference. 
    
    
     BACKGROUND 
     Electronic devices include a housing for enclosing or securing various device components and circuitry. The characteristics of housings vary from device to device. For example, housings for computers, phones, and keyboards are generally different, and may be constructed using different materials and assembly techniques. Despite the variation in construction, many conventional housing are generally formed from two or more housing parts that are fixed together. The use of multiple housing parts typically requires that the housing parts be designed to be fixed to each other to secure electronic components in place. This can result in seams or other non-aesthetic blemishes at the junction between housing parts. Accordingly, housings for electronic devices that are aesthetically pleasing and substantially one piece constructions are needed. 
     SUMMARY 
     Electroformed housings for electronic devices and methods for making the same are provided. In some embodiments, an electronic device is provided having at least one electronic part and an electroformed housing constructed from a metal that encloses the at least one electronic part. 
     In other embodiments, an earbud is provided having electronic circuitry comprising at least one speaker and a circuit board, a cable fixed to the circuit board, the cable having first and second portions, and an electroformed earbud housing constructed from a metal that completely encloses and secures the electronic circuitry and the first portion of the cable within a cavity of the housing such that the second portion extends away from an outer surface of the housing. 
     In yet other embodiments, a method for making an electroformed housing for an electronic device is provided. The method provides encapsulating electronic circuitry in a material to form a mandrel, the mandrel encompasses the electronic circuitry and has a first shape. The method further provides electroforming a metal layer around the mandrel to form the electroformed housing, the electroformed housing encompasses the mandrel and has a second shape that resembles the first shape, and removing at least a portion of the mandrel from the electroformed housing such that, after the portion of the mandrel is removed, the electronic circuitry is retained within the electroformed housing and the electroformed housing retains the second shape. 
     In yet other embodiments, an earbud is provided having earbud electronics, and an electroformed metal structure that encloses the earbud electronics, the metal structure having a non-rectilinear three dimensional shape and a substantially uniform thickness. 
     In yet other embodiments, an earbud is provided having potted earbud electronics having a first earbud shape, wherein the potted earbud electronics are incorporated in a plastic resin, and an electroformed metal structure that encloses the potted earbud electronics, the metal structure having a second earbud shape that substantially resembles the first earbud shape. 
    
    
     
       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. 1A  shows an illustrative view of an electroformed housing in accordance with some embodiments of the invention; 
         FIG. 1B  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 1A  taken along line IB-IB in accordance with some embodiments of the invention. 
         FIG. 1C  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 1A  taken along line IB-IB in accordance with some embodiments of the invention; 
         FIG. 1D  shows an illustrative view of a cross-sectional view of user interface region  113  for the device with the housing of the device taken across line ID-ID of  FIG. 1A  in accordance with embodiments of the invention; 
         FIG. 1E  shows an illustrative view of a cross section view of user interface region  113  for the device with the housing of the device taken across line ID-ID of  FIG. 1A  in accordance with embodiments of the invention; 
         FIG. 1F  is a schematic view of an illustrative electroforming process in accordance with some embodiments of the invention; 
         FIG. 2A  shows an illustrative cross-sectional view of an electroformed housing in accordance with embodiments of the invention; 
         FIG. 2B  shows an illustrative cross-sectional view of a mandrel in accordance with embodiments of the invention; 
         FIG. 3A  shows an illustrative cross-sectional view of a mandrel in accordance with an example of an embodiment of the invention; 
         FIG. 3B  shows an illustrative cross-sectional view of an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 4  shows illustrative cross-sectional view of an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 5  shows an illustrative view of an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 6A  shows a side view of an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 6B  shows a top plan view of an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 7  shows an illustrative cross-sectional view of a mandrel and an electroformed housing in accordance with an example of an embodiment of the invention; 
         FIG. 8A  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention; 
         FIG. 8B  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention; 
         FIG. 8C  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention; 
         FIG. 8D  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention; 
         FIG. 9A  shows an illustrative cross-sectional view of multiple mandrels in accordance with some embodiments of the invention; 
         FIG. 9B  shows an illustrative cross-sectional view of an electroformed housing in accordance with some embodiments of the invention; 
         FIG. 10A  is a flowchart of an illustrative process for electroforming a housing in accordance with some embodiments of the invention; 
         FIG. 10B  is a flowchart of an illustrative process for electroforming a housing in accordance with some embodiments of the invention; 
         FIG. 11A  shows an illustrative cross-sectional view of a mandrel in accordance with some embodiments of the invention; 
         FIG. 11B  shows an illustrative top view of an electroformed housing in accordance with some embodiments of the invention; 
         FIG. 11C  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 11B  taken along line XIC-XIC in accordance with some embodiments of the invention; 
         FIG. 11D  shows an illustrative side view of an electroformed housing in  FIG. 11B ; and 
         FIG. 12  shows an isometric view of an electroformed housing in accordance with an example of an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Electroformed housings for an electronic device and methods for making the same are disclosed. Electroformed housings according to embodiments of the invention enclose electronic parts in a manner that is both aesthetically pleasing and ensures enclosed electronic parts are functional for a device. 
     An electroformed housing is an electroformed metal structure created using an electroforming metal deposition process. The use of the electroforming metal deposition process allows for creation of a resulting electroformed housing that can be a unitary or single-piece metal structure that substantially encloses or surrounds the electronic parts of a device. The electroformed housing may be unitary in that it does not require two or more housing components to be fixed together to form the housing to enclose electronic parts for a device. The unitary structure of the resulting electroformed housing can provide desired aesthetics because no housing component junctions or seams exist to enclose electronic parts of a device. 
     The electroformed housing is created by first encapsulating electronic parts and/or circuitry in a material to form a mandrel. The mandrel may be any desired three dimensional shape that defines the shape of a resulting electroformed housing for a device. The mandrel (and enclosed circuitry and/or parts) is subjected to an electroforming metal deposition process that deposits a material around the mandrel to form the electroformed metal structure of the housing. In the electroforming process, layers of the metal may be deposited onto the mandrel via a chemical bath. In some embodiments, surfaces of the mandrel intended to be used for creation of the resulting housing may be created from a conductive material and/or pretreated to ensure surfaces of the mandrel are conductive. During the electroforming process, metal layers may be deposited onto conductive surfaces of the mandrel. The metal is deposited with a sufficient number of layers and/or thickness to create a self-supporting structure such that even if the entire mandrel or a portion of the mandrel is removed, the resulting electroformed metal structure remains intact. 
     Removal processes for the mandrel may depend on the material used to create the mandrel. Mandrels may be created from a conductive material, a material treated to be conductive, any type of plastic, any type of metal (e.g., aluminum), any other suitable material, and/or combination of materials that can be shaped as desired to make a resulting electroformed housing. One or more drainage holes may be created in an electroformed housing allowing the mandrel to flow out of the electroformed housing to at least partially remove the mandrel. The mandrel may be removed by heating the electroformed housing to a predetermined temperature to cause the mandrel material, such as plastic, to flow out of one or more drainage holes in the electroformed housing. In other embodiments, an acid bath or other chemicals may be used to remove or etch away at the mandrel material, such as aluminum. In some embodiments, multiple materials may be used to create the mandrel and each material used to create the mandrel may be selectively removed as desired. For example, a first portion of the mandrel formed from a first material (e.g., plastic) may be removed using a particular removal method (e.g., heated to a particular temperature) while a second portion of the mandrel formed from a second material (e.g., a metal or plastic with a different melting point) remains intact. Drainage holes may be strategically placed in an electroformed housing to ensure the mandrel can flow out of the electroformed housing. 
     In some embodiments, holes in an electroformed housing may serve a dual purpose as a drainage hole and a functional port for the device. Any number of ports can be created in an electroformed housing for a device including, but not limited to, a connector port, a port through which a cable or wire can pass through, or a sound port through which sound waves can pass. Drainage holes and ports may be strategically placed in electroformed housings to ensure that mandrel material is entirely removed and/or removed from particular electronic parts. 
     In embodiments where the mandrel is removed, the electroformed metal structure may be constructed to have one or more retaining structures that secure the electronic parts in place. For example, the mandrel may be shaped in such a way that when the metal is deposited thereon, the resulting metal structure forms a self-locking retaining mechanism for an electronic part and the electronic part may remain in place, when the mandrel is removed. The retaining structures may ensure that the electronic parts remain in particular positions within the housing to be functional for the device. 
     The electroformed housing can be used for any suitable number of different devices. For example, the electroformed housing may be a housing for earbuds, headphones, and the like. In another example, the electroformed housing may be a housing for a keyboard or other user input device. In yet another example, the electroformed housing may be an aesthetically pleasing housing for a portable media device, such as a small form factor media player. 
       FIG. 1A  shows an illustrative view of an electroformed housing in accordance with some embodiments of the invention.  FIG. 1A  shows electroformed housing  101  for a device constructed from a metal using an electroforming process. Electroformed housing  101  may be a one-piece, unitary, or unibody metal shell with an interior space for one or more electronic parts. Electroformed housing  101  may substantially surround electronic parts for a device, such that less housing parts are fastened together to form the device housing, and as a result, there are less seams visible on the housing for the device. For example, electroformed housing  101  may serve as the main housing for a device and only user interface components, such as buttons, to control interface circuitry of the device may be attached. 
     Electronic parts enclosed by electroformed housing  101  may provide device circuitry for a particular device or a particular function of a device. By way of example, electroformed housing  101  may be a one-piece housing enclosing electronic parts for a computer. In another example, electroformed housing  101  may be a single housing for a peripheral device, such as a display or a keyboard. Electronic device may have a single function or multiple functions. Although shown as a generic box in  FIG. 1A , electroformed housing  101  may be a housing for any type of device, including, but not limited to, the following: earphones, media players, video players, still image players, game players, music recorders, voice recorders, cameras, radios, medical equipment, domestic appliances, vehicle instruments, musical instruments, calculators, cellphones, wireless communication devices, personal digital assistants, programmable remotes, pagers, laptops, computers, printers, and/or any combination thereof. 
     Electroformed housing  101  may enclose electronic parts for a device, including, but not limited to: a processor, a storage device, a circuit board, communications circuitry, interface circuitry, a bus, system on a chip (SOC), application specific integrated circuits (ASIC), and/or a power supply. The bus can provide a data transfer path for transferring data to/from elements of device. The processor or any other component that can execute instructions can control functions of the device and other circuitry. For example, processor can receive user inputs that drive output. 
     Storage device can include one or more storage mediums, including, for example, a hard drive, a permanent memory, such as ROM, a semi-permanent memory, such as RAM, and/or a cache that can store data. Data can include, but is not limited to, the following: media, software, configuration information, and/or any other type of data. 
     Communications circuitry can include circuitry for wireless communication (e.g. short and long range communication). For example, the wireless communication circuitry of device can be Wi-Fi enabling circuitry that permits wireless communication according to one of the 802.11 standards. Other standards can be supported, such as Bluetooth®. Communication circuitry can include circuitry that enables device to be coupled to another device and communication with that other device. Additional electrical components can be provided for sending and receiving media, including, but not limited to, microphones, amplifiers, digital signal processors, image sensors, optics, antennas, receivers, transmitters, transceivers, and the like. 
     Electroformed housing  101  may have at least one user interface region  113  that allows a user to interact with the device. User interface region  113  may include output components (although not shown) and/or input components or controls. Embodiments of electroformed housing  101  may allow for connecting user interface components or user interface controls directly to the electroformed housing. For example, electroformed housing  101  can include one or more user interface components, including, but not limited to, the following: switches, sliding switches, keypads, dials, scroll wheels, touch screen displays, electronics for accepting audio, and/or visual information, antennas, infrared ports, or combinations thereof. 
     In certain embodiments, each of the one or more input components of a device can be configured to trigger execution of instructions to provide device functionality. For example, an input component can provide one or more dedicated control functions for making selections or issuing commands associated with operating the device. Continuing with the example, in the case of a media player, an input component can be associated with powering up or down the device, opening or closing a menu, playing or stopping a song, changing a mode, and/or the like. 
     In one or more embodiments, electroformed housing  101  may have user interface region  113  with an input component or user interface control that is integrated or incorporated in to the electroformed housing  101 . For example, a button may be formed on the surface of metal structure for electroformed housing  101 . Electroformed housing  101  may have interface circuitry for processing user inputs events initiated with user interface components or controls. Interface circuitry may be positioned substantially adjacent to a user interface region  113 , such that user input events can be processed when a user interacts with the user interface. 
     Electroformed housing  101  may have openings, indentations, ports, and/or connections  106  for attaching additional components (connections  106  are discussed in more detail below), electronic parts, and/or housings for a particular function or device to the housing  101 . Certain embodiments of electroformed housing  101  can include at least one output component attached to electroformed housing  101  that provides the user with information, sound, and/or a display of information. Output components can take various forms including, but not limited to, the following: audio speakers, headphones, audio line-outs, visual displays, antennas, infrared ports, ports, or the like. 
     Electroformed housing  101  may have exterior retention features to allow for attaching additional electronic parts, components, and/or housings to the electroformed housing, such as a display screen. For example, electroformed housing  101  may be shaped to provide exterior retention features for securing or attaching a display screen or housing for a display screen. In an embodiment, a display screen may be a touch screen that receives input through a user&#39;s touch to the screen. 
       FIG. 1B  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 1A  taken along line IB-IB in accordance with some embodiments of the invention.  FIG. 1B  shows an electroformed housing  101  for a device with a mandrel  105 . Mandrel  105  may encapsulate device electronics  107  (e.g., electronic parts) in a material. For example, electronic parts may be potted in a plastic resin within mandrel  105 . 
     Mandrel  105  may define a shape for creation of resulting electroformed housing  101  using an electroforming process. Resulting electroformed housing  101  may take a shape resembling mandrel  105  or a shape substantially similar to mandrel  105 . Mandrel  105  may be shaped to form a single housing that substantially encloses one or more electronic parts for a device or a set of electronic parts that perform a particular function for a device. Mandrel  105  may be created with a desired shape by being molded, formed, machined, and/or processed. Mandrel  105  may have a shape to create a particular shaped housing  101  in accordance with the intended function of the device. For example, mandrel  105  may be shaped to create an earbud, a phone, or any other device. 
     Mandrel  105  for the device may be shaped to create housing  101  that is aesthetically pleasing and accommodates the electronics contained within. For example, housing  101  may enclose one or more electronic parts for a computer, such that an additional housing is unnecessary for covering or enclosing the electronic parts of the computer or electronic parts providing a particular function of the computer. In this way, the resulting device housing may ultimately have less seams and have a more aesthetically pleasing appearance. 
     A unitary housing with less seams on the housing may additionally be more comfortable for the user to wear against their body. For example, the seams on earbud housings may be jagged and uneven such that the seams may be uncomfortable when placed next to the ear. As such, an earbud housing with less seams may be smooth and less irritating for the user to wear next to the ear. 
     Mandrel  105  and resulting device or housing  101  created with mandrel  105  may be a three dimensional shape that is rectilinear or non-rectilinear. As shown in  FIG. 1A , the resulting electroformed housing  101  can have a substantially hexahedral shape. Although, it should be noted that electroformed housing  101  is only exemplary and need not be substantially hexahedral. Housing  101  can be formed in any other shape, including, but not limited to, the following: spherical, ellipsoidal, conoidal, octahedral, or any combination thereof. 
     Mandrel  105  may have retention forming features to create retention features that ensure electronics are retained in a particular place within the housing and/or the device electronics perform optimally. For example, a mandrel may be created with retention features to secure circuitry in a particular position. Continuing with the example, mandrel  105  may be created with retention features to retain interface circuitry substantially adjacent to a user interface region  113 . In another example, retention features may keep electronic parts in place so as not to obstruct a port of a device, such as a sound port. 
     Mandrel  105  may have connection forming features to ensure that housing  101  electrically connects to the electronics within. Connection forming features may form a connection or a contact area to allow for integrating a user interface control and/or accommodating attachment of a control to housing  101  for the electronic part or device circuitry. 
     In some embodiments, mandrel  105  may have user interface forming features to create a user interface, such as a button, on the surface of resulting electroformed housing  101 . Mandrel  105  may be shaped such that the application of layers of metal during the electroforming process on user interface forming feature create a metal button that is integrated (e.g., on the surface of electroformed housing  101 ) in to electroformed housing  101 . For example, it may be desirable to create a button on the surface of electroformed housing  101  as opposed to attaching a user interface component above a contact area on electroformed housing  101 . 
       FIG. 1C  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 1A  taken along line IB-IB in accordance with some embodiments of the invention. Electroformed housing  101  may be a self-supporting structure without mandrel  105 . At least a portion of the material for mandrel  105  may be removed from region  111  of electroformed housing  101 .  FIG. 1C  shows an electroformed housing  101  for a device with a region  111  with no mandrel  105 . As shown in  FIG. 1C , a substantial amount of mandrel  105  may be removed or drained from electroformed housing  101  and the shape of electroformed housing  101  may remain intact. In an embodiment, portions of mandrel  105  may remain within housing  101  to cushion a particular electronic part, ensure that an electronic part remains in place, form a barrier between particular electronic parts, and/or any other reason for keeping portions of the mandrel within the device. 
     Retention features may ensure that electronic parts remain in place after removal of a material used for mandrel  105 . For example, retention features may ensure that a fan remains in particular position and is secured such that the fan does not shake and make excessive noise, or otherwise interfere with operation of other electronics. Continuing with the example, retention features may ensure that particular electronic parts that generate heat remain secured in place and do not cause the device to overheat or destroy another electronic part within the device. In another example, retention features may ensure that circuitry remains in place to allow for user interaction with the device circuitry, such as user interface components. 
       FIG. 1D  shows an illustrative view of a cross-sectional view of user interface region  113  for the device with the housing of the device taken across line ID-ID of  FIG. 1A  in accordance with embodiments of the invention.  FIG. 1D  shows user interface  115  in user interface region  113  of housing  101  with an interface component (e.g., an interface control, an LED to visually provide device status, or any other interface component) integrated in to electroformed housing  101 . A user can initiate an input event by interacting with the user interface  115  on electroformed housing  101 . For example, user interface  115  may be a button, a dome switch or any other type of user interface component having a top surface  117  of an actuator  119  that may be depressed or deformed to close an otherwise open circuit of device, or to open an otherwise closed circuit. 
     At rest, electrical contact area  121  of user interface  115  is separated from conductive inner surface  123  and a switch is said to be electrically “open.” When actuator  119  is compressed to a point where it deforms, opposing conductive inner surface  123  of the switch may be moved to be in physical and electrical contact with opposing contact area  121  to complete an electrical circuit, and the contact is said to electrically “close” the switch. Contact area  121  may be coupled to electronic part  107 , such as a circuit board for interface circuitry of a device. In this example, when the switch is closed, at least one circuit of circuit board  107  is completed and the user input event processing may begin with the interface circuitry. 
       FIG. 1E  shows an illustrative view of a cross section view of user interface region  113  for the device with the housing of the device taken across line ID-ID of  FIG. 1A  in accordance with embodiments of the invention. In this example, the user can initiate an input event by exerting force on top surface  117  of actuator  119  of user interface  115 . Force in direction A applied to top surface  117  may depress or deform actuator  119  of user interface  115  from an original position to an actuated position to change a functional state of a device, such as to turn a device off or on. 
     As shown, actuator  119  is compressed to a point where it deforms, opposing conductive inner surface  123  of switch is moved to be in physical and electrical contact with opposing contact area  121  to complete at least one electrical circuit on circuit board  107 , and the contact is said to electrically “close” the switch. Actuator  119  may be dome shaped, conical shaped, and/or have any other shape that can be deformed to move contact areas closer together and return to an original position. When a user terminates the force at top surface  117 , actuator  119  may return to its original position as shown in  FIG. 1D . 
       FIG. 1F  is a schematic view of an illustrative electroforming process in accordance with some embodiments of the invention. Process  600  is used to form a housing that is self-supporting when mandrel  105  is removed. Mandrel  105  provides a support structure for three dimensional shaped housing  100  during the electroforming process. In an electroforming process, material  612  from anode  610  is moved in bath  620  towards mandrel  632 , such as mandrel  105 , forming cathode  630  when electric current  602  is applied between anode  610  and cathode  630 . Material  612  may be deposited as a thin layer  634  on a surface of mandrel  632  and/or an electronic part exposed with a hole or an opening in the mandrel  632 . 
     Any suitable material can be used as anode  610  to be deposited on mandrel  632 . In some cases, anode  610  can include a nickel-based metal or alloy such that nickel is the primary material deposited on mandrel  632 . In addition, any suitable material can be used for mandrel  632 . In particular, the material can be selected such that mandrel  632  can be easily removed when layer  634  is sufficiently thick to be self-supporting. For example, mandrel  632  can be constructed from a plastic resin. As another example, mandrel  632  can be constructed from a non-conductive material that has a conductive coating. As still another example, mandrel  632  can be constructed from aluminum or other suitable metal. 
     The electroforming process can have several advantages or benefits in constructing electroformed housings. For example, the exact composition of the material deposited on the mandrel can be known and controlled by choosing the material for anode  610 . In particular, it may be possible to ensure that a high percentage of the material deposited on mandrel  632  is pure nickel. For example, the nickel purity of layer  634  may be larger than 95%, larger than 98%, larger than 99%, larger than 99.5%, larger than 99.8%, or larger than 99.9%. By providing a very pure electroformed housing, or at least an electroformed housing having a known chemical composition, alloy variations in the component may be reduced and the mechanical response of the component can be easily predicted and calculated based on the mechanical properties of the chemical composition. 
     Another related benefit can include knowing the mechanical and material properties of an electroformed housing. In particular, the grain of the material may not include any unexpected or undesired discontinuities or singularities. As still another benefit, the electroformed housing may not include any stresses or strains caused by a manufacturing process. The resulting electroformed housing will therefore react in a manner that is predictable and can be easily calculated using classical mechanics, quantum mechanics, finite element analysis, or any other analytical means. This approach enables engineers to rationally design earbuds to have particular mechanical properties, and to produce earbuds that behave as designed. 
     Still another benefit of an electroforming process can include a high degree of precision in the thickness of the electroformed housing. In particular, by virtue of the bath, material from the anode is evenly deposited on the mandrel. The particular thickness of the deposited material is determined, for example, from the amount of current applied between the anode and the cathode, chemical properties of the bath, chemical properties of the anode and cathode, the amount of time that the mandrel is left in the bath, the amount of time that current is applied between the anode and the cathode, or combinations of these. These factors, however, can be easily controlled and repeated between batches to ensure that all electroformed housings have substantially the same thickness. Electroformed housings can have any suitable thickness including, for example, a thickness in the range of 15 to 800 microns, 15 to 500 microns, 15 to 100 microns, 15 to 50 microns, 15 to 30 microns, or 15 to 20 microns. 
     In addition, because the nickel or other material is deposited atom by atom in a tightly controlled chemical and physical environment, variations in the thickness of the deposited material can be tightly controlled. For example, the tolerance for deposited material can be +/−1500 nanometers, +/−1000 nanometers, +/−500 nanometers, +/−200 nanometers, +/−100 nanometers, +/−50 nanometers, +/−30 nanometers, or +/−10 nanometers. In addition, this may enable the deposition of additional material in specific regions, for example to create a nub or a texture. For example, portions of the housing can be masked, and additional material can be deposited over the mask such that when the mask is removed, the housing has additional material defining a particular texture in specific regions. 
     A further benefit of the electroforming process may be the use of nickel for the housing. Nickel can have a much higher tensile strength than some stainless steel alloys (e.g., 500 MPa for steel, but 2000 MPa for nickel), and therefore can potentially produce a more reliable part. 
       FIG. 2A  shows an illustrative cross-sectional view of an electroformed housing in accordance with embodiments of the invention. Electroformed housing  100  may be a three dimensional shaped structure having one or more electronic parts, such as  102  and  104  contained therein. The outer surface  120  of housing  100  may be an electroplated metal. Embodiments of housing  100  may be created as one piece or a plurality of pieces that are coupled to form housing  100 . For example, an electroformed earbud piece that encloses earbud electronics may be coupled to an articulated region  118  piece that encloses a cable or a wire  116  to form housing  100 . 
     Three dimensional shaped housing  100  may be any shape that accommodates and/or substantially encloses one or more electronic parts, such as  102  and  104 . Three dimensional shaped housing  100  may have a shape that allows one or more electronic parts to be used to perform a particular function and/or is aesthetically pleasing. For example, three dimensional shaped housing  100  may be shaped to enable three dimensional shaped housing  100  to be used or function as an earbud and/or an earbud component. Housing  100  may be shaped to fit just within an ear canal or rest within the ear. 
     Housing  100  may have a shape that positions one or more electronic parts (e.g.,  102  and  104 ) for optimal use, performance, and/or intended functionality. For example, housing  100  may have a shape that positions electronic parts and/or ports in relation to the ear for optimal sound quality when the earbud is on the ear. Housing  100  may be used for a particular function and/or have an aesthetically pleasing shape. For example, housing  100  may be formed to accommodate a driver for an earbud as well as have a smooth shape with no jagged edges to fit comfortably next to the ear. 
     Earbuds may have occluding or non-occluding styles. Non-occluding earbuds are generally designed not to form an airtight seal between the ear (or ear canal) and the outer surface  120  of the earbud. By way of contrast, occluding earbuds are generally designed to fit inside of the user&#39;s ear canal and form a substantially airtight seal. More detail on different shapes for earbuds is provided below with the discussion of  FIGS. 8A-D . 
     An earbud may function as housing for a speaker, a driver, a circuit board, a microphone, and/or any other electronic part. The earbud may be held close to the ear and connected to a signal source, such as a media player, an amplifier, a radio, a phone, and/or any other device. One or more retention features may be used to retain the one or more electronic parts in particular positions within the housing to ensure the electronic parts are functional. For example, retention features may be user to secure interface circuitry near a user interface component. 
     Connection  106  may be formed between electroformed three dimensional shaped housing  100  and electronic part  102  during the electroforming process. In an embodiment, layers may be applied during the electroforming process directly to electronic part  102  to form connection  106 , such as a contact area formed on a circuit board that allows for completing at least one circuit on a circuit board. Connection  106  may allow for a user interface component to be connected thereto and/or above connection  106 , such as a button over a contact area. 
     Connection  106  may allow for providing a control and/or accommodating attachment of a user interface control to the three dimensional shaped housing  100  for the electronic part  102 . For example, connection  106  may allow for providing controls, including, but not limited to, the following: volume control, on/off switch, reset, time, media management, stopwatch controls, keys, switches, levers, buttons, and/or any other type of control for a user interface. A button for controlling the electronic part(s) may be integrated in to the three dimensional housing  100  and the button may be electrically connected to electronic part  102 . Those with skill in the art will recognize that there are a variety of controls that can be integrated in to the three dimensional shaped housing  100  to work with the connection  106 . 
     In other embodiments, connection  106  may allow for incorporating an output component such as a visual indicator for the status of the device (e.g., an LED). Those with skill in the art will recognize that providing connection  106  between housing  100  and electronic part  102  allows for attachment of a wide variety of components to allow a user to interact with electronic part  102  of a device. 
     Electronic parts  102  and  104  may be retained within the housing  100  in a particular position with the use of retention features  110 ,  112 ,  122 , and  124 . Retention forming features may be provided on a mandrel and the retention features may be formed on or within housing  100  during the electroforming process. Retention features  110 ,  112 ,  122 , and  124  may be created to retain electronic parts  102  and  104  after at least a portion of the mandrel is removed. Retention features  110 ,  112 ,  122 , and  124  may secure electronic parts (e.g.,  102  and  104 ) in a particular position and/or allow for some movement of electronic parts (e.g.,  102  and  104 ). Retention features  110 ,  112 ,  122 , and  124  may restrict movement of electronic parts (e.g.,  102  and  104 ), such as within a particular portion of three dimensional housing  100  so that the electronic part remains functional for the device. 
     In an embodiment, drain hole  108  may be provided for removal of a mandrel from three dimensional shaped housing  100 . The mandrel may be used for creation of three dimensional shaped housing  100  during an electroforming process, and at least a portion of the mandrel can be removed through the drain hole  108 . For example, the mandrel may be made of a material, such as a plastic resin, that can be heated such that at least a portion of the mandrel melts, and at least a portion of the mandrel may seep or drain from the drain hole. In another example, the mandrel may be made of a material, such as aluminum, which can be dissolved in an acid bath, and at least a portion of the mandrel may be dissolved. 
     After removal of at least a portion of the mandrel, retention features  110 ,  112 ,  122 , and  124  may secure electronic parts  102  and  104  within housing  100  after removal of the mandrel. In an embodiment, retention features  110 ,  112 ,  122 , and  124  may secure electronic part  102  and  104  in a particular position or place within three dimensional shaped housing  100  after removal of the mandrel. Assuming, for example, that electronic parts  102  and  104  are speaker components, retention features  110 ,  112 ,  122 , and  124  can secure speaker components in particular positions to ensure that the speakers perform as expected after removal of the mandrel. 
     Three dimensional shaped housing  100  may have port  114  and one or more wires  116  may exit or extend out of the port  114 . Port  114  may be positioned relative to electronic parts  102  and  104  to allow for receiving any wires and/or cables that extend out of port  114  from electronic parts  102  and  104 . In an embodiment, port  114  may be positioned such that wires  116  and/cables extend out from port  114  for use with an articulated region of housing  100 . 
     Three dimensional shaped housing  100  may have articulated region  118  that provides strain relief for one or more wires  116 . In an embodiment, one or more wires  116  may be covered by a cable and articulated region  118  may have a bellows shape that bends and/or is flexible at the junction between three dimensional shaped housing  100  and the cable to provide strain relief. Articulated region  118  may be any shape that allows for bending of one or more wires  116  exiting port  114 . For example, a bellows shaped housing may be a separate piece that is attached or coupled to the three dimensional shaped housing  100  at port  114  to form articulated region  118 . 
     In another embodiment, three dimensional shaped housing  100  may be an electroformed structure that is created with articulated region  118 , such that articulated region  118  is an integrated part of housing  100 . For example, articulated region  118  of three dimensional shaped housing  100  may have a spring or a bellow shaped texture and the mandrel may have at least one forming feature to create articulated region  118  of three dimensional shaped housing  100  during the electroforming process. Those with skill in the art will recognize that use of articulated region  118  is optional and housing  100  may be created without articulated region  118 . 
     In an embodiment, port  114  may also serve as a drain hole in the electroforming process for three dimensional shaped housing  100  to allow for removal of the mandrel. Those with skill in the art will recognize that any hole within housing  100  may optionally serve as a drain hole for removal of the mandrel. For example, port  114  may serve dual purposes as a port within the housing and a drainage hole for removal of the mandrel. 
       FIG. 2B  shows an illustrative cross-sectional view of a mandrel in accordance with embodiments of the invention. Mandrel  200  may encapsulate one or more electronic parts, illustrated with  102  and  104 , in one or more materials. For example, electronic parts  102  and  104  may be encapsulated by potting electronic parts in a plastic resin to form mandrel  200 . In another example, one or more electronic parts  102  and  104  may be encapsulated in aluminum. 
     Mandrel  200  may be shaped to create particular features in three dimensional shaped housing  100  and/or to create three dimensional shaped housing  100  that is shaped for performing a particular function. For example, mandrel  200  may be shaped to create three dimensional shaped housing  100  that may be used for an earbud. Mandrel  200  may be shaped to create housing  100  with a shape that substantially encloses one or more electronic parts for the earbud. It may be desirable to create a housing that substantially encloses the one or more electronic parts for a particular device so that there is no need to fasten pieces of a housing together to cover an electronic part. Mandrel  200  may be shaped to create housing  100  that completely encloses one or more electronic parts for an earbud. For example, mandrel  200  may be shaped to surround all of the electronic parts for housing  100  and create resulting housing  100  that fits comfortably within an ear. 
     Housing  100  may be shaped to ensure the electronics perform optimally, shaped to be aesthetically pleasing, and/or shaped to provide particular functionality. The shape of three dimensional shaped housing  100  created with mandrel  200  for an earbud may allow the three dimensional shaped housing  100  to sit adjacent to an ear canal. In another example, a resulting housing may be created to provide a component of an earbud, such as a microphone, a user interface, or a control, that may be attached to wires extending out from the earbud. For example, a resulting housing may provide a user interface component with controls including, but not limited to, the following: volume control, control for playback and/or recording of media, communication controls, and/or any other type of user interface for electronics. 
     Mandrel  200  may have retention forming feature  206  to form retention feature  110 , retention forming feature  208  to form retention feature  112 , retention forming feature  214  to form retention feature  124 , and retention forming feature  216  to form retention feature  122  in three dimensional shaped housing  100 . Metal layers may be applied to mandrel  200  during the electroforming process to form retention features  110 ,  112 ,  122 , and  124 , in accordance with the shape provided by retention forming features  206 ,  208 ,  214 , and  216  in the mandrel  200 . Retention features  110 ,  112 ,  122 , and  124  may be any shape, ridge, indentation, groove, and/or any other feature that may secure electronic parts  102  and  104  within three dimensional shaped housing  100  after mandrel  200  is removed. 
     Mandrel  200  may have drain hole forming feature  210  to form drain hole  108  in a three dimensional shaped housing  100 . Drain hole  108  may be used to allow the mandrel  200  to drain or seep out from the three dimensional shaped housing  100 . Drain holes may be strategically placed to serve a dual purpose. For example, drain hole  108  may serve as a sound port for an earbud in addition to being used for removal of mandrel. 
     Mandrel  200  may have connection forming feature  212 , such as a gap or a hole, to allow metal to be applied directly to electronic part  102  and form connection  106  between an electronic part  102  and the three dimensional shaped housing  100 . The three dimensional shaped housing  100  may be electrically connected to the electronic part  102 . 
     In another embodiment, mandrel  200  may encapsulate an area of electronic part  102  and  104  with a connection  106  (e.g., contact area for incorporating a component) already formed on electronic part  102 , and connection forming feature  212  may be a drain hole that remains in a resulting housing and is in close proximity to the area of electronic part  102  and  104  that allows for connecting a control or a user interface. Continuing with the example, positioning of a hole near the portion of the mandrel covering the area of electronic part  102  and  104  that allows for connection  106  may also ensure that a sufficient amount of the mandrel seeps out leaving the area of electronic part  102  and  104  exposed for attachment of a user interface or control to connection  106 . 
     Embodiments may encapsulate one or more electronic parts  102  and  104  in more than one material to create one or more mandrels. For example, electronic part  102  may be encapsulated in aluminum to form a first mandrel and electronic part  104  may be encapsulated in plastic resin to form a second mandrel. It may be desirable to use different materials to encapsulate a first and second mandrel to allow for removal of the mandrel materials at different times. For example, different materials may melt at different temperatures which may allow for removal of material for one mandrel while another mandrel made from a different material may stay intact. Alternatively, a single mandrel may be formed with multiple materials to control when portions of the mandrel are removed. Those with skill in the art will recognize that a variety of materials, shapes, and configurations for one or more mandrels are available for creating three dimensional shaped housing  100 . 
       FIG. 3A  shows an illustrative cross-sectional view of a mandrel in accordance with an example of an embodiment of the invention. Mandrel  300  may have electronic part  302  encapsulated within mandrel  300 . Mandrel  300  may have retention forming features  304  and  308  that may allow for creation of retention features in electroformed three dimensional shaped housing  100  that is substantially similar in shape to mandrel  300 . The retention features formed with mandrel  300  may secure electronic part  302  within three dimensional shaped housing  306  (described below with  FIG. 3B ). 
     Retention features may secure electronic part  302  in a particular position within three dimensional shaped housing  100 . For example, electronic part  302  may need to be positioned in a particular place within three dimensional shaped housing  100  to provide functionality, such as a preferred level of sound quality. In another example, the retention feature may hold electronic part  302  in place to limit or reduce the movement of the electronic part within three dimensional shaped housing  100 . Retention forming features  304  and  308  may be indentations, crevices, particular shapes, and/or any other features that can be modeled in a material, such as plastic resin or aluminum, and reproduced in three dimensional shaped housing  100  with an electroforming process. 
     Electronic part  302  may be potted in a plastic resin within mandrel  300 . Mandrel  300  may be shaped and/or molded with retention forming features  304  and  308  that allow for the creation of retention feature in three dimensional shaped housing  306  to secure electronic part  302  in place after at least a portion of mandrel  300  is removed. For example, a portion of mandrel  300  may be heated such that the material seeps out through drain hole  108 , and the retention feature created in three dimensional shaped housing  306  may hold electronic part  302  in place after the portion of mandrel  300  seeps out. 
       FIG. 3B  shows an illustrative view of an electroformed housing with a retention feature in accordance with an example of an embodiment of the invention. Three dimensional shaped housing  306  may be created with mandrel  300 . Electronic part  302  may remain in place after the removal of the mandrel  300  from three dimensional shaped housing  306  with retention features  310  and  312 . As shown in  FIG. 3A , retention forming features  304  and  308  provide for the creation of three dimensional shaped housing  306  with retention features  310  and  312  that secures electronic part  302  in place. 
     Retention features  310  and  312  may cause three dimensional shaped housing  306  to have a shape that partially resembles the electronic part within to accommodate the electronic part  302  and ensure that electronic part  302  stays in place and/or allows for movement of electronic part  302  permitted to maintain optimal performance of electronic part  302 . For example, retention features  310  and  312  may have a shape to support the corners of electronic part  302  and hold or secure electronic part  302  in place with limited movement, and as a result portions of housing  306  may have a shape to resemble a portion of electronic part  302  within. In another example, housing  100  supports electronic part  102  with retention features  110 ,  112 ,  122 , and  124  at each corner of the electronic part  102 , and housing  100  partially resembles or takes the shape of the electronic part  102  within. 
       FIG. 4  shows illustrative cross-sectional view of an electroformed housing in accordance with an example of an embodiment of the invention. Mandrel  400  may have connection forming feature  402 , such as an opening, that allows for the creation of connection  404  between three dimensional shaped housing  406  and electronic part  408 . Connection forming feature  402  of mandrel  400  may be an opening, a gap, or a hole in mandrel  400  that exposes electronic part  408  during the electroforming process. Connection forming feature  402  may be a size and a shape that allows for electroforming metal layers  410  to form connection  404  with the exposed electronic part  408 . Electroforming metal layers  410  may be applied to the surface of exposed electronic part  408 . Connection  404  may be used to provide an electrical pathway to electronic part  408  or contact area on electronic part  408 . In some embodiments, a user interface component for electronic part  408  may be coupled to connection  404 . 
       FIG. 5  shows an illustrative view of an electroformed housing in accordance with an example of an embodiment of the invention. Electroformed housing  100  may have plurality of holes  504  therein for permitting sound waves to pass through. In one or more embodiments, a photomask and/or any other type of film may be applied to three dimensional shaped electroformed housing  100 , such as an earbud housing illustrated in  FIG. 5 , and laser cutting or etching may be performed to create plurality of holes  504  in housing  100  to form sound region  506  for the earbud. 
     In another embodiment, a photomask or a film may be applied to mandrel  200  that has a particular pattern to create a sound region and layers of a material may be applied to mandrel  200  with photomask to create housing  100 . For example, photomask may have a pattern to form a plurality of holes in housing  100 . Continuing with the example, the photomask may be removed such that plurality of holes  504  remain on housing  100  in the pattern provided by the photomask to form sound region  506 . 
       FIG. 6B  shows a side view of an electroformed housing in accordance with an example of an embodiment of the invention.  FIG. 6B  shows a side view of an electroformed housing  100  for an earbud. As illustrated, electroformed housing  100  may be created as a single piece with no seams. Electroformed housing  100  may have an integrated sound region  506  and articulated region  118 . 
       FIG. 6A  shows a top plan view of an electroformed housing in accordance with an example of an embodiment of the invention.  FIG. 6A  shows a top plan view of an electroformed housing  100  for an earbud. As illustrated, electroformed housing  100  may be created as a single piece with no seams. Electroformed housing  100  may have an integrated sound region  506  and articulated region  118 . Those with skill in the art will recognize that there are an infinite number of patterns available for creating plurality of holes for sound region  506 . For example, as shown in  FIG. 6A  plurality of holes can be formed in concentric circles on electroformed housing  100 . In other embodiments, plurality of holes for sound region  506  can have a seemingly random pattern, as depicted in  FIGS. 5 and 6A . 
       FIG. 7  shows an illustrative cross-sectional view of a mandrel and an electroformed housing in accordance with an example of an embodiment of the invention. Mandrel  700  may be shaped to have texture forming features  702  to enable the creation of texture  706  on three dimensional shaped housing  704  as shown in  FIG. 7 . Three dimensional shaped housing  704  may have texture  706  to create an integrated articulated region in three dimensional shaped housing  704 . For example, texture  706  could create a spring or a bellow shaped articulated region  118  on the surface of three dimensional shaped housing  704 . 
       FIGS. 8A-D  show illustrative isometric views of electroformed housings in accordance with embodiments of the invention. Each of housings  800 ,  804 ,  806 , and  808  can encompass different types of electronics.  FIG. 8A  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention. Over-the ear earbud  800  is an example of an electroformed housing for electronic parts that can be created with an electroforming process. Over-the ear earbud  800  can be non-occluding or occluding, and over-the ear earbud  800  can be held and/or sit adjacent to the ear with the curved region  802  of the earbud  800  that can fit over the ear. 
       FIG. 8B  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention. Occluding earbud  804  and non-occluding earbud  806  are examples of electroformed housings for electronic parts. Occluding earbud  804  can be designed to fit inside of the user&#39;s ear canal and form a substantially airtight seal. 
       FIG. 8C  shows an illustrative isometric view of an electroformed housings in accordance with embodiments of the invention. Non-occluding earbud  806  can be designed not to form an airtight seal between the ear (or ear canal) and the outer surface of the earbud. Non-occluding earbud  806  can be created to perform a particular function optimally and/or be aesthetically pleasing. 
       FIG. 8D  shows an illustrative isometric view of an electroformed housing in accordance with embodiments of the invention. Electroformed housing for electronic parts  808  may be a component and/or accessory of an earbud that houses electronic parts, such as a microphone or volume control. 
       FIG. 9A  shows an illustrative cross-sectional view of multiple mandrels in accordance with some embodiments of the invention. One or more mandrels can be used to create an electroformed housing as illustrated with  FIG. 9A . A first mandrel  900  can be combined with a second mandrel  902  to create electroformed housing in  FIG. 9B , discussed in more detail below. The first mandrel  900  can be combined with the second mandrel  902  to form the electroformed housing in a variety of ways including, but not limited to, the following: the first mandrel  900  can be placed inside the second mandrel  902 , the first mandrel  900  can be coupled to the second mandrel  902 , and/or any other method for combining mandrels to form an electroformed housing. 
     In  FIG. 9A , the first mandrel  900  sits inside the second mandrel  902 , and mandrel  900  and mandrel  902  are shown coupled together to maintain their positions relative to each other during the electroforming process, as shown with coupling portions  915  and  916  to couple mandrels  900  and  902  together. The coupling portions  915  and  916  can be formed from any suitable material to hold mandrels  900  and  902  in place during the electroforming process. 
     First mandrel  900  retains electronic part  914  and provides opening  906  with wire  918  to electronic part  914  extending out from opening  906 . Metal layers may be applied to the first mandrel  900  during the electroforming process through openings  904  and  908  in the second mandrel  902 . Each of the mandrels (e.g.  900  and  902 ) can have drain holes (e.g. openings  906  and  908 ) to allow for creation of an electroformed housing with drain holes for removal of the mandrels. 
       FIG. 9B  shows an illustrative cross-sectional view of an electroformed housing in accordance with some embodiments of the invention. As shown in  FIG. 9B , a first three dimensional shaped housing  910  and a second three dimensional shaped housing  912  may be created during the electroforming process. Metal layers may be applied to mandrels  900  and  902  and coupling portions  915  and  916 . Mandrels  900  and  902  may be removed from first housing  912  and second housing  910 , as illustrated with regions  920  of empty space in each of the housings. Electronic part  914  is secured within housing  910 , and port  922  may be formed from opening  906  in mandrel  900  with wire  918  extending out from port  922 . 
     The first mandrel  900  and second mandrel  902  may be made of different materials and removed with different methods. For example, the first mandrel  900  may be made from plastic resin and the second mandrel  902  may be formed from aluminum, and each mandrel may be removed with a different process (e.g. acid bath, heating, etc.). Mandrels  900  and  902  may be removed through openings  922 ,  924 , and  926  that may serve as drain holes. Optionally, the coupling portions  915  and  916  may be made from a similar material as at least one mandrel and be removed. In  FIG. 9B , coupling portions  915  and  916  remain within the electroformed housing formed from the mandrels  900  and  902 . 
       FIG. 10A  is a flowchart of an illustrative process  1000  for electroforming a housing in accordance with some embodiments of the invention. Beginning at step  1002 , electronic circuitry may be encapsulated in a material to form a mandrel. For example, the electronic parts may be encapsulated by potting the one or more electronic parts in a plastic resin. The electronic parts may be encapsulated in a plastic resin using, for example, injection molding, insert molding, compression molding, or other suitable molding technique. The mandrel may have a three dimensional shape that encompasses one or more electronic parts. The mandrel may be shaped to create housing for a particular function. In an embodiment, the mandrel may have a three dimensional non-rectilinear shape to produce an electroformed housing for an earbud. The mandrel may have retention forming features to create retention features in the three dimensional shaped housing based on the retention forming features. For example, the retention features may hold an electronic part in a particular position within the housing. 
     At step  1004 , a metal layer may be electroformed around the mandrel to form electroformed housing. The metal layers may resemble the three dimensional shape of the mandrel to form an enclosure for the one or more electronic parts, as described in connection with the description accompanying  FIG. 1F . The retention features may be formed in the housing resembling the retention forming features in the mandrel after application of the metal layers. 
     During the electroforming process, the metal layer may be electroformed around the mandrel, such that the metal seeps through a hole or a gap in the mandrel to enable the three dimensional shaped housing to be electrically connected to at least one electronic part in an embodiment. The connection between the three dimensional shaped housing and the electronic part may allow for integration of a button for controlling electronics integrated into the three dimensional shaped housing. In one or more embodiments, a bellows shaped housing may be coupled to the three dimensional shaped housing to form an articulated region in the electroformed housing. 
     At step  1006 , at least a portion of the mandrel may be removed from the electroformed housing. After a portion of the mandrel is removed, electronic circuitry may be retained within electroformed housing. For example, the mandrel may be heated to remove a portion of the mandrel by allowing the melted material of the mandrel to drain. In another example, the mandrel may be removed by submersing the three dimensional shaped housing in an acid bath. In some embodiments, substantially all of the mandrel can be removed. Retention features may secure an electronic part after a portion of the mandrel is removed. 
       FIG. 10B  is a flowchart of an illustrative process  1001  for electroforming a housing in accordance with some embodiments of the invention. Beginning at step  1008 , interface circuitry is encapsulated in a material to form a mandrel. The mandrel encompasses the interface circuitry and has a first shape. The interface circuitry may be encapsulated in plastic resin using injection molding, insert molding, and compression molding. The mandrel may be shaped to create a housing for a particular function. In an embodiment, the mandrel may have a hexahedral shape for a keyboard housing. 
     The mandrel may be shaped to have retention forming features to create retention features in an electroformed housing to retain interface circuitry. For example, the resulting retention features may hold interface circuitry substantially adjacent to a user interface region to allow a user to initiate input events that can be processed using interface circuitry. 
     At step  1010 , a metal layer is electroformed around the mandrel to form the electroformed housing with a user interface region. The electroformed housing encompasses the mandrel and has a second shape that resembles the first shape. 
     During the electroforming process, the metal layer may be electroformed around the mandrel such that the metal seeps through a hole or a gap in the mandrel to enable the three dimensional shaped housing to be electrically connected to at least one electronic part of the interface circuitry. The resulting connection between the electroformed housing and the electronic part may allow for integration of a user interface control for initiating input events. 
     In an embodiment, one or more user interface features in the user interface region may be created in electroformed housing during the electroforming process based on one or more user interface forming features provided with the mandrel shape. The user interface region in the resulting electroformed housing may have input controls and/or components formed in the electroformed housing based on the user interface forming features. 
     At step  1012 , at least a portion of the mandrel is removed from the electroformed housing. The mandrel material may be removed by heating it to cause the material to flow from the electroformed housing. Alternatively, the material, such as aluminum, can be removed by submersing the electroformed housing in an acid bath to remove the material. After the portion of the mandrel is removed, the resulting electroformed housing is self-supporting and retains the second shape. In particular, the interface circuitry is retained within the electroformed housing in a position substantially adjacent to the user interface region. 
       FIG. 11A  shows an illustrative cross-sectional view of a mandrel in accordance with some embodiments of the invention. Specifically,  FIG. 11A  shows an illustrative view of mandrel  1100  for a keyboard. Mandrel  1100  encapsulates one or more electronic parts  1102  and  1110  in a material, such as a plastic resin. Mandrel  1100  may have a particular three dimensional shape to accommodate keyboard electronics and ensure that the resulting keyboard created with mandrel  1100  is shaped for the intended function of becoming a keyboard. 
     Mandrel  1100  may have a shape for creating a particular type of keyboard with a particular user interface region, such as a particular number of buttons. For example, mandrel  1100  may be shaped to create a keyboard for a particular language, such as English, Greek, Chinese, or any other language. In some embodiments, mandrel  1100  may have a shape to create an ergonomically correct keyboard, a numeric keyboard, a particular sized keyboard, a wireless keyboard, and/or any other input device designed for a particular function. 
     Mandrel  1100  may have retention forming features  208  to accommodate the keyboard electronics. Retention forming features  208  may be used to create retention features  310  in a keyboard housing to retain electronic parts  1102 , such as a circuit board or other interface circuitry, in a particular position and/or reduce movement of electronic parts  1102  within the keyboard. For example, retention forming features  208  may secure interface circuitry in place to ensure that when a user interacts with the keyboard to initiate a user input event, the user input event is processed by the interface circuitry. Electronics for a keyboard, may include, but are not limited to, the following: circuit board, wireless transmitter and receiver, interface circuitry, switches, and/or any other keyboard electronics. 
     The resulting retention features  310  may allow for an amount of movement of interface circuitry (e.g., a circuit board) that will not interfere with optimal performance of the keyboard. For example, retention features  310  may ensure that each switch (e.g., switch  1110 ) or contact area on circuit board  1102  remains underneath each user input component of user interface region in electroformed housing. Continuing with the example, retention feature  310  may retain switch  1110  underneath a corresponding button on the user interface region of a keyboard, so that the button and corresponding switch  1110  is functional. 
     As shown in  FIG. 11A , mandrel  1100  encapsulates electronic part  1102 , such as a circuit board, with switch  1110  for a keyboard. Mandrel  1100  has connection forming feature  1104  to allow for connecting a button, a control, or a user interface component to the electronic part  1102 . In an embodiment, connection forming feature  1104  is a hole or a gap in mandrel  1100  to allow for an electroformed metal layer to seep through connection forming feature  1104  (e.g., opening) to allow the keyboard housing to be electrically connected (e.g., create a contact area) to the electronic part  1102 . 
     In an embodiment, connection forming feature  1104  may serve dual purposes to provide an area for creating a contact area as well as provide a drain hole for removal of mandrel  1100  from a housing. A film may be placed over a portion of mandrel  1100  at an opening for connection forming feature  1104  and the film may be removed to expose the mandrel  1100  to ensure mandrel  1100  can be heated and removed from within a housing. 
     Mandrel  1100  may have user interface forming feature  1101  to create an integrated user interface control or component in a user interface region of a resulting keyboard housing created with mandrel  1100 . User interface forming feature  1101  of mandrel  1100  may allow for creation of an integrated user interface component in a resulting keyboard housing. For example, user interface forming feature  1101  may allow for creation of an integrated user input control, such as a button, in the electroformed housing. User interface forming feature  1101  may have a particular shape to allow for creation of interface features in an electroformed keyboard housing during the electroforming process. For example, user interface forming feature  1101  may be shaped to be a user interface component, such as a button, and layers of metal on user interface forming feature  1101  may create the user interface component. 
     In another embodiment, user interface forming feature  1101  may allow for creation of an output display or component for a user interface. In this case, user interface forming feature  1101  may be a mask applied to mandrel material that can later be removed to expose an output user interface component below. For example, a mask, a film, or other removable covering may be applied to a mandrel prior to an electroforming process and removed after formation of an electroformed housing to expose an output electronic part below. Continuing with the example, an output electronic part may be an LED, a display screen, and/or any other electronic part for providing output. 
     User interface forming feature  1101  of mandrel  1100  may be positioned substantially adjacent to corresponding interface circuitry to process input events for the resulting integrated input component in a keyboard housing. For example, encapsulated electronic part  1102  may have one or more switches (e.g.,  1110 ) or electrical contacts that can be positioned beneath user interface forming feature  1101  to ensure that the switches or electrical contacts are underneath the resulting integrated input component or controls (e.g., buttons) in an electroformed housing. 
     In an embodiment, mandrel  1100  may have a drain hole in close proximity to a switch or a contact area on circuit board  1102  to ensure that a sufficient amount of mandrel  1100  is removed from a contact area on the circuit board  1102 . For example, a portion of mandrel  1100  may be removed or drained from a housing such that a contact area created with connection forming feature  1104  on circuit board  1102  is functional when a button is secured to the housing above. 
       FIG. 11B  shows an illustrative top view of an electroformed housing in accordance with some embodiments of the invention.  FIG. 11B  illustrates a top view of electroformed keyboard  1106  formed using mandrel  1100  of  FIG. 11A . In an electroforming process, layers of the material may be deposited onto mandrel  1100  via a chemical bath. The material is deposited with sufficient number of layers and thickness to create a self-supporting structure for a keyboard, such that at least a portion of mandrel  1100  may be removed from the three dimensional shaped housing and the structure for the keyboard may remain intact. 
     At least a portion of mandrel  1100  may be removed or drained leaving the resulting self-supporting electroformed keyboard  1106 . For example, a portion of mandrel  1100  may be removed to ensure that the buttons of the keyboard are functional. In another embodiment, electronic parts  1102 , such as a circuit board may remain at least partially potted in a material. For example, a particular electronic part may perform optimally if it is cushioned in a mandrel material or remains isolated from other electronic parts in a material. 
     Electroformed keyboard  1106  may take a shape resembling mandrel  1100  or a shape substantially similar to mandrel  1100 . In an embodiment, electroformed keyboard  1106  may have a substantially rectilinear shape. Electroformed keyboard  1106  may have user interface region  1108  with a single button, a single user interface input, a plurality of user interface inputs, or a plurality of buttons or keys, as illustrated. Plurality of buttons of user interface region  1108  may be labeled with alphanumeric characters and/or symbols. Plurality of buttons may be engraved or printed with alphanumeric characters and/or symbols. 
     Interface circuitry may be positioned substantially adjacent to user interface region  1108  in order to process user initiated input events. For example, beneath each button from the plurality of buttons of user interface region  1108  may be switches or electrical contacts that allow a circuit on the circuit board to be completed when an actuator is pressed and/or touched by a user. A processor of interface circuitry can receive user inputs and drive output component. For example, a key may be pressed on the keyboard and interface circuitry may insure that the selected key is displayed on a display. 
       FIG. 11C  shows an illustrative cross-sectional view of an electroformed housing in  FIG. 11B  taken along line XIC-XIC in accordance with some embodiments of the invention. Cross-section of housing  1106  shows button  1112  from the plurality of buttons of user interface region  1108 . A switch  1114  for circuit board  1102  is provided underneath button  1112 . Upon touch or depression of button  1112 , the switch  1114  may complete a circuit on the circuit board  1102 , and device circuitry may process the user input event. 
     Button  1112  may be fastened to user interface region  1108  of electroformed keyboard housing  1106  at a connection  1114  formed with connection forming feature  1104  of mandrel  1100 . In another embodiment, interface region  1108  of electroformed housing  1106  may have an integrated user interface control component  1118  on the surface of electroformed housing created with user interface forming feature  1101  of mandrel  1100 . Interface circuitry, such as circuit board  1102 , may be positioned substantially adjacent to the user interface region  1108  to capture and process user initiated events using user interface of a device. 
     As shown in  FIG. 11C , mandrel  1100  may be substantially removed or drained from keyboard  1106  to ensure that material from mandrel  1100  does not interfere with optimal performance of the keyboard  1106 . In another embodiment, at least a portion of mandrel  1100  may remain within electroformed keyboard  1106  housing. 
       FIG. 11D  shows an illustrative side view of electroformed housing in  FIG. 11B .  FIG. 11D  shows electroformed keyboard  1106  with plurality of buttons from user interface region  1108  from the side. Keyboard  1106  may have a thickness  1116  to accommodate keyboard electronics and/or ports for connecting one or more accessories or devices. 
       FIG. 12  shows an isometric view of an electroformed housing in accordance with an example of an embodiment of the invention. A top view of an electroformed housing  1200  for a keyboard is illustrated. As shown, electroformed housing  1200  is formed with no seams. A plurality of buttons  1202  are integrated in to form interface region  1204  for electroformed housing  1200 . 
     In one or more embodiments, electroformed housing may serve as a housing for any portable, mobile, hand-held, or miniature mobile electronic device. Miniature devices may have a form factor that is smaller than a hand held device, such as an iPod™Shuffle available by Apple Inc. of Cupertino, Calif. Illustrative miniature devices may be incorporated into various objects that include, but are not limited to, the following: watches, rings, necklaces, belts, headsets, shoe accessories, virtual reality devices, other wearable electronics, sports or fitness equipment accessories, key chains, or any combination thereof. Alternatively, electronic device may not be portable at all. 
     While there have been described electroformed housings, earbuds, keyboards, devices, and systems and methods for the producing earbuds, keyboards, devices, and housings thereof, it is to be understood that many changes may be made therein without departing from the spirit and scope of the invention. Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, no known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. The described embodiments of the invention are presented for the purpose of illustration and not of limitation.

Metadata:
Filing Date: 20150428
Publication Date: 20190205
Grant Date: 20190205
Priority Date: 20121207
Inventors: RUSSELL-CLARKE, Peter N.
Assignee: APPLE INC
CPC Classifications: [{"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R31/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "C25D1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "C25D1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "C25D1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "C25D1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "C25D1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "C25D1/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R31/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49005", "inventive": false, "first": false, "tree": "[]"}, {"code": "C25D1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R1/021", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1058", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R2201/105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R31/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/025", "inventive": true, "first": false, "tree": "[]"}, {"code": "C25D1/20", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 49293847