PATENT DOCUMENT

Publication Number: US-8126138-B2
Application Number: US-65090807-A
Country: US
Kind Code: B2

Title: Integrated speaker assembly for personal media device

Abstract:
Systems and methods are provided for media devices including a housing, a frame disposed adjacent to the housing, and an acoustic source that is integrated with the frame for emitting sound from the media device.

Claims:
What is claimed is: 
     
       1. A media device comprising:
 a housing, 
 a frame disposed adjacent to the housing, and 
 an acoustic source being integrated with the frame for emitting sound from the media device, wherein the frame supports the acoustic source by extending beyond an outer surface of an enclosure that encloses at least a portion of the acoustic source. 
 
     
     
       2. The device of  claim 1 , wherein integrated with includes detachably connected to. 
     
     
       3. The device of  claim 1 , wherein integrated with includes unitarily formed with. 
     
     
       4. The device of  claim 1 , wherein integrated with includes mounted to. 
     
     
       5. The device of  claim 1 , wherein the frame is disposed substantially within the housing. 
     
     
       6. The device of  claim 1 , wherein the frame includes a sidewall. 
     
     
       7. The device of  claim 6 , wherein the sidewall includes an aperture in acoustic communication with the acoustic source. 
     
     
       8. The device of  claim 1 , wherein the frame includes a backplane. 
     
     
       9. The device of  claim 8 , wherein a portion of the acoustic source is positioned substantially on a top surface of the backplane. 
     
     
       10. The device of  claim 9 , wherein a portion of the acoustic source is enclosed within an upper casing of the enclosure, the upper casing being attached to the frame. 
     
     
       11. The device of  claim 8 , wherein a portion of the acoustic source is positioned substantially on a bottom surface of the backplane. 
     
     
       12. The device of  claim 11 , wherein a portion of the acoustic source is enclosed within a lower casing of the enclosure, the lower casing being attached to the frame. 
     
     
       13. The device of  claim 1 , wherein the frame is connected to the housing at least one gasket. 
     
     
       14. The device of  claim 1 , wherein the enclosure comprises an upper casing and a lower casing, wherein the frame extends beyond outer surfaces of the upper and lower casings and ends with a sidewall portion adjacent to the housing. 
     
     
       15. The device of  claim 1 , wherein at least a first portion of the frame comprises a plurality of backplanes, and wherein each one of the plurality of backplanes is positioned parallel with another one of the plurality of backplanes. 
     
     
       16. The device of  claim 1 , wherein the frame extends through the enclosure and beyond the outer surface of the enclosure. 
     
     
       17. A method for emitting sound from a media device comprising:
 integrating an acoustic source with a frame of the media device, wherein the frame supports the acoustic source by extending beyond an outer surface of an enclosure that encloses at least a portion of the acoustic source, and 
 emitting sound from the acoustic source to an external aperture of the housing. 
 
     
     
       18. The method of  claim 17 , wherein integrating includes detachably connecting to. 
     
     
       19. The method of  claim 17 , wherein integrating includes unitarily forming with. 
     
     
       20. The method of  claim 17 , wherein integrating includes mounting to. 
     
     
       21. The method of  claim 17  comprising disposing the frame substantially within the housing. 
     
     
       22. The method of  claim 17 , wherein the frame includes a sidewall. 
     
     
       23. The method of  claim 22 , wherein the sidewall includes an aperture in acoustic communication with the acoustic source. 
     
     
       24. The method of  claim 17 , wherein the frame includes a backplane. 
     
     
       25. The method of  claim 24  comprising positioning a portion of the acoustic source substantially on a top surface of the backplane. 
     
     
       26. The method of  claim 25  comprising enclosing a portion of the acoustic source within an upper casing of the enclosure, the upper casing being attached to the frame. 
     
     
       27. The method of  claim 24 , comprising positioning a portion of the acoustic source substantially on a bottom surface of the backplane. 
     
     
       28. The method of  claim 27  comprising enclosing a portion of the acoustic source within an upper casing of the enclosure, the upper casing being attached to the frame. 
     
     
       29. The method of  claim 24  comprising connecting the frame to the housing at least one gasket. 
     
     
       30. The method of  claim 17 , wherein the enclosure comprises an upper casing and a lower casing, wherein the frame extends beyond outer surfaces of the upper and lower casings and ends with a sidewall portion adjacent to the housing. 
     
     
       31. The method of  claim 17 , wherein at least a first portion of the frame comprises a plurality of backplanes, and wherein each one of the plurality of backplanes is positioned parallel with another one of the plurality of backplanes. 
     
     
       32. The method of  claim 17 , wherein the frame extends through the enclosure and beyond the outer surface of the enclosure. 
     
     
       33. A device comprising:
 an acoustic source; 
 a frame comprising a sidewall portion and a backplane portion extending from the sidewall portion; and 
 an enclosure that encloses at least a portion of the acoustic source, wherein the backplane portion extends through the enclosure, and wherein the sidewall portion is external to the enclosure. 
 
     
     
       34. The device of  claim 33  further comprising a housing secured to the sidewall portion. 
     
     
       35. The device of  claim 33  further comprising at least one gasket sealing the enclosure about at least a portion of the backplane portion.

Description:
REFERENCE TO RELATED APPLICATIONS 
     This application is co-pending with U.S. patent application publication No. 2008/0165999, published on Jul. 10, 2008, entitled “Integrated Microphone Assembly for Personal Media Device”, the entire contents of which are incorporated herein by reference. 
     BACKGROUND 
     This invention relates to personal media devices and, more particularly, to integrated speaker assemblies for personal media devices. 
     The proliferation of compact portable personal media devices (e.g., portable MP3 players, portable video players, and media capable cellular telephones) has created a need for delivery of audio (e.g., voice and music) via more durable, reliable, and robust audio sources to users while respecting the need to minimize the overall form factor of personal media devices. 
     One problem with existing media devices such as cellular telephones is that the media device&#39;s acoustic source, e.g., a speaker assembly, is susceptible to external forces that can damage subassembly components such as a diaphragm, electric components, or the housing. For example, a hand-held media device may be dropped by a user. An impact, even from a relatively short distance, could result in structural damage to a speaker assembly mounted on an internal printed circuit board (PCB) or mounted to the housing of the media device. Additionally, a gasket that provides a seal between the speaker assembly and device housing could buckle or become deformed due to the impact, resulting in reduced acoustic coupling from the acoustic source to the external aperture of the device. Accordingly, there is a need for mounting an acoustic source, such as a speaker assembly, in such a way as to reduce the susceptibility of the source to physical stress resulting from, for example, a physical impact on the device or “drop shock.” 
     Another problem with existing media devices is that the structural rigidity of the acoustic source or its surrounding components or materials may not be sufficient to adequately mitigate the effects of vibrations. For example, vibrations induced from another acoustic source, a user, an alarm, or another vibration source could adversely affect, introduce interference, or reduce the acoustic coupling from an acoustic source to the external aperture of the media device. Accordingly, there is a need for enhanced structural rigidity of the acoustic source or its surrounding materials to enable the acoustic source to more efficiently couple audio to the external housing aperture of a media device while mitigating the effects of vibration or other interference. 
     SUMMARY 
     The invention, in various embodiments, addresses deficiencies in the prior art by providing systems, methods and devices that enhance the ability of the acoustic source to withstand physical stresses and enhance sound quality while respecting the need for a compact and portable form factor for such devices. 
     In various aspects, the invention employs an acoustic source, e.g., a speaker assembly, in a media device. The acoustic source is integrated with at least a portion of the frame of the media device. Because a frame provides structural support for the media device, the frame generally has greater structural strength than, for example, a housing or internal circuit board of the media device. By integrating the acoustic source with a frame having greater structural strength and integrity, the ability of the acoustic source to withstand physical stresses or vibrations is enhanced. The term “integrated with” may include integrally formed with, unitarily formed with, attached to, detachably connected to, mounted on, or any like permanent, semi-permanent, or temporary configuration whereby the acoustic assembly, or a portion thereof, is in physical communication or contact with the frame of the media device. 
     In one aspect, a media device includes a housing, a frame disposed adjacent to the housing, and an acoustic source that is integrated with the frame for emitting sound from the media device. The frame may be disposed substantially within the housing. The frame may include a sidewall or plurality of sidewalls. At least one sidewall may include an aperture in acoustic communication with the acoustic source. 
     The frame may include a backplane. A portion of the acoustic source may be positioned substantially on a top surface of the backplane. A portion of the acoustic source may be enclosed within an upper casing where the upper casing is attached to the frame. Also, a portion of the acoustic source may be positioned substantially on a bottom surface of the backplane. A portion of the acoustic source may be enclosed within a lower casing where the lower casing is attached to the frame. The frame may be connected to the housing at least one gasket. 
     Another aspect of the invention includes a method for manufacturing a media device. The method includes providing a housing, attaching a frame to the housing, and integrating an acoustic source with the frame. The integration may include inserting an acoustic source within a recess of the frame. In one feature, an upper casing is mounted to the frame proximate to the acoustic. In another feature, a lower casing is mounted to the frame proximate to the acoustic source. 
     Various advantages and applications using an acoustic source integrated with a media device frame in accordance with principles of the present invention are discussed in more detail below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1A  is a perspective view of a media device with an exposed frame assembly according to an illustrative embodiment of the invention; 
         FIG. 1B  is another perspective view of a media device according to an illustrative embodiment of the invention; 
         FIG. 2  shows the media device of  FIGS. 1A and 1B  with tethered headphones and, alternatively, a wireless earpiece according to an illustrative embodiment of the invention; 
         FIG. 3  shows a simplified functional block diagram of a media device according to an illustrative embodiment of the invention; 
         FIG. 4  shows a transverse sectional view of a conventional cellular telephone; 
         FIG. 5  shows an exploded perspective view of the various sections of a conventional cellular telephone including a frame; 
         FIG. 6  shows a transverse sectional view of a media device according to an illustrative embodiment of the invention; 
         FIG. 7  shows a cross-sectional view of an acoustic assembly according to an illustrative embodiment of the invention; 
         FIG. 8  shows a perspective view of a frame including an integrated acoustic assembly according to an illustrative embodiment of the invention; 
         FIG. 9  shows a transverse sectional view of a portion of a media device including an acoustic assembly that is integrated with a frame according to an illustrative embodiment of the invention; and 
         FIG. 10  is a flow chart of a process for manufacturing a media device according to an illustrative embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
       FIG. 1A  is a perspective view of a media device  100  according to an illustrative embodiment of the invention. The media device  100  includes a housing  102 , a first housing portion  104 , a second housing portion  106 , a display  108 , a keypad  110 , a speaker housing aperture  112 , a microphone housing aperture  114 , a headphone jack  116 , and frame sidewall  122 . Although not shown, in certain embodiments, the frame sidewall  122  is the exposed portion of a frame residing within or adjacent to the housing  102  that provides structural support for the media device  100  and various internal components. The housing  102  also includes various gaps  118  that may include openings, separations, vents, or other pathways between elements of the housing  102  that enable the passage of air or sound through the housing  102 . 
     In one embodiment, the housing  102  includes a first housing portion  104  and a second housing portion  106  that are fastened together to encase various components of the media device  100 . In certain embodiments, the housing  102  also includes an exposed frame  120  that provides structural support for the media device  100 . The housing  102  and its housing portions  104  and  106  may include polymer-based materials that are formed by, for example, injection molding to define the form factor of the media device  100 . In one embodiment, the housing  102  surrounds and/or supports internal components such as, for example, one or more circuit boards having integrated circuit components, internal radio frequency (RF) circuitry, an internal antenna, a speaker, a microphone, a hard drive, a processor, and other components. Further details regarding certain internal components are discussed later with respect to  FIG. 3 . The housing  102  provides for mounting of a display  108 , keypad  110 , external jack  116 , data connectors, or other external interface elements. The housing  102  may include one or more housing apertures  112  to facilitate delivery of sound, including voice and music, to a user from a speaker within the housing  102 . The housing  102  may including one or more housing apertures  114  to facilitate the reception of sounds, such as voice, for an internal microphone from a media device user. 
     In certain embodiments, the housing  102  includes one or more gaps  118  associated with the housing  102 . These gaps  118  may result from the manufacturing and/or assembly process for the media device  100 . For example, in certain circumstances, the mechanical attachment of the first housing portion  104  with the second housing portion  106  or the sidewall  122  results in a crease  120  or joint between the portions  104  and  106 . In certain media devices  100 , the crease  120  is not airtight, resulting in gaps  118  along the crease. Other gaps may be formed during assembly between, for example, one or more keys of the keypad  110  and the housing  102  or the display  108  and the housing  102 , resulting in additional gaps  118 . In other embodiments, the housing  102  may include additional portions that are integrated to form the housing  102  for the media device  100 . 
     The media device  100  may include a wireless communications device such as a cellular telephone, satellite telephone, cordless telephone, personal digital assistant (PDA), pager, portable computer, or any other device capable of wireless communications. In fact,  FIG. 1  shows an exemplary cellular telephone version of a broad category of media device  100 . 
     The media device  100  may also be integrated within the packaging of other devices or structures such a vehicle, video game system, appliance, clothing, helmet, glasses, wearable apparel, stereo system, entertainment system, or other portable devices. In certain embodiments, device  100  may be docked or connected to a wireless enabling accessory system (e.g., a wi-fi docking system) that provides the media device  100  with short-range communicating functionality. Alternative types of media devices  100  may include, for example, a media player such as an iPod available by Apple Computer Inc., of Cupertino, Calif., pocket-sized personal computers such as an iPAQ Pocket PC available by Hewlett Packard Inc., of Palo Alto, Calif. and any other device capable of communicating wirelessly (with or without the aid of a wireless enabling accessory system). 
     In certain embodiments, the media device  100  may synchronize with, for example, a remote computing system or server to receive media (using either wireless or wireline communications paths). Wireless syncing enables the media device  100  to transmit and receive media and data without requiring a wired connection. Media may include, without limitation, sound or audio files, music, video, multi-media, and digital data, in streaming and/or discrete (e.g., files and packets) formats. 
     During synchronization, a host system may provide media to a client system or software application embedded within the media device  100 . In certain embodiments, media and/or data is “downloaded” to the media device  100 . In other embodiments, the media device  100  is capable of uploading media to a remote host or other client system. Further details regarding the capabilities of certain embodiments of the media device  100  are provided in U.S. Pat. No. 7,627,343, issued on Dec. 1, 2009, entitled “Media Player System,” the entire contents of which are incorporated herein by reference. 
       FIG. 1B  is another perspective view of a media device  100  according to an illustrative embodiment of the invention. In this embodiment, as opposed to the embodiment of  FIG. 1A , the media device&#39;s frame and/or the frame&#39;s sidewalls are not exposed to an external surface of the device. However, in certain embodiments, the frame is connected internally with at least a portion of one of the first housing portion  104  or the second housing portion  106 . 
       FIG. 2  shows the media device  100  of  FIG. 1  with tethered headphones  200  and, alternatively, a wireless earpiece  206  according to an illustrative embodiment of the invention. The tethered headphones  200  include a cable  212  that connects to the media device  100  via external jack  116 . In one embodiment, the cable provides for transport of an audio signal from the media device  100  to the headphones  200 . In another embodiment, the headphones  200  include a left housing  202  and a right housing  204 , corresponding to the left and right ears of a user, respectively. Each housing  202  and  204  may include a speaker and/or an acoustic assembly as described later with respect to  FIG. 4 . The headphones  200  may optionally include a microphone to facilitate sending sounds from the user to the media device  100 . As an alternative to the headphones  200 , a user may utilize the wireless earpiece  206  which includes a housing  208 . In one embodiment, the earpiece  206  employs wireless channel  210  to receive audio signals from the device  100  or transmit audio signals to the device  100 . The housing  208  may include a speaker, microphone, and/or acoustic assembly as described later with respect to  FIG. 4 . 
       FIG. 3  shows a simplified functional block diagram of the media device  100  according to an illustrative embodiment of the invention. The media device or player  300  may include a processor  302 , storage device  304 , user interface  306 , display  310 , CODEC  312 , bus  318 , memory  320 , communications circuitry  322 , a speaker or transducer  324 , and a microphone  326 . Processor  302  may control the operation of many functions and other circuitry included in media player  300 . Processor  302  may drive display  310  and may receive user inputs from user interface  306 . 
     Storage device  304  may store media (e.g., music and video files), software (e.g., for implanting functions on device  300 ), preference information (e.g., media playback preferences), lifestyle information (e.g., food preferences), exercise information (e.g., information obtained by exercise monitoring equipment), transaction information (e.g., information such as credit card information), wireless connection information (e.g., information that may enable media device to establish wireless communication with another device), subscription information (e.g., information that keeps track of podcasts or television shows or other media a user subscribes to), and any other suitable data. Storage device  304  may include one more storage mediums, including for example, a hard-drive, permanent memory such as ROM, semi-permanent memory such as RAM, or cache. 
     Memory  320  may include one or more different types of memory which may be used for performing device functions. For example, memory  320  may include cache, ROM, and/or RAM. Bus  318  may provide a data transfer path for transferring data to, from, or between at least storage device  304 , memory  320 , and processor  302 . Coder/decoder (CODEC)  312  may be included to convert digital audio signals into an analog signal for driving the speaker  324  to produce sound including voice, music, and other like audio. The CODEC  312  may also convert audio inputs from the microphone  326  into digital audio signals. 
     User interface  306  may allow a user to interact with the media device  300 . For example, the user input device  306  can take a variety of forms, such as a button, keypad, dial, a click wheel, or a touch screen. Communications circuitry  322  may include circuitry for wireless communication (e.g., short-range and/or long range communication). For example, the wireless communication circuitry may be wi-fi enabling circuitry that permits wireless communication according to one of the 802.11 standards. Other wireless network protocol standards could also be used, either in alternative to the identified protocols or in addition to the identified protocols. Other network standards may include Bluetooth, the Global System for Mobile Communications (GSM), and code divisional multiple access (CDMA) based wireless protocols. Communications circuitry  322  may also include circuitry that enables device  300  to be electrically coupled to another device (e.g., a computer or an accessory device) and communicate with that other device. 
     In one embodiment, the media device  300  may be a portable computing device dedicated to processing media such as audio and video. For example, media device  300  may be a media player (e.g., MP3 player), a game player, a remote controller, a portable communication device, a remote ordering interface, an audio tour player, or other suitable personal device. The media device  300  may be battery-operated and highly portable so as to allow a user to listen to music, play games or video, record video or take pictures, communicate with others, and/or control other devices. In addition, the media device  300  may be sized such that it fits relatively easily into a pocket or hand of the user. By being handheld, the media device  300  (or media device  100  shown in  FIG. 1 ) is relatively small and easily handled and utilized by its user and thus may be taken practically anywhere the user travels. 
     As discussed previously, the relatively small form factor of certain prior art media devices has constrained the ability of these media devices to protect certain acoustic components such as speaker or microphone assemblies from damaging physical forces. Also, the quality of sound emitted from an acoustic source or received by an acoustic receptor has been adversely affected by the supporting structure or structures for these acoustic components. For example, a speaker that is mounted on a circuit board may be susceptible to vibrations that are propagated along the circuit board structure which can introduce interference or noise into the speaker&#39;s sound output. Accordingly, embodiments of the invention provide for improved sound quality and enhanced structural support for acoustic components such as an acoustic source. 
       FIG. 4  shows a transverse sectional view of a conventional cellular telephone  400 . The conventional cellular telephone  400  comprises an upper housing  402 . The main structural frame  404  is secured to the housing  402  which may be fabricated from a die-castable material using a die-casting process. The frame  404  includes a surrounding sidewall  406  and a web or backplane  408 . The web  408  extends between the sidewall  406  and forms a printed circuit board compartment between the housing  402  and web  408 . The printed circuit board compartment is bounded on the top by the housing  402  and on the bottom by the web  408 . The printed circuit board compartment includes a printed circuit board  410  and associated electrical components  412 . The web  408  supports or houses a battery  414  which, in turn, forms the back of the cellular telephone  400 . The conventional cellular telephone  400  employs a unitized frame member  404  which is composed of a single die-castable material, typically magnesium or zinc, where the sidewall  406  and the web  408  are constructed of the same or different material via a die-cast fabrication technique. 
       FIG. 5  shows an exploded perspective view of the various sections of a conventional cellular telephone  500  including a frame  502 . The cellular telephone  500  generally comprises an upper enclosure or housing  504 , a printed circuit board  506 , the structural frame member  502 , and a battery  508 . As shown in  FIG. 5 , there are a number of features formed on the housing  504  that correspond with components located on the printed circuit board  506 . For example, disposed on the exterior face of the housing  504  is a display panel aperture  510  that corresponds with a display panel  512  disposed on the printed circuit board  506 . 
     Adjacent to the display panel aperture  510  is an earphone or speaker aperture  514  that corresponds with a speaker component or assembly  516  on the printed circuit board  506 . Also disposed on the face of the housing  504  is an array of keypad apertures  518  that corresponds with a tactile keypad component  520  mounted on the printed circuit board  506 . A microphone aperture  522  is located adjacent the keypad apertures  518  that corresponds with a microphone component or assembly  524  which is mounted on the printed circuit board  506 . 
     The cellular telephone  500  includes a structural frame  502 , that also includes a surrounding sidewall  526  and a web or backplane  528 . An antenna receptacle  530  is formed as part of the frame  502  that enables the transfer of radio frequency (RF) communications with the enclosed printed circuit board  506 . The sidewall  526  is formed through a die-casting process using material such as magnesium or zinc or alloys of each. The term die-cast typically refers to a structure formed by a process wherein the casting material is melted into a liquid phase and poured into a die-cast mold. The casting material then assumes the shape of the mold upon cooling and solidification. 
     The backplane  528  typically includes a thin, high strength formed structure, such as a plate of stainless steel. A formed structure typically includes components that have been stamped, pressed, punched, rolled or otherwise fabricated while the formed material is in a solid phase. The thin plate or backplane  528  is typically secured to the sidewall  526  using a mechanical or die-casting technique. 
     The backplane  528  typically extends between the surrounding sidewall  526  and divides the enclosed interior space into a printed circuit board compartment and a battery compartment. The printed circuit board compartment is typically bounded on the top by the housing  504 , and on the bottom by the backplane  528 . The printed circuit board compartment typically contains the printed circuit board  506  and various associated electrical components. The backplane  528  also acts as an upper boundary for the battery compartment. The battery pack  508  can be attached to the frame  502  and forms the back of the cellular telephone  500 . It should be understood that the frame  528  typically establishes front and back compartments on each side of the backplane  528 . 
       FIG. 6  shows a transverse sectional view of a media device  600  according to an illustrative embodiment of the invention. The media device  600  comprises an upper housing  602 , lower housing  604 , a frame  606 , a printed circuit board  608 , printed circuit board components  610 , and an acoustic source  612 . In one embodiment, the acoustic source  612  is integrated with the frame  606  and includes an acoustic subassembly  622 , an upper casing  624 , a lower casing  626 , and casing seals  628 . The frame  606  includes a sidewall or sidewalls  614  and a backplane  616 . In one embodiment, the main structural frame  606  is secured to at least one of the upper housing  602  and lower housing  604 . At least a portion of the housings  602  and  604  may be fabricated from a die-castable material using a process including die-casting, molding, injection-type molding, and/or the like. 
     In one embodiment, the frame  606  includes a surrounding sidewall  614  or plurality of sidewalls  614  and a web or backplane  616 . The web  616  extends between the sidewall  614  or between two or more sidewalls  614  to form a printed circuit board compartment  618  between the upper housing  602  and the web  616 . Thus, the printed circuit board compartment  618  may be bounded on the top by the upper housing  602  and on the bottom by the web  616 . In certain embodiments, the sidewall  614  extends completely along the perimeter of the frame  606 . Alternatively, the sidewall  614  extends along one or more portions of the perimeter of frame  606 , effectively forming a plurality of sidewalls  614 . In one embodiment, the frame  606  does not have a sidewall  614 , but is connected to or integrated with at least one of the upper housing  602  and the lower housing  604  or integrated with at least one of the first housing portion  104  and the second housing portion  106  of the media device  100 . 
     In certain embodiments, the web  616  and lower housing  604  form a second compartment  620  that contains a battery and/or electrical components. The media device  600  may employ a unitized or composite frame  606  that includes a die-castable or other material, such as steel, magnesium and/or zinc, or related alloys, where the sidewalls  614  and the web  616  are constructed of the same or different materials via a die-cast and/or assembly fabrication technique. The assembly fabrication technique may include connecting one or more portions of the frame  606  together using glue, one or more mechanical connectors, or another like attachment mechanism or medium. 
     In certain embodiments, the acoustic source  612 , e.g., a speaker assembly, is integrated with the frame  606  as shown in  FIG. 6 . As previously discussed, the acoustic source  612  includes an acoustic subassembly  622 , an upper casing  624 , a lower casing  626 , and casing gaskets or seals  628 . The acoustic subassembly  622  may be, for example, a speaker subassembly including a diaphragm and other speaker components. By integrating the acoustic source  612  with the frame  606 , the frame  606  advantageously protects the acoustic subassembly  622  components from external forces and/or mitigates the effects of vibration or other interference. For example, in some embodiments, web  616  of frame  606  may support acoustic source  612  and may extend beyond an outer surface of an enclosure that encloses at least a portion of the acoustic subassembly  622  (e.g., an enclosure that may be formed by at least upper casing  624  and/or lower casing  626 ). 
     In one embodiment, the frame  606  includes a recess  630  within which the acoustic subassembly  622  is disposed. In another embodiment, the acoustic source  612  includes an upper casing  624  that is disposed above the acoustic subassembly  622 . In a further embodiment, the acoustic source  612  includes a lower casing  626  that is disposed below the acoustic subassembly  622 . One or more casing seals may be employed to fasten either or both the upper casing  624  and the lower casing  626  to the frame  606 . Because the upper casing  624  and the frame  606  form an upper volume  632  and the lower casing  626  and frame  606  form a lower volume  634 , the upper and lower volumes  632  and  634  may be adjusted by adjusting the size of the upper and lower casings  624  and  626  respectively. By adjusting the size of the volumes  632  and  634 , the quality of sound emitted by the acoustic source  612  may be adjusted. In one embodiment, the seals  628  include adhesive to enable the casing  624  and/or  626  to connect with the web and/or sidewall of frame  606 . 
     In an alternative embodiment, the acoustic source  612  is integrated with the frame  606  substantially within the upper casing  624 . The acoustic source  612  may include an upper and lower volume, or other volumes, substantially within the upper casing  624 . In another alternative embodiment, the acoustic source  612  is integrated with the frame  606  substantially within the lower casing  626 . The acoustic source  612  may include an upper and lower volume, or other volumes, substantially within the lower casing  626 . Thus, in certain embodiments, the frame  606  includes a casing for an acoustic source  612  on either its top or bottom side as opposed to on both sides of the frame  606 . 
     Although  FIG. 6  shows the acoustic source  612  being integrated with the frame  606  while contacting both the sidewall  614  and web  616 , the acoustic source  612  may be positioned at any one of a plurality of possible positions on the web  616  and/or between the sidewalls  614 . In one embodiment, the upper and lower casings  624  and  626  are connected to the web  616 , with or without casing seals  628 . The size and shape of the acoustic source  612  and the casings  624  and  626  may vary depending on the available space, desired sound quality, and positioning of other components in the media device  600 . For example, the shape of the acoustic source  612  may be, without limitation, rectangular, circular, helical, spherical, stepped, or any other shape dictated by surrounding components and/or other design requirements. 
     The frame  606  may include one or more apertures, cutouts, openings, and/or recesses to support the acoustic source  612 . In one embodiment, the sidewall  614  includes at least one aperture to enable the transport of sound from the acoustic source  612  to outside of the media device  600 . 
       FIG. 7  shows a cross-sectional view of an acoustic source  700  according to an illustrative embodiment of the invention. The acoustic source  700  includes an acoustic subassembly  702 , a first chamber  704 , a second chamber  706 , a housing  708 , a first lateral wall  710 , a second lateral wall  712 , a retaining wall  714 , an output aperture  716 , a first source aperture  718 , a second source aperture  720 , a first transfer aperture  722 , a second transfer aperture  724 , and a leak aperture  726 . A user&#39;s ear  728  is typically positioned in proximity to the output aperture  716  to enable the user to receive sound, e.g., voice or music, from the aperture  716 . The acoustic subassembly  702  may include a micro-speaker such as a speaker in the 2403 Receiver family manufactured by NXP Semiconductors of Eindhoven, The Netherlands. 
     In certain embodiments, the acoustic source  700  is included within, for example, the housing  102  of the media device  100  as shown in  FIG. 1 . In one embodiment, the housing  708  corresponds to the housing  102  of  FIG. 1 . Thus, the first chamber  704  may be a cavity, void, space, or enclosure within the housing  102 . Also, the second chamber may be a second cavity, void, space, or enclosure within the housing  102 . In one embodiment, the retaining wall  714  is a portion of the web  616  of the frame  606  of  FIG. 6 . In other embodiments, at least one of the first lateral wall  710 , a second lateral wall  712 , a retaining wall  714 , an output aperture  716 , a first source aperture  718 , a second source aperture  720 , a first transfer aperture  722 , a second transfer aperture  724 , and a leak aperture  726  is integrated with a frame such as frame  606  of  FIG. 6 . In certain embodiments, the acoustic subassembly  702  emits sound through at least one aperture such as apertures  718  and  720  into the first chamber  704 . In one embodiment, the second chamber  706  is in contact with or directly coupled to the acoustic subassembly  702 . Either chamber  704  or  706  may be filled with air, a gas mixture other than air, a liquid, or other acoustically permeable material. The acoustic subassembly  702  may include a transducer, a speaker, or a micro-speaker. The acoustic subassembly  702  may be referred to as an acoustic receiver which is distinct from an RF receiver. 
     In one embodiment, the size or area of the leak aperture  726  is derived from a plurality of actual apertures or gaps  118  in the housing  102  (as shown in  FIG. 1 ). In certain embodiments, the effective area of the leak aperture  726  is calculated, measured, and/or algorithmically modeled from an aggregation of the gaps  118  to estimate the effective leak rate of sound from the second chamber  706 . In one embodiment, the second chamber  706  includes a cavity within the housing  708  (or housing  102  of  FIG. 1 ) other than the volume of the chamber  704 . Thus, the effective area of the aperture  726  may include the sum of the areas of all of the gaps  118  of the housing  102 . Because, in certain embodiments, the media device  100  is manufactured and/or assembled using a repeatable and/or predictable process with consistent component dimensions, the effective area and/or leak rate of the aperture  726  can be predicted and/or estimated within a reasonable tolerance for every media device  100 . Thus, for example, the volume of the first chamber  704  or the area of the apertures other than the effective aperture  726  may be configured to optimize the tuning of the sound emitted from the aperture  716  for a large volume of media devices  100 . 
     In another embodiment, the acoustic subassembly  702  is disposed in a position that overlaps or is adjacent to only a portion of the output aperture  716 . To direct sound or sound waves from the acoustic source  702  to the aperture  716 , the acoustic subassembly  702  employs the first chamber  704 , i.e., a front cavity, which is defined by the lateral walls  710  and  712  and the retaining wall  714  that extends between the lateral walls  710  and  712 . The retaining wall may include at least one transfer aperture such as apertures  722  and  724  that permit sound waves to flow from the first chamber  704  to the second chamber  706 . The transfer apertures  722  and  724  may be considered leak apertures from the first chamber  704 . In one embodiment, the second chamber  706  includes the internal volume of the media device  100  other than the volume of the first chamber  704 . To provide an outlet for sound waves that have leaked into the chamber  706 , a plurality of apertures (represented conceptually as leak aperture  726 ) may be disposed throughout the housing of the media device (e.g., gaps  118 ). Alternatively, one or more gaps  118  may be selectively machined through the housing  708  to adjust the effective leak aperture  726  size. 
     In one embodiment, the retaining wall  714  provides a surface to which the acoustic subassembly  702  is affixed. The retaining wall  714  may be a portion of a backplane or web  616  as shown in  FIG. 6 . The retaining wall may include apertures such as source apertures  718  and  720  that permit the flow of sound waves from the acoustic subassembly  702  into the first chamber  704 . In certain embodiments, the transfer or internal leak apertures  722  and  724  permit improved control of the acoustic quality of the sound emitted from the aperture  716 . 
     In certain embodiments, the housing  708  is defined by the upper and/or lower casings  624  and  626  of  FIG. 6 . In other embodiments, the housing  708  is defined by either the upper casing  624  or the lower casing  626 . Thus, for example, the first chamber  704  may be defined by an upper casing  624  while the second chamber  706  is defined by an inner volume of the media device  100  because a lower casing  626  is not present. In another example, only the lower casing  626  may be present wherein the acoustic subassembly resides in the second chamber  706 . Thus, the first chamber  704  is defined as a portion of the volume of the housing  102  which may include, for example, the printed circuit board compartment  618  as shown in  FIG. 6 . In one embodiment, the aperture  716  is included in a portion of the frame  606 . More particularly, the aperture  716  may reside within a sidewall  614  of the frame  606 , or in the skin of a media device that is adjacent to the frame  606 , and thereby enable the coupling of sound to outside of a media device such as media device  100 . In an alternative embodiment, the aperture  716  may couple sound to an intermediate chamber for subsequent coupling via another aperture to outside of the media device  100 . Further details regarding various embodiments of the acoustic source  700  are described in further detail in U.S. Patent application publication No. 2008/0149417, published on Jun. 26, 2008, entitled “Acoustic Assembly for Personal Media Device,” the entire contents of which are incorporated herein by reference. 
       FIG. 8  shows a perspective view of a frame  800  including an upper casing  802  and a lower casing  804  for supporting an integrated acoustic source according to an illustrative embodiment of the invention. In one embodiment, the upper and lower casings  802  and  804  are connected to the backplane or web  806  of the frame  800 . In addition to providing support and shock protection to an enclosed acoustic subassembly, the casings  802  and  804  provide increased structural support and integrity to the frame  800  itself. In another embodiment, a portion of at least the upper and lower casings  802  and  804  may be connected to a sidewall or sidewalls  808  of the frame  800 . The frame  800  may include a backplane  806  that extends between sidewalls  808 . Although shown as a solid sheet or plane of material, the backplane  806  may include one or more openings, cut-outs, or voids. In one embodiment, the frame  800  includes only sidewall  808  with substantially no backplane  806 . In another embodiment, the backplane  806  includes sections or portions that are stepped or shifted vertically from one another. In yet another embodiment, the frame  800  includes a plurality of backplanes  806  or has portions wherein a plurality of backplane sheets overlap or are positioned in parallel with one another. For example, in one embodiment, the backplane section  810  overlaps and/or is positioned in parallel with the backplane  806 , both of which are portions of the frame  800 . In a further embodiment, a multilayered frame  800  provides increased firmness and structural integrity for a media device and its various components. 
       FIG. 9  shows a transverse sectional view of a housing portion  900  of a media device including an acoustic source  902  that is integrated with a frame  904  according to an illustrative embodiment of the invention. The acoustic source  902  includes an acoustic subassembly  906 , an upper casing  908 , and casing seals or gaskets  910 . The housing portion  900  also includes a housing shell or skin  912  having a plurality of output apertures  914  in a grill pattern. The frame  904  also includes seals or gaskets  916 . The acoustic subassembly  906  may further employ one or more gaskets for mounting on the frame  904 . Because the acoustic subassembly  906  is disposed within or adjacent to the frame  904 , relatively short gaskets, with respect to conventional gaskets, may be employed between the acoustic subassembly  906 , the frame  904 , and the skin  912  to cushion the acoustic subassembly  906  from external forces that could damage or cause interference with the acoustic subassembly  906  components. Without the frame  904  between the acoustic subassembly  906  and/or the skin  912 , a longer gasket is required that is susceptible to buckling when exposed to sufficient external force. Once a gasket buckles or is deformed, the gasket&#39;s ability to, for example, couple sounds efficiently is reduced. In contrast, the shorter gaskets  910  and/or  916  are able to withstand greater external forces and, therefore, are less susceptible to buckling and deformation due to physical shock. In certain embodiments, the width or thickness of a gasket is less than about 1.5 mm, less than about 1.25 mm, less than about 1 mm, less than about 0.75 mm, less than about 0.5 mm, less than about 0.25 mm, less than about 0.125 mm, less than about 0.1 mm, less than about 0.075 mm, and/or less than about 0.05 mm. Accordingly, by employing these relatively shorter gaskets  910  and  916 , a media device becomes more robust and reliable with respect to physical stresses and for delivering quality sound  918 . 
     In certain embodiments, as shown in  FIG. 9 , the acoustic source  902  is able to provide sound  918  to an output aperture  914  along a curved surface of the skin  912  because the acoustic source  902  can be positioned away from the skin  912 . The acoustic source  902  can be positioned a distance away from the skin  912  because the acoustic source  902  is integrated with and/or supported by the frame  904 . 
       FIG. 10  is a flow chart of a process  1000  for manufacturing a media device according to an illustrative embodiment of the invention. The process  1000 , in one embodiment, includes providing a media device housing such as housing  102  of  FIG. 1  (Step  1002 ). Then, attaching a frame such as frame  800  to the housing (Step  1004 ). Also, an acoustic source such as acoustic source  902  is integrated with the frame to enable the delivery of sound outside of a media device such as media device  100  (Step  1006 ). The integration of the acoustic source with the frame may include mounting an acoustic subassembly to the frame and then mounting either or both an upper and lower casing to the frame wherein the acoustic subassembly resides. 
     It is understood that the various features, elements, or processes of the foregoing figures and description are interchangeable or combinable to realize or practice the invention describe herein. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20070105
Publication Date: 20120228
Grant Date: 20120228
Priority Date: 20070105
Inventors: DINH RICHARD HUNG MINH
TAN TANG YEW
BARRENTINE DEREK BOYD
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/03", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M1/72442", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0254", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/72442", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/0254", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/2842", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R2499/11", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/2842", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 39594329