Wireless listening device

Abstract

The present disclosure relates to a wireless listening device. A headset includes: a device housing that defines an internal cavity within the device housing; an acoustic port that is formed through a wall of the device housing and has an opening at an outer surface of the device housing; an audio driver that is disposed within the device housing and is aligned to emit sound through the acoustic port; and a mesh that is disposed within the acoustic port and has an outer perimeter spaced apart from the device housing wall, wherein the mesh forms a part of an outer surface of the headset, and the part is recessed from the opening at the outer surface of the device housing.

Description

[0001] Cross - Reference to Related Applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 134,922, filed on January 7, 2021, entitled "WIRELESS LISTENING DEVICE"; U.S. Provisional Patent Application No. 63 / 165,991, filed on March 25, 2021, entitled "WIRELESS LISTENING DEVICE"; and U.S. Patent Application No. 17 / 496,746, filed on October 7, 2021, entitled "WIRELESS LISTENING DEVICE", the entire disclosures of which are incorporated herein by reference for all purposes.

[0003] This patent application relates to U.S. Patent Application No. 17 / 496,748, filed on October 7, 2021, entitled "WIRELESS LISTENING DEVICE", the entire disclosure of which is incorporated herein by reference for all purposes. BACKGROUND OF THE INVENTION

[0004] Portable listening devices such as headphones can be used with a variety of electronic devices, such as portable media players, smartphones, tablet computers, laptop computers, stereo systems, and other types of devices. Historically, portable listening devices have included one or more small speakers configured to be placed on, in, or near a user's ear, structural components to hold the speakers in place, and a cable to electrically connect the portable listening device to an audio source. More recently, wireless portable listening devices that do not include a cable but instead wirelessly receive an audio data stream from a wireless audio source have become prevalent. Such wireless portable listening devices can include, for example, wireless earbud devices or wireless in-ear listening devices that operate in pairs (one for each ear) or individually to output sound to a user and receive sound from the user.

[0005] While wireless portable listening devices have many advantages over wired portable listening devices and have become very common for consumers, there is a need for improved wireless portable listening devices. SUMMARY OF THE INVENTION

[0006] This disclosure describes various embodiments of portable listening devices that can enable a user to experience high-end acoustic performance and a pleasant positive user experience.

[0007] In some embodiments, a headset includes: a device housing that defines an internal cavity within the device housing; an acoustic port formed through a wall of the device housing and having an opening at an outer surface of the device housing; an audio driver disposed within the device housing and aligned to emit sound through the acoustic port; and a mesh disposed within the acoustic port and having an outer perimeter spaced apart from the device housing wall, wherein the mesh forms a portion of the outer surface of the headset that is recessed from the opening at the outer surface of the device housing.

[0008] In some embodiments, a portable acoustic device is provided that includes: a device housing that defines an internal cavity within the device housing, the device housing including a speaker housing portion and a stem portion extending away from the speaker housing portion, wherein the speaker housing portion and the stem portion combine to define the internal cavity within the device housing; an acoustic port formed through a wall of the device housing and having an opening at an outer surface of the device housing, wherein the wall includes a first edge and a second edge separated by a ledge that extends completely around a perimeter of the acoustic port; an audio driver disposed within the device housing and aligned to emit sound through the acoustic port; and a mesh disposed within the acoustic port and having an outer perimeter spaced apart from the device housing wall, wherein the mesh forms a portion of the outer surface of the portable acoustic device that is recessed from the opening at the outer surface of the speaker housing.

[0009] In additional embodiments, a portable acoustic device is provided that includes: a device housing that defines an internal cavity within the device housing, the device housing including a speaker housing portion and a stem portion extending away from the speaker housing portion, wherein the speaker housing portion and the stem portion combine to define the internal cavity within the device housing; a wireless antenna disposed within the housing; an acoustic port formed through a wall of the device housing and having an opening at an outer surface of the device housing, wherein the wall includes a first edge and a second edge separated by a ledge that extends completely around a perimeter of the acoustic port; an audio driver disposed within the device housing and aligned to emit sound through the acoustic port; a battery disposed within the housing; and a mesh disposed within the acoustic port and having an outer perimeter spaced apart from the device housing wall, wherein the mesh forms a portion of the outer surface of the portable wireless acoustic device that is recessed from the opening at the outer surface of the device housing.

[0010] In some embodiments, a portable wireless acoustic device includes: a device housing that defines an internal cavity, the device housing including a speaker housing portion and a stem portion that extends away from the speaker housing portion; a first acoustic port formed through a wall of the speaker housing; an audio driver disposed within the speaker housing portion and aligned to emit sound through the first acoustic port; a battery disposed within the speaker housing portion and positioned on a side of the audio driver opposite the acoustic port; an antenna disposed within the stem; a user input area disposed along the stem; and a system-on-chip disposed within the stem, the system-on-chip including: a processor that controls operation of the portable wireless acoustic device, a charging circuit, an accelerometer, a wireless communication controller, a support component for the antenna, and a support component for the user input area.

[0011] In some additional embodiments, a portable wireless acoustic device includes: a device housing that defines an internal cavity; an acoustic port formed through the device housing; an audio driver disposed within the device housing and aligned to emit sound through the acoustic port; one or more electronic components that require power to operate; a battery disposed within the device housing and operable to provide power to the one or more electronic components, the battery having an outer surface and including a first electrical interconnect and a second electrical interconnect that extend away from the outer surface and are configured to operatively couple the battery to the one or more electronic components; and a hydrophobic coating deposited over the entire outer surface of the battery in addition to the first electrical interconnect and the second electrical interconnect.

[0012] In another embodiment, a headset includes: a device housing that includes a speaker housing that defines an internal cavity within the device housing; an acoustic port formed through the device housing; an audio driver disposed within the device housing and aligned to emit sound through the acoustic port, wherein the audio driver mates with an inner surface of the speaker housing to define a front volume within the device housing for the audio driver, the front volume being sealed relative to the surrounding environment except for a free-flowing air path through the acoustic port to the surrounding environment; a microphone disposed within the front volume of the device housing; and a processor operatively coupled to receive an output from the microphone, the processor being configured to change an audio profile of the audio driver based on the output from the microphone.

[0013] Various specific embodiments of the earphones or portable acoustic devices described herein may include one or more of the following features. The mesh may be recessed 0.5 mm to 2.0 mm from an opening at the outer surface of the device housing within the acoustic port. The mesh may have a convex profile, where the outer edge of the mesh is recessed more from the opening at the outer surface of the housing compared to the center of the mesh. The wall may include a first edge and a second edge separated by a ledge that extends completely around the perimeter of the acoustic port. The ledge may define an acoustic dead zone surrounding the outer perimeter of the acoustic port, and the outer perimeter of the mesh is disposed within the acoustic dead zone. The mesh may be a multi-layer mesh including an outer decorative mesh and an inner acoustic mesh. The device housing may include a speaker housing and a stem extending away from the speaker housing. The speaker housing and the stem may be combined to define an internal cavity within the device housing. The earphones or portable acoustic device may include a user input area along a portion of the stem. The earphones or portable acoustic device may include a force sensor disposed within the stem adjacent to the user input area. The earphones or portable acoustic device may include an antenna disposed within the stem. The earphones or portable acoustic device may further include a bass port that forms through the housing and is configured to provide an acoustic path from the driver that allows air to flow more easily within the acoustic path for low-frequency sounds, and a control leak hole that forms through the housing and is configured to provide atmospheric passage between the external environment and the acoustic port such that when the earphones or portable acoustic device is worn by a user, the housing does not completely seal the user's ear canal and trap pressure within the ear canal.

[0014] Various specific implementations of the earphones or acoustic devices described herein may include one or more of the following features. The device may include a second port that forms through the device housing a surface that faces the user's ear when the portable wireless acoustic device is worn by the user. The device may include an optical sensor operatively coupled to the second port. The optical sensor may include a transmitter that emits radiation of a first wavelength and a second wavelength different from the first wavelength through the second port, and a detector that is operable to detect the radiation of the first wavelength and the second wavelength after the radiation is reflected from the user's ear, wherein the first wavelength and the second wavelength have different frequency dependencies on human skin. A processor is operatively coupled to receive the output from the detector, and may be configured to calculate a ratio of the detected first-wavelength radiation to the detected second-wavelength radiation, and generate an in-ear detection signal based on the calculated ratio being within a predetermined range. The device may further include an accelerometer, and the processor may generate an in-ear detection signal based on a combination of the signal output by the accelerometer and the calculated ratio of the detected first-wavelength radiation to the detected second-wavelength radiation. The speaker housing portion may include a front volume acoustically separated from a rear volume, wherein the front volume is disposed between the audio driver and a first acoustic port, and the rear volume is disposed behind the audio driver. A battery may be disposed within the rear volume, and may have an outer surface and a first electrical interconnect and a second electrical interconnect that extend away from the outer surface and enable the battery to be operatively coupled to one or more electronic components within the device housing. The battery may have, in addition to the first electrical interconnect and the second electrical interconnect, a hydrophobic coating deposited on the entire outer surface of the battery. The hydrophobic coating may be N-type parylene. The hydrophobic coating may be between 15 micrometers and 30 micrometers thick. The battery may further include a second hydrophobic coating sprayed on a first coating in a portion of the battery facing the rear volume. The second hydrophobic coating may be a fluorinated compound acrylic polymer. The audio driver may mate with the inner surface of the speaker housing to define a front volume within the speaker housing portion for the audio driver, the front volume being sealed relative to the surrounding environment except for a free-flowing air path through the first acoustic port to the surrounding environment. The earphones or acoustic device may further include a microphone disposed within the front volume of the device housing. The processor is operatively coupled to receive the output from the microphone, and may be configured to change the audio profile of the audio driver based on the output from the microphone. The speaker housing may be sized and shaped to fit within the user's ear, with no part of the earphones inserted into the user's ear canal. The microphone may be tuned to listen for low frequencies within the front volume, the low frequencies indicating the fit quality of the earphones within the user's ear, and the processor may be configured to adjust the audio settings of the audio driver based on the output from the microphone. If the processor determines that the speaker housing forms a poor seal within the user's ear, the processor may be configured to enhance the low-frequency sounds generated by the audio driver.

[0015] To better understand the essence and advantages of the present invention, the following description and drawings should be referred to. However, it should be understood that each drawing is provided for illustrative purposes only and is not intended to define the scope of the present invention. Moreover, as a general rule, and unless clearly contrary to the description, if elements in different drawings use the same reference numerals, the elements are generally the same or at least similar in function or purpose. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a simplified illustration of an exemplary portable electronic listening device system according to some embodiments, the system having a host device configured as a smart phone, a housing, and a pair of wireless listening devices configured as earbuds;

[0017] Figure 2 is a simplified block diagram of various components of a portable wireless listening system according to some embodiments;

[0018] Figures 3A to 3C is a simplified view of a portable wireless earbud according to some embodiments;

[0019] Figure 3D is a simplified partial cross-sectional view of a speaker housing according to some embodiments, illustrating Figures 3A to 3C the placement of a selection component within the earbud depicted therein;

[0020] Figure 3E is a simplified perspective view of a battery having a hydrophobic coating formed thereon according to some embodiments;

[0021] Figure 3F is a simplified perspective view of an optical sensor according to some embodiments;

[0022] Figure 3G is Figure 3F a simplified cross-sectional view of the optical sensor shown in

[0023] Figure 3H and Figure 3I is according to some embodiments Figure 3E and Figure 3F simplified cross-sectional views of the optical sensor shown in

[0024] Figure 4A is Figures 3A to 3C a simplified side view of the earbud depicted in

[0025] Figure 4B is Figure 4A a simplified cross-sectional view of the earbud depicted in

[0026] Figure 4CIs a simplified exploded view of various components located within the stem portion of an earbud;

[0027] Figure 5A Is a view looking towards the acoustic port of the Figures 3A to 3C Simplified partial view of the earbud (without the stem) depicted in;

[0028] Figure 5B Is Figure 5A Simplified cross-sectional view of the earbud taken through the acoustic port as shown in;

[0029] Figure 5C Is a simplified illustration of the speaker housing portion of an earbud including a multi-layered mesh with a convex profile according to some embodiments;

[0030] Figure 5D Is according to some embodiments of the Figure 5C Simplified exploded view of the multi-layered mesh shown in;

[0031] Figure 5E Depicts Figure 5C And Figure 5D The multi-layered mesh shown in, respectively, through the Figure 5C Two separate cross-sections taken along line A-A and line B-B shown in;

[0032] Figures 6A to 6C Is a simplified plan view of a charging case that can store a pair of earbuds such as the Figures 3A to 3C Earbuds depicted in;

[0033] Figure 7A Is a simplified exploded view of the individual components of a cover housing assembly that can be assembled together to form the Figures 6A to 6C Cover of the charging case depicted in;

[0034] Figure 7B Shows a bistable hinge according to some embodiments that can be incorporated into a charging case such as the Figures 6A to 6C Charging case depicted in;

[0035] Figure 7C Is a simplified perspective view of a bistable hinge according to additional embodiments that can be incorporated into a charging case such as the Figures 6A to 6C Charging case depicted in;

[0036] Figure 8 Is a simplified exploded view of the individual components of an insert sub-assembly that can be assembled together to form the Figures 6A to 6C Internal portion of the charging case depicted in;

[0037] Figure 9 Is a component that can form Figures 6A to 6CSimplified exploded view of the various components of the skeleton subassembly of the internal portion of the depicted charging housing;

[0038] Figure 10A is a simplified exploded view of the various components of a coil subassembly that can be attached to the Figure 9 depicted skeleton subassembly according to some embodiments;

[0039] Figure 10B is a simplified illustration of a wireless power charging device that can wirelessly supply power to the Figures 6A to 6C charging housing depicted therein according to some embodiments;

[0040] Figure 10C is a simplified perspective view of a charging housing according to some embodiments positioned on a wireless charger during a charging operation;

[0041] Figure 10D is a simplified top view illustration of a wireless charger, showing the position of magnets disposed within the charging housing relative to the magnetic array of the wireless charger according to some embodiments;

[0042] Figure 10E is Figure 10C a simplified cross-sectional view of the area C-C shown therein;

[0043] Figure 11 is a simplified exploded view of the various components of a bottom shell cover subassembly that makes up the Figures 6A to 6C depicted charging housing according to some embodiments; and

[0044] Figure 12 is a simplified exploded view of subassemblies 700, 800, 900, 1000, and 1100 arranged together according to some embodiments. DETAILED DESCRIPTION

[0045] Some embodiments of the present disclosure relate to portable wireless listening, which can provide users with high-end acoustic performance and a pleasant and intuitive user experience. Other embodiments relate to a housing for charging and storing one or more portable wireless listening devices. Still other embodiments relate to a system including a pair of portable wireless listening devices and a charging housing for the devices.

[0046] As used herein, the term "portable listening device" includes any portable device configured to be worn by a user and positioned such that a speaker of the portable listening device is adjacent to or in the user's ear. A "portable wireless listening device" is a portable listening device that is capable of receiving and / or transmitting an audio data stream from / to a second device without a wire connecting the portable wireless listening device to the second device, using, for example, a wireless communication protocol.

[0047] A headset is a type of portable listening device, a headphone (a combination of headphones and an attached microphone) is another type of portable listening device, and a hearing aid (an in-ear device designed to enhance sounds from the surrounding environment to improve a user's hearing) is also another type of portable listening device. The term "headphone" refers to a pair of small portable listening devices designed to be worn on or around a user's head. They convert an electrical signal into a corresponding sound that can be heard by the user. Headphones include traditional headphones that are worn over the user's head and include left and right earcups connected to each other by a headband, and in-ear headphones (very small headphones designed to fit directly in the user's ear). Traditional headphones include both: over-ear headphones (sometimes called circum-aural or full-size headphones) that have earpads that completely enclose the user's ears; and on-ear headphones (sometimes also called supra-aural headphones) that have earpads that press against the user's ears rather than surround them.

[0048] The term "in-ear headphone", which can also be referred to as an earbud, includes both: small headphones, sometimes called "earplugs", that fit inside the user's outer ear facing the ear canal without inserting into the ear canal; and in-ear headphones, sometimes also called canalphones, that are inserted into the ear canal itself. Thus, in-ear headphones can be another type of portable listening device that is configured to be located substantially within the user's ear. As used herein, the term "ear insert", which can also be referred to as an ear mold, includes a preformed, postformed, or custom-molded sound-guiding structure that at least partially fits within the ear canal. Ear inserts can be formed to have a comfortable fit that can be worn for long periods of time. They can have different sizes and shapes to achieve a better seal with the user's ear canal and / or ear cavity.

[0049] Exemplary Wireless Listening System

[0050] Figure 1 is an example of a wireless listening system 100 according to some embodiments. The system 100 can include a host device 110, a pair of portable wireless listening devices 130, and a charging case 150. The host device 110 is depicted in Figure 1 as a smart phone, but can be any electronic device that can transmit audio data to the portable listening devices 130. Other non-limiting examples of suitable host devices 110 include laptop computers, desktop computers, tablet computers, smart watches, audio systems, video players, etc.

[0051] As Figure 1As depicted in the figures, host device 110 may be wirelessly coupled to portable wireless listening device 130 and charging case 150 via wireless communication links 160 and 162. Similarly, portable wireless listening device 130 may be communicatively coupled to charging case 150 via wireless communication link 164. Each of wireless communication links 160, 162, and 164 may be a known and established wireless communication protocol, such as a Bluetooth protocol, a WiFi protocol, or any other acceptable protocol that enables electronic devices to communicate wirelessly with each other. Thus, host device 110 may directly exchange data with portable wireless listening device 130, such as audio data that may be transmitted via wireless link 160 to wireless listening device 130 for playback to a user, and audio data that may be received by host device 110 as recordings / inputs from a microphone in portable wireless listening device 130. Host device 110 may also be wirelessly communicatively coupled to charging case 150 via wireless link 162, such that host device 110 may exchange data with charging case 150, such as data indicating the battery charge level data of case 150, data indicating the battery charge level of portable wireless listening device 130, data indicating the pairing status of portable wireless listening device 130.

[0052] Portable wireless listening device 130 may be stored within case 150, which may protect device 130 from loss and / or damage when not in use, and may also provide power to recharge the battery of portable wireless listening device 230, as described below. In some embodiments, portable wireless listening device 130 may also be wirelessly communicatively coupled to charging case 150 via wireless link 164, such that when the device is worn by a user, audio data from case 150 may be transmitted to portable wireless listening device 130. As an example, charging case 150 may be coupled to an audio source different from host device 110 via a physical connection (e.g., an auxiliary cable connection). Audio data from the audio source may be received by charging case 150, which may then wirelessly transmit the data to wireless listening device 130. In this way, even if the audio source does not have wireless audio output capabilities, the user can hear the audio stored on or generated by the audio source through wireless listening device 130.

[0053] According to some embodiments, each individual portable wireless listening device 130 may include a housing 132 formed by a body 134 and a stem 136 extending from the body 134. The housing 132 may be formed of an integral outer structure. The body 134 may include an inward-facing microphone 138 and an outward-facing microphone 140 for the purposes discussed herein. The outward-facing microphone 140 may be positioned within an opening defined by portions of the body 134 and the stem 136. By extending into both the body 134 and the stem 136, the microphone 140 may be large enough to receive sound from a wider area around the user. In some embodiments, the housing 132 may define an acoustic port 142 that may direct sound from an internal audio driver out of the housing 132 and into the user's ear canal. In other embodiments, the portable wireless listening device 130 may include a deformable ear tip that may be inserted into the user's ear canal such that the wireless listening device can be configured as an in-ear hearing device.

[0054] In the depicted embodiment, the stem 136 has a generally cylindrical configuration and a planar region 144 that does not follow the curvature of the cylindrical configuration. The planar region 144 may indicate an area where the wireless listening device is capable of receiving user input. For example, in some embodiments, a user input may be entered by squeezing the stem 136 at the planar region 144. In some embodiments, in addition to or instead of the pressure sensing capability, the planar region 144 may include a touch-sensitive surface that allows the user to enter touch commands, such as contact gestures. The stem 136 may also include electrical contacts 146, 148 for contacting corresponding electrical contacts in a charging case 150, as will be further discussed herein.

[0055] As will be understood herein, the portable wireless listening device 130 may include a number of features that may enable the device to be comfortably worn by a user for an extended period of time, even all day. The housing 132 may be shaped and sized to fit snugly between the tragus and antitragus of the user's ear such that the portable listening device does not fall out of the ear even when the user is exercising or otherwise moving about. Its functionality may also enable the wireless listening device 130 to provide an audio interface to the host device 110 such that the user may not need to utilize the graphical interface of the host device 110. In other words, the wireless listening device 130 may be so sophisticated that it may enable the user to perform daily operations from the host device 110 by interacting with only the wireless listening device 130. This may create further independence from the host device 110 by not requiring the user to physically interact with and / or view the display screen of the host device 110, particularly when the functionality of the wireless listening device 130 is combined with the voice control capabilities of the host device 110. Thus, the wireless listening device 130 may enable a truly hands-free experience for the user.

[0056] Figure 2 is a simplified block diagram of the various components of a wireless listening system 200 according to some embodiments. The wireless listening system includes a host device 210, a pair of portable wireless listening devices (PWLDs) 230 (e.g., a right PWLD 230 and a left PWLD 230), and a charging case 250. The system 200 may represent Figure 1 the system 100 shown in

[0057] and the host device 210, the portable wireless listening device 230, and the charging case 250 may respectively represent the host device 110, the portable wireless listening device 130, and the charging case 150. Each portable wireless listening device 230 may receive and generate sound to provide an enhanced user interface for the host device 210. For convenience, the following discussion refers to a single portable wireless listening device 230, but it should be understood that in some embodiments, a pair of portable listening devices may cooperate together for the user's left and right ears respectively, and each portable wireless listening device in the pair may include the same or similar components.

[0058] The computing system 231 is operatively coupled to a user interface system 232, a communication system 234, and a sensor system 236 to enable the portable wireless listening device 230 to perform one or more functions. For example, the user interface system 232 may include a driver (e.g., a speaker) for outputting sound to the user, one or more microphones for inputting sound from the environment or the user, one or more LEDs for providing visual notifications to the user, a pressure sensor or a touch sensor (e.g., a resistive or capacitive touch sensor) for receiving user input, and / or any other suitable input or output device. The communication system 234 may include wireless and wired communication components for enabling the portable wireless listening device 230 to send and receive data / commands from the host device 210. For example, in some embodiments, the communication system 234 may include circuitry that enables the portable wireless listening device 230 to communicate with the host device 210 via a wireless link 260 using Bluetooth or other wireless communication protocols. In some embodiments, the communication system 234 may also enable the portable wireless listening device 230 to communicate wirelessly with the charging case 250 via a wireless link 264. The sensor system 236 may include a proximity sensor (e.g., an optical sensor, a capacitive sensor, radar, etc.), an accelerometer, a microphone, and any other type of sensor that can measure parameters of an external entity and / or the environment.

[0059] The portable wireless listening device 230 may also include a battery 238, which may be any suitable energy storage device capable of storing energy and releasing the stored energy to operate the portable wireless listening device 230, such as a lithium-ion battery. The released energy may be used to power the electronic components of the portable wireless listening device 230. In some embodiments, the battery 238 may be a rechargeable battery, which enables the battery to be repeatedly charged as needed to replenish the stored energy. For example, the battery 238 may be coupled to a battery charging circuit (not shown), which is operatively coupled to receive power from the charging case interface 239. The case interface 239 may in turn be electrically coupled to the earbud interface 252 of the charging case 250. In some embodiments, power may be received by the portable wireless listening device 230 from the charging case 250 via electrical contacts within the case interface 239. In some embodiments, power may be received wirelessly by the portable wireless listening device 230 via a wireless power receiving coil within the case interface 239.

[0060] The charging case 250 may include a battery 258 that stores and releases energy to power the circuits within the charging case 250 and to recharge the battery 238 of the portable wireless power listening device 230. As described above, in some embodiments, the circuits within the earbud interface 252 may transfer power to the portable wireless listening device 230 via a wired electrical connection between contacts in the charging case 250 that are electrically coupled to contacts in the portable wireless listening device 250 to charge the battery 238. While the case 250 may be a device that charges the battery 238 by providing power through a wired interface with the device 230 in some embodiments, in other embodiments, the case 250 may provide power to charge the battery 238 via a wireless power transfer mechanism, instead of or in addition to the wired connection. For example, the earbud interface may include a wireless power transmitter coil that may be coupled to a wireless power receiver coil within the portable wireless listening device 230.

[0061] The charging case 250 may also include a case computing system 255 and a case communication system 251. The case computing system 255 may be one or more processors, ASICs, FPGAs, microprocessors, etc. for operating the case 250. The case computing system 255 may be coupled to the earbud interface 252 and may control the charging function of the case 250 to recharge the battery 238 of the portable wireless listening device 230, and the case computing system 255 may also be coupled to the case communication system 251 for operating interactive functions of the case 250 with other devices, including the portable wireless listening device 230. In some embodiments, the case communication system 251 includes Bluetooth components or any other suitable wireless communication components that wirelessly send and receive data with the communication system 234 of the portable wireless listening device 230. To this end, each of the charging case 250 and the portable wireless listening device 230 may include an antenna formed by a conductive body to send and receive such signals. The case 250 may also include a user interface 256 that is operatively coupled to the case computing system 255 to alert the user of various notifications. For example, the user interface may include a speaker that emits an audible noise that can be heard by the user, and / or one or more LEDs or similar lights that emit light that can be seen by the user (e.g., to indicate whether the portable listening device 230 is being charged by the case 250 or to indicate whether the case battery 258 is low on energy or is being charged).

[0062] The host device 210 (to which the portable wireless listening device 230 is an accessory) can be a portable electronic device, such as a smartphone, a tablet computer, or a laptop computer. The host device 210 can include a host computing system 212 coupled to a battery 214 and a host memory bank 134 that contains lines of code executable by the host computing system 212 for operating the host device 210. The host device 210 can also include a host sensor system 215 (e.g., an accelerometer, a gyroscope, a light sensor, etc.) for allowing the host device 210 to sense the environment, and a host user interface system 216 (e.g., a display, a speaker, buttons, a touchscreen, etc.) for outputting information to and receiving input from a user. Additionally, the host device 210 can also include a host communication system 218 for allowing the host device 210 to send and / or receive data from the Internet or a cellular tower via wireless communication (e.g., Wi-Fi (Wireless Fidelity), Long Term Evolution (LTE), Code Division Multiple Access (CDMA), Global System for Mobile Communications (GSM), Bluetooth, etc.). In some embodiments, the host communication system 218 can also communicate with a communication system 234 in the portable wireless listening device 230 via a wireless communication link 262, such that the host device 210 can send audio data to the portable wireless listening device 230 for outputting sound, and receive data from the portable wireless listening device 230 for receiving user input. The communication line 262 can be any suitable wireless communication line, such as a Bluetooth connection. By enabling communication between the host device 210 and the portable wireless listening device 230, the wireless listening device 230 can enhance the user interface of the host device 210.

[0063] Earbud

[0064] Portable wireless devices according to some embodiments can include a number of different features that provide an improved audio quality and an excellent user experience compared to many previously known portable wireless devices. To illustrate and explain some such features, reference is made to Figures 3A to 3C , which are simplified views of wireless earbuds 300 according to some embodiments. Specifically, Figure 3A is a simplified plan view of the first side of the earbud 300, Figure 3B is a simplified plan view of the second side opposite the first side of the earbud 300, and Figure 3C is a simplified top view of the earbud 300.

[0065] Earbud Housing

[0066] The earbud 300 includes a housing 302, which may be made of, for example, a rigid radio frequency (RF) transparent plastic such as acrylonitrile-butadiene-styrene (ABS) or polycarbonate. In some embodiments, the housing 302 may be made of one or more components that may be joined together (e.g., using tongue and groove joints and suitable adhesives) to form an integral housing structure with a substantially seamless appearance. The housing 302 forms a shell that defines an internal cavity in which various components of the earbud 300 are housed. As depicted, the housing 302 may include two main sections: a speaker housing 310 and a stem 312 that projects away from the speaker housing at an angle. As discussed below, the cavity portion within the speaker housing 310 may hold the audio driver and the battery, while the cavity portion within the stem 312 may hold the main circuit board and other electronics. In some embodiments, the stem 312 may also include electrical contacts 322, 324 at the distal end of the stem. The electrical contacts 322, 324 provide a physical interface that may be electrically coupled to corresponding electrical contacts in a corresponding charging case (e.g., charging case 150). It should be understood that the embodiments are not limited to Figures 3A to 3C the specific shape and form of the housing 302 depicted. For example, in some embodiments, the housing does not include a stem or a similar structure, and in some embodiments, an anchor or other structure may be attached to or extend away from the housing to further secure the earbud to the user's ear feature.

[0067] The earbud 300 may be configured to have an open unsealed acoustic architecture, which is sometimes referred to as a "leaky acoustic architecture". That is, in some embodiments, the earbud 300 does not include a deformable ear tip that is included on an ear canal phone and is configured to be inserted into the user's ear canal to form an airtight seal between the ear tip and the user's ear. Instead, the speaker housing 310 may be sized and shaped to fit within the user's ear without being inserted into the ear canal, and all the acoustic air volumes within the earbud 300 have a free-flowing air path to the environment.

[0068] The speaker housing 310 is the main support mechanism for the earbud 300 when the earbud is positioned within a user's ear. The speaker housing 310 can be shaped to rest between the user's tragus and antitragus without applying unwanted pressure on the helix, which can be a source of discomfort when the earbud is engaged in the user's ear for an extended period of time. To this end, the speaker housing 310 is contoured to allow a portion of the speaker housing to sit deeply within the space between the tragus and antitragus of the user's ear to form a pseudo-seal (sometimes referred to as a passive seal) between the housing and the user's ear, even if the earbud 300 is not an in-ear canal phone and does not include a deformable ear tip that inserts into the user's ear canal. Compared to other leaky architecture earbuds, the pseudo-seal allows the earbud 300 to have improved audio quality without creating potential pressure buildup within the user's ear, which can be created by earbuds with deformable ear tips and which some users find uncomfortable.

[0069] The speaker housing 310 is further contoured such that certain surfaces of the housing do not contact any part of a typical user's ear. These non-contact portions provide locations for various features of the earbud 300, including the main acoustic port 314, the bass port 316, and the control vent 318. The acoustic port 314 provides an acoustic path for sound generated by a driver ( Figures 3A to 3C not shown) within the speaker housing 310 to reach the user's ear canal. When the earbud 300 is inserted into the user's ear, the acoustic port 314 is positioned at a location that generally does not physically contact the user's ear and is adjacent to but slightly spaced from the user's ear canal. In some embodiments, the acoustic port 314 may be covered by an acoustic membrane and a mesh, as described below.

[0070] The bass port 316 can be an opening in the speaker housing 310 that provides an acoustic path from the driver that allows air to flow more easily within the acoustic path for low-frequency sounds (such as bass sound waves below 20 Hz). For low-frequency sounds, the driver may move a large amount of air when generating sound waves. When the driver can move air more easily, the driver can achieve better sound quality. Thus, the bass port 316 can provide an opening for air to easily move out to the atmosphere and to be easily inhaled from the atmosphere, thereby allowing the earbud 300 to provide higher-quality bass notes. The tuned bass port 316 can be configured to achieve a specific air flow rate when the driver is operating. The air flow rate can be changed by the shape and size of the tuned bass port 316, which can be tuned in various ways according to the design. As Figure 3B depicted, the bass port 316 can be positioned at a location that generally does not physically contact the user's ear when the earbud 300 is worn.

[0071] The earbud 300 may further include a control vent 318 positioned at a location that generally does not physically contact the user's ear. The control vent 318 may be an opening within the speaker housing 310 that allows air to flow out of the housing 302. However, the results achieved by releasing air through the control vent 318 out of the housing 302 may be different from those achieved by the bass port 316. For example, rather than improving bass sound quality, the control vent 318 may provide atmospheric passage between the external environment and the acoustic port 314 when the user wears the earbud 300, such that the speaker housing 310 does not completely seal the ear canal and pressure builds up within the ear canal. This can allow for a more comfortable user experience and can also improve the acoustic performance of the listening device. Like the bass port 316, the control vent 318 may be configured to achieve a specific airflow rate when pressure builds up in the ear canal. The airflow rate may be changed by the shape and size of the tuned control vent 318, which may be tuned in various ways according to the design. To this end, the control vent 318 may be a circular hole or may be configured with any other shape, such as oval, rectangular, square, triangular, octagonal, etc., without departing from the spirit and scope of the present disclosure. It should be understood that the specific locations of the bass port 316 and the control vent 318 may be selected to minimize blockage and acoustic coupling with other internal components. Moreover, in some embodiments, the control vent 318 and / or the bass port 316 may be covered with a suitable mesh to prevent moisture and contaminants from entering the internal cavity of the speaker housing 310.

[0072] The earbud 300 may further include an optical sensor 320 that can be used to determine when the ear tip has been inserted into the ear canal. The optical sensor 320 may be strategically positioned at a location along the housing 302 that may contact or directly face the inner surface of a typical user's ear when the user wears the earbud. In this way, the optical sensor 320 may sometimes be used in combination with other sensors to determine whether the earbud 300 is being worn by the user and positioned within the user's ear, as discussed in more detail below. In some embodiments, the optical sensor 320 may be positioned behind an optically transparent window 328 positioned along the speaker housing 310.

[0073] Battery

[0074] Figure 3D is a partial cross-section of the speaker housing 310 illustrating the placement of selected components within the earbud 300. Figure 3D Specifically shown therein are the audio driver 330 and the battery 340, as well as inner walls 350 and 356 that divide an internal portion of the speaker housing 310 to form a front volume 352 and a rear volume 354 for the audio driver 330. The wall 356 further separates the rear volume 354 from a non-acoustic volume 358 that extends from behind the battery 340 within the speaker housing 310 into the stem 312.

[0075] Figure 3D The embodiments depicted do not include a wall separating the battery 340 from the audio driver 330. Removing this wall allows for an increase in the size of the battery 340 (and thus more energy storage, which in turn enables the earbud 300 to be powered for a longer usage time), but placing the battery 340 in the rear volume 354 of the driver 330 may expose the battery to moisture ingress from the environment (e.g., the port 316 couples the rear volume 354 to the environment). To protect the battery from potential corrosion, embodiments may coat the battery 340 with a hydrophobic coating, such as a parylene coating. Figure 3E is a simplified perspective view of a battery 340 having a hydrophobic coating 342 formed thereon. In some specific embodiments, a 15 - 30 micron thick N - type parylene coating is deposited over the entire surface of the battery 340 except for two battery contacts 344, 346, which may be masked during the coating process. In some embodiments, a second hydrophobic coating may be formed over the first coating on all or a portion of the battery 340. The second coating may provide additional protection against moisture ingress into the battery and help prevent defects or pores that may occur in the first coating during the assembly phase. The second coating may be, for example, polyurethane, fluorinated compound acrylic polymer, or a similar material, which may be sprayed over the hydrophobic coating 342. In some embodiments, the second coating may be between 12 - 30 microns thick and / or may be coated over only a portion of the battery 340, such as the portion 345 facing the rear volume 340 and in the area where the battery may be handled during the assembly of the earbud 300 (designated by the dashed line in Figure 3D ).

[0076] User - Specific Audio Settings

[0077] As described above, the speaker housing 310 of the earbud 300 may be sized, shaped, and contoured such that when the earbud 300 is worn, the speaker housing 310 is placed between the tragus and antitragus of the user's ear, forming a passive seal with the inner surface of the user's ear surrounding the ear canal. When a relatively strong passive seal is formed, the earbud 300 may be referred to as having a high - quality fit because the passive seal can block noise from the external environment, thus providing an improved listening experience. However, since the ears of users can vary widely, the strength of the passive seal or whether a passive seal is formed can vary between users. Depending on the strength or presence of the passive seal, certain frequencies of the audio signal may be adjusted to obtain a higher - quality signal.

[0078] In some embodiments, the earbud 300 includes an internal microphone 332 within the front volume of the speaker housing 310. The microphone 332 can be tuned to listen for low frequencies in the front volume, and electronics (e.g., a processor) within the earbud 300 can detect the quality of the fit of the earbud within the user's ear and adjust the audio settings based on the fit quality. For example, if the speaker housing 310 does not form a passive seal in the user's ear, the low-frequency sound generated by the driver 330 can be boosted to compensate for the leaky fit of the earbud. On the other hand, if the speaker housing 310 forms a strong passive seal in the user's ear, boosting the low-frequency sound may not be needed at all. In one particular implementation, the earbud 300 can adjust the audio settings (e.g., adjust the low frequencies of the sound generated by the driver 330) according to any one of six different profiles, depending on how strong or leaky the fit is between the speaker housing 310 and the individual user's ear. As an example, each of the six different profiles can have different settings for bass and / or midrange frequencies, depending on the amount of bass picked up by the microphone 332. In embodiments where the earbud 300 is one of a left earbud or a right earbud, each of the left and right earbuds can detect the strength of that earbud within the user's respective ear and adjust the frequency response of that earbud independently of the other earbud. As will be understood by those skilled in the art, the embodiments are not limited to any particular number of audio profiles, and some embodiments may include fewer than six different profiles while other embodiments may include more than six profiles.

[0079] In - Ear Detection

[0080] As described above, the earbud 300 can include an optical sensor 320, which can be used to determine whether the earbud is in the user's ear. The optical sensor 320 is positioned along the surface of the earbud 300 and faces the user's ear when the user is wearing the earbud. The optical sensor 320 can include one or more transmitters and one or more detectors. In some embodiments, the transmitter can be a laser diode or a light-emitting diode (LED), and the detector can be a photodiode.

[0081] The optical sensor 320 can emit radiation (e.g., infrared light), which is reflected back to the sensor 120 when it contacts a surface and is detected by the sensor 120. When the earbud 300 is worn, the emitted radiation is reflected from the inner portion of the user's ear and is detected by a detector within the sensor 120. When it is determined that the earbud 300 is positioned within the user's ear, audio can be played through the earbud for the user to enjoy. On the other hand, if the optical sensor 320 determines that the earbud is not in the user's ear, the audio playback can be aborted or otherwise stopped. To avoid false positives, the optical sensor 320 can distinguish between a scenario where the optical sensor is positioned adjacent to the skin (i.e., the skin of the user's ear) and a scenario where the optical sensor is positioned adjacent to some other material (e.g., a tabletop, fabric in the user's pocket, etc.), as described below.

[0082] The spectral response of human skin is characterized by peaks and valleys. For example, the reflectivity of human skin is relatively high (e.g., about 50 - 60%) at a wavelength of 1065 nm and relatively low (e.g., about 5 - 10%) at a wavelength of 1465 nm. Thus, the presence of skin can be monitored by a sensor that emits light at 1065 nm and 1465 nm and measures the amount of light reflected from the target object at these wavelengths. In some embodiments, the optical sensor 120 includes two separate emitters that emit two different wavelengths of radiation having different frequency responses to human skin. Thus, when the reflected light emitted by the sensor 120 is detected by the sensor, the ratio of these two wavelengths can be used to determine whether the surface reflecting the radiation is human skin or some other material, such as a wooden or metal tabletop. For example, when the ratio between these two wavelengths is within a certain range, the sensor 320 can determine that the detected radiation is reflected by human skin, which can in turn be used, alone or in conjunction with data from other sensors (e.g., an accelerometer) within the earbud 300, to determine that the earbud 300 is positioned within the user's ear.

[0083] As an illustrative non - limiting embodiment, reference Figure 3F and Figure 3G , which depict an embodiment of the optical sensor 320. As Figure 3F shown, the optical sensor 320 includes a circuit board 360 (e.g., a printed circuit board) and two optical emitters 362 and a detector 364, all of which are mounted to the circuit board 360. The optical emitter 362 can be a light - emitting diode, and the detector 364 can be a common photodiode, an avalanche photodiode (APD), or a collection of single - photon avalanche diodes (SPADs). In other embodiments, the optical emitter 362 can be a laser (e.g., a vertical - cavity surface - emitting laser known as a "VCSEL") or other suitable light - emitting device, and the detector 364 can be a phototransistor.

[0084] The circuit board 360 can be mounted in the sensor package 365, as Figure 3G shown. In some embodiments, the sensor package 365 includes respective outer and inner walls 367 that create two separate cavities that are spaced apart from each other and optically isolated from each other. The light emitter 362 can be positioned within the first cavity 365(1), while the detector 364 can be positioned with the second cavity 365(2). An optical window 370 that is transparent to the wavelength of the radiation emitted from the light emitter 362 can be mounted (e.g., attached by a pressure sensitive adhesive or other suitable mounting method) to the top surface of the sensor package 365, and the package 365 can include first and second through-regions 366, 368 that are spaced apart from the light emitter 362 and the detector 364, respectively, and are directly above the light emitter 362 and the detector 364, respectively. The through-regions 366, 368 can be, for example, openings formed through the outer wall 367 of the package 365. In some embodiments, the first through-region 366 can include two separate openings such that one of the two openings is spaced apart from each of the two light emitters 362 and is directly above each of the two light emitters 362.

[0085] As Figure 3F shown, the sensor package 365 can also include a first filter 372 and a second filter 374. The filter 372 can be positioned in the optical path between the light emitter 362 and the first through-region 366, while the filter 374 can be positioned in the optical path between the photodetector 366 and the second through-region 368. Each of the filters 372, 374 can be configured to allow a predetermined set of radiation wavelengths to pass through the filter while blocking radiation outside of the predetermined set. The filters 372, 374 can also beneficially serve as mechanical barriers to isolate contaminants (liquids, dust, other ingress).

[0086] In some embodiments, each of the filters 372, 374 can be a bandpass filter. Since the two light emitters 362 emit radiation at different wavelengths, in some embodiments, the filter 372 can include first and second regions that pass different radiation frequency bands corresponding to the emission wavelengths from the light emitter 362. For example, in a configuration where the two light emitters 362 emit radiation at 1065 nm and 1465 nm, respectively, the filter 372 can include a bandpass filter in the first region that allows a relatively narrow first radiation frequency band centered at 1065 nm to pass through while blocking radiation outside of the first band and a bandpass filter in the second region that allows a relatively narrow second radiation frequency band centered at 1465 nm to pass through while blocking radiation outside of the second band.

[0087] Similarly, in some embodiments, filter 374 may be configured to form a dual-band bandpass filter that includes first and second passbands at the same first and second wavelengths emitted by optical transmitter 362. Thus, filter 374 may be configured to allow only the light emitted from optical transmitter 362 and reflected back into opening 368 through window 370 to reach detector 364, while blocking light of other wavelengths (including ambient light). To distinguish measurements associated with two different optical transmitters 362, in some embodiments, the two optical transmitters 362 may emit radiation at different times (e.g., using time division multiplexing). As an example, the two optical transmitters 362 may emit light in an alternating pattern. The measurements of detector 364 may then be synchronized to the emitted light pattern such that separate measurements of the first and second wavelengths may be made.

[0088] In one particular implementation, the optical sensor includes two optical transmitters 362, where one of the optical transmitters emits light at a wavelength of 1065 nm and the second optical transmitter emits light at a wavelength of 1465 nm. The ratio R of the reflected light at 1065 nm to the reflected light at 1465 nm may be monitored and compared to a threshold level X (e.g., 2.0 or other suitable value). When the ratio R is less than X, it may be inferred that the optical sensor 320 is not adjacent to human skin. When the ratio R is greater than X, it may be inferred that the sensor 320 is adjacent to human skin.

[0089] As Figure 3G and Figure 3H shown, optical transmitter 362 may be aligned to emit radiation through filter 372, through channel 366, and through window 370, while detector 364 may be aligned to detect radiation passing through window 370 into channel 368 and through filter 374. The radiation emitted from optical transmitter 362 may be in the form of a light cone, where the radiation diverges from each optical transmitter 362 as it travels further from each transmitter. Thus, the two optical transmitters 362 may emit light cones 376, 377, respectively. Similarly, the field of view (FOV) of detector 364 may be considered a cone 378, where the field becomes larger with distance from the photodetector. In some embodiments, optical transmitters 362 are aligned and configured to emit light cones 376, 377 that overlap in region 380 ( Figure 3G ). The optical transmitters and optical paths of sensor 320 are configured such that the overlapping region 380 is at a distance where the skin of the user's ear would reasonably be located when the earbud including optical sensor 320 is worn. The FOV of detector 364 is configured such that it overlaps the light cones 376 and 378 of optical transmitters 362 in region 382 at a distance where the skin of the user's ear would reasonably be located when the earbud including optical sensor 320 is worn, but does not overlap in region 384, thereby forming an FOV gap adjacent to the outer surface of window 370 (Figure 3H )。In this manner, the photodetector 362 is configured and aligned to detect radiation emitted from the light detector 362 and reflected back to the detector 364 from the user's ear.

[0090] Force Sensor

[0091] A force sensor may be positioned along the stem 312 to allow a user to control various aspects of the earbud 300. In some embodiments, the force sensor (not visible in any of Figures 3A to 3C which) may be disposed within the stem 312, adjacent to a planar region 326 on the stem. The user may provide input via the force sensor by squeezing the stem 312 at the planar region 326. The planar region 326 provides convenient tactile feedback to the user in the area where the user input provided by the force sensor is located. Those skilled in the art will understand that the planar region may be replaced or enhanced by one or more other features that provide additional and / or improved tactile feedback, including, for example, bumps, grooves, recesses, etc.

[0092] Reference Figures 4A to 4C explains further details of the force sensor, where Figure 4A is a side view of the earbud 300, Figure 4B is a simplified cross-sectional view of the earbud 300 taken through a portion of the stem 312, and Figure 4C is an exploded view of some of the components assembled within the stem 312. The planar region 326 of the stem 312 is clearly visible in Figure 4A and, as described above, the planar region provides visual and tactile indications to the user that define a pressure-sensitive area in which the earbud 300 receives user input by squeezing the stem 312.

[0093] The stem 312 defines an internal cavity 400 that extends along the length of the stem, and the components of the earbud 300 are positioned within the internal cavity. As Figure 4BAs shown, a force sensor 410, an antenna 420, and a system-in-package (SIP) 430 may be positioned within a cavity 400. The antenna 420 may extend along a majority of the length of the stem 312, and the SIP 430 may be positioned in an opposite relationship to the antenna. The force sensor 410 may include a full-ring flexure 412 having a first side that directly biases against the inner surface of the stem 312 and a second side that faces the SIP 430. A conductive coating 414 that serves as a first electrode of two electrodes that function as a force sensor or other conductive elements that are either included within the flexure 412 or laminated to the flexure 412 may be formed on the second side (e.g., a copper layer already within the flexure may serve as the electrode). An external portion 432 of the SIP 430 may be coated with a thin metal layer to serve as a second electrode of this pair of electrodes of the force sensor 410. The flexure ring 412 wraps around the SIP 430 and is separated from the sidewall of the SIP by a foam insert 440. When a user squeezes the stem 312 in a planar region 326, the flexure 410 is pushed toward the SIP 430, and the gap between the two electrodes 414, 432 decreases, thereby generating a detectable change in capacitance and generating a user input signal that can be acted upon by electronics within the earbud 300 to perform a predetermined function. For example, in some embodiments, squeezing the stem 312 may initiate a voice-activated virtual assistant, such as Siri built into various Apple products, and / or activate play, pause, skip, and / or return functions to control an audio stream being played through the earbud 300.

[0094] In some embodiments, touch pixels may be formed on a side of the flexure 412 that faces the inner wall of the stem 312 such that the planar region 326 can function as both a touch surface and a force-sensitive region. For example, the touch pixels may be built into a copper layer formed within the flexure 412.

[0095] As Figure 4C shown, in some embodiments, the SIP 430 may be fully assembled within a cavity defined by the stem 312. The SIP 430 may include a contact region 452 and circuitry (not visible in Figure 4C ), including one or more integrated circuits that control most of the operations of the earbud 300 and are overmolded. For example, in some embodiments, the SIP 430 may include a main processor that controls the operations of the earbud 300, a charging circuit, an accelerometer, a wireless communication controller, support components for the antenna 420, uplink and downlink communication circuits, and user interface circuitry, among other things. Moving the SIP and its associated circuitry to the stem portion 312 of the earbud 300 allows the speaker housing 310 to be smaller than it otherwise would be (while including an appropriately sized battery), thus enabling the speaker housing to fit more comfortably in a user's ear and improving the user experience.

[0096] Figure 4CAlso shown is a cap 450, which is part of the overall housing 302 and can be attached to the end of the stem 312 to form a watertight seal with the stem. A bottom microphone 454 can be attached to the inner surface of the cap 450, and the cap includes an acoustic port (not shown) that allows the microphone to capture sound from the environment. The cap 450 can also include two seats on opposite sides of the cap along its outer surface for two contacts 322, 324. The seats are recessed enough such that the contacts 322, 324 can be fixed to the seats and positioned flush with the outer surface of the cap 450, resulting in a smooth seamless structure with improved appearance and reliability. Electrical connection of each of the contacts 322, 324 to the circuitry within the stem 312 can be made through a suitable cutout or opening in the cap 312 that can be covered by the contacts.

[0097] Acoustic Port Mesh

[0098] The earbud 300 can include a mesh that covers the acoustic opening 314 to prevent dust and debris from entering the housing 302. In some embodiments, the mesh can be formed as a multi-layer structure, including a decorative mesh and an acoustic mesh, where the decorative mesh forms the outer surface of the earbud 300 and is formed by an interlaced network of rigid wires, and the acoustic mesh is positioned below the decorative mesh within the acoustic port 314 and is formed by a porous fabric. As a specific non-limiting example, the decorative mesh can be formed by interlaced stainless steel, and the acoustic mesh can be formed by polyester.

[0099] Because the earbuds are worn directly in the user's ears, the earbuds are prone to accumulating or collecting earwax, which can collect within the acoustic port between the speaker driver and the user's ear canal. Such earwax accumulation can muffle or otherwise adversely affect the sound quality of the earbuds. In some embodiments, the earbud 300 can include an earwax groove adjacent to but outside of the acoustic region of the earbud and that collects earwax such that the earwax does not interfere with the sound quality of the earbud.

[0100] Embodiments of the earbud 300 that include an earwax groove are shown in Figure 5A and Figure 5B where Figure 5A is a simplified partial view of the earbud 300 (without the stem 312) viewed towards the acoustic port 314, Figure 5B is a simplified cross-sectional view of the earbud 300 taken through the acoustic port 314. In some embodiments, the acoustic port 314 can be formed as a cutout through the wall 311 of the speaker housing 310. As Figure 5B shown, the wall 311 has a thickness Y and can include a first edge 311a and a second edge 311b separated by a shelf 311c. The edges 311a, 311b can extend around the entire perimeter of the acoustic port 314, and the acoustic port can include an opening 501 defined by the edge 311a at the outer surface of the speaker housing 310.

[0101] As Figure 5A and Figure 5B shown, the earbud 300 may include a multi-layer grid 500 disposed within the main acoustic port 314 and extending above the cross-section of the acoustic port. The grid 500 may include an outer decorative grid 504 and a separate acoustic grid 506. The grid 500 may be coupled to the speaker housing 310 by an annular support 508 and may be positioned across the entire acoustic port 314. The earbud 300 may include an acoustic dead zone 510 surrounding the outer perimeter of the acoustic port 314. The dead zone 510 includes a wax groove 502 that is a gap or space formed between the inner edge of the speaker housing 310 and the grid 500, and an area occupied by the support 508. During use of the earbud 300, earwax may collect in the wax groove 502. Then, as additional earwax accumulates on the earbud 300, the earwax may begin to spread from the groove 502 into the acoustic dead zone 510. The combination of the wax groove 502 and the acoustic dead zone 510 allows a certain amount of earwax to be collected on the earbud 300 without adversely affecting the sound quality of the earbud.

[0102] To further reduce earwax accumulation, in some embodiments, the grid 500 is recessed into the acoustic port 314 such that the grid 500 is spaced a distance X from the opening 501 at the outer surface of the speaker housing 310 to space the grid further from the user's ear. In some embodiments, X may be between 0.3 mm and 2.0 mm, and in some embodiments, X may be between 0.5 mm and 1.0 mm.

[0103] In Figure 5B the depicted embodiment, the grid 500 is illustrated as having a concave profile where the center of the grid 500 is recessed more within the acoustic port 314 compared to the outer edge of the grid 500. However, in some embodiments, the grid 500 may have a convex shape where the center of the grid 500 is still recessed within the acoustic port 314 but is less recessed compared to the outer edge of the grid 500. The convex shape may help keep earwax accumulation within the acoustic dead zone 510 and away from interfering with the audio waves 512 directed through the acoustic port 314.

[0104] Figure 5C is a simplified illustration of a speaker housing 310 including a multi-layer grid 550 having a convex profile according to some embodiments. For ease of illustration, the speaker housing 310 is depicted in Figure 5C without depicting the stem 312. As Figure 5C shown, the wax groove 502 surrounds the multi-layer grid 550 and the multi-layer grid has two side-by-side openings 552, 554 instead of a single opening.

[0105] Figure 5Dis a simplified exploded view of a multi-layer grid 550 that can be disposed above the acoustic port 314 according to some embodiments. Similar to the grid 500, the multi-layer grid 550 can include an outer decorative grid 560 and a separate acoustic grid 564. A reinforcement 568 made of a rigid material can provide additional structure to the grid and can define side-by-side openings 552, 554 that allow sound to leave the earbud from the acoustic port 314. The acoustic grid 564 can be adhered to the reinforcement 568 by an adhesive 566. Similarly, the decorative grid 560 can be adhered to the acoustic grid 564 by an adhesive 562. In some embodiments, one or both of the adhesives 562, 566 can be a thin flexible pressure-sensitive adhesive (PSA) layer.

[0106] Figure 5E depicts two separate cross-sections of the multi-layer grid 550 taken through lines A-A and B-B shown in Figure 5C respectively. As Figure 5E shown, the grid 550 can have a convex shape such that the edges of the grid are spaced farther from the outer surface of the speaker housing 310 than the central portion of the grid. The central portion of the grid 550 can still be recessed from the outer surface of the speaker housing 310 by a distance X, which can be between 0.3 mm and 1.5 mm in some embodiments, and in some embodiments, X can be between 0.5 mm and 1.0 mm.

[0107] Charging Case

[0108] Some embodiments of the present disclosure relate to a charging case that can store and charge a portable wireless listening device or a pair of portable wireless listening devices such as a pair of earbuds 300. The charging case can protect the wireless listening device from physical damage and provide a power source for charging the wireless listening device.

[0109] Figures 6A to 6C is a simplified plan view of a charging case 600 that can store a pair of earbuds such as earbuds 300 according to some embodiments of the present disclosure. As shown in each of Figures 6A to 6C , the case 600 can include a lid 602 and a body 604 that forms an internal cavity for accommodating a pair of wireless listening devices 300a, 300b that can be worn in a user's left and right ears, respectively. Figure 6A and Figure 6B are front plan views of the charging case 600, and Figure 6C is a rear plan view of the charging case. The charging case 600 with the lid 602 in the open position is depicted in Figure 6A , while Figure 6B and Figure 6C depict the charging case with the lid in the closed position. The lid 602 can be hinged at 610 ( Figure 6Cshown) is attached to the main body 604, and the hinge enables the cover to move between an open position (where the earbuds 300a, 300b can be inserted into or removed from the housing 600) and a closed position (where the cover 602 covers the earbuds 300a, 300b, thereby completely sealing the earbuds within the charging housing).

[0110] In some embodiments, the charging housing 600 may include an internal frame (not visible in Figures 6A to 6C ), the internal frame includes portions designed to provide contours and surface features against which the wireless listening devices 300a, 300b can rest in strategic positions discussed herein to minimize the size of the housing 600. Details of an exemplary internal frame according to some embodiments are discussed below.

[0111] To minimize the overall size of the charging housing 600, the earbuds 300a, 300b can be positioned at a strategic angle when placed in the housing 600. In some embodiments, each stem of the earbuds 300a, 300b is positioned at an angle relative to two axes: the x-axis and the y-axis, rather than being positioned substantially vertically within the charging housing. For purposes of description, the x-axis travels between the earbuds 300a, 300b, the y-axis travels between the front and rear of the charging housing 600, and the z-axis travels between the bottom of the main body 604 and the top of the cover 602.

[0112] The housing 600 can be configured to charge the wireless listening devices 300a, 300b when they are housed within the housing 600. To this end, in some embodiments, the housing 600 may include two pairs of electrical contacts (not visible in Figures 6A to 6C ) for making electrical contact with corresponding contacts on the stem of each earbud, such that charge can flow from an internal battery (not shown) of the housing 600 to the internal batteries of the earbuds 300a, 300b. The internal battery of the charging housing can be charged by an external power source that is electrically coupled to the housing 600 via a connector 606. The connector 606 can be any suitable physical connector interface, such as the Lightning connector port developed by Apple, a USB-C port, a micro USB port, etc. In some embodiments, the charging housing 600 also includes a wireless power receiving coil (not shown) to wirelessly receive power that can be used to charge the internal battery, as discussed in more detail below.

[0113] In some embodiments, the charging case 600 is highly resistant to moisture ingress and can be designed to meet the IPX4 water resistance standard. To this end, the electronic components within the case 600 (e.g., the charging case battery, the processor, and the circuit board of other electronic circuits that control the operation of the charging case, etc.) can be sealed within an internal system volume sealed with an external system seal. Additionally, each electronic component can be separately sealed with a conformal coating or an adhesive. Some embodiments may also include a pressure vent within the connector 606 module, which can permeate air but not liquid. The pressure vent allows the case to be tested immediately after manufacturing the charging case 600 on the production line to determine whether the charging case is fully sealed as expected by the manufacturer, e.g., in accordance with the IPX4 requirements.

[0114] The case 600 may also include a visual indicator 608 configured to emit different colors of light. The visual indicator 608 can change color according to the charge state of the case. For example, the indicator 608 can emit green light when the case is charged, orange light when the charging case battery is charging and / or when the charging case battery is less than fully charged, and red light when the charging case battery is depleted. When viewed from the outside of the case 600, the visual indicator 608 can have a circular shape or any other suitable shape, such as square, rectangular, oval, etc. The case 600 may also include a user interface 612 such as a button, which, when activated and when the earbuds are stored within the case 600 and the lid 602 is open, initiates a pairing routine that allows the earbuds to pair with a host device.

[0115] In some embodiments, the charging case 600 can include a plurality of different sub-assemblies, which, when assembled together, constitute the entire charging case. Figures 7A to 11 is a simplified exploded view of the individual sub-assemblies that can be combined together according to some embodiments, as Figure 12 shown.

[0116] Cover Housing Sub - Assembly

[0117] Figure 7A is a simplified exploded view of the individual components that can constitute the lid housing sub-assembly 700 and can be assembled together to form the lid 602. As Figure 7A shown, some of the main components of the sub-assembly 700 include the lid housing 710, the lid insert 720, and the hinge 740, in Figure 7BThis is discussed in more detail below. The cover housing 710 defines the outer surface of the cover 602 of the charging housing 600. The cover insert 720 is assembled within the cover housing 710 and can be coupled to the cover housing 710 to define the inner surface of the cover 602. When stored in the charging housing 600, the earbuds 300a, 300b can include a first portion (including the stem) that extends into an earbud receiving portion (e.g., cavity) of the body 604 of the charging housing and a second portion (including an upper portion of the speaker housing) that is positioned within the earbud receiving portion of the cover. The lower surface of the cover insert 720 can be contoured to match the contour of the portion of the speaker housing of each earbud that extends into the cover 602.

[0118] A cover retaining magnet 712 and a cover retaining sub-rotor 714 can be fixed to the cover insert 720. The magnet 712 can be attracted to a magnetic component within the body 604. For example, when the cover 602 is in the closed position, a sub-rotor 822 ( Figure 8 as shown in ) formed of a block of ferromagnetic material such as steel can be positioned within the body 604 directly below the top surface of the charging housing body and aligned with the magnet 712. When the magnetic field from the magnet 712 interacts with the ferromagnetic properties of the sub-rotor 822, the magnet 712 can be attracted to the sub-rotor 822. According to some embodiments, the sub-rotor 822 can operate as a hybrid retaining and sensor sub-rotor that can help keep the cover 602 closed by attracting the magnet 712, but can also function as a sensor component such that a sensor (such as a Hall effect sensor) positioned below the sub-rotor 822 can detect when the cover 602 is opened or closed by the presence of a magnetic field passing through the sub-rotor 822.

[0119] Two magnets 716 can be disposed within the space between the cover housing 710 and the cover insert 720 and positioned along the rear surface of the charging housing. The magnets 716 can help align the charging housing to a wireless charging device, as discussed in more detail below. A pair of DC shields 718 can be disposed between the magnets 716 and the earbud receiving portion of the cover 602 defined by the cover insert 720. The DC shields can be used to isolate electronic components (including the earbuds stored within the housing) within the charging housing 600 from the magnetic field generated by 716. A pair of foam inserts 722 can also be included in the upper cover assembly 700 and disposed between the cover housing 710 and the cover insert 720.

[0120] In some embodiments, the hinge 740 can be a bistable hinge having two stable states, namely an open state and a closed state. Between the open state and the closed state, the hinge 740 can have a neutral position in which it does not pull to open or close the cover, but once the cover is moved past the neutral position in one direction, the bistable hinge will pull the cover open or pull the cover closed, depending on the direction in which the cover is moved away from the neutral position. Thus, the cover can be closed without the need for a large number of magnets to generate a high magnetic attraction to close the cover.Figure 7B Shows a bistable hinge 740 according to some embodiments. Specifically, Figure 7B is a simplified perspective view of a hinge 740 that can be incorporated into a cover 602 according to some embodiments.

[0121] The bistable hinge 740 can be formed as part of a cover 602 of a housing. The bistable hinge 740 can include a first leaf 741 and a second leaf 743 that provide a frame for the hinge 740. The first leaf 741 can be assembled between a cover shell shroud 710 and a cover insert 720 to connect the hinge 740 to the cover. The second leaf 743 can be fixed to the body 604. Each of the two leaves 741, 743 includes a planar rear surface 745 that forms a part of the outer surface of the charging housing.

[0122] The hinge 740 includes first and second pivot points about which the bistable hinge 740 can move to effect bistable opening and closing of the cover 602. By way of example, the bistable hinge 740 can include: a first pivot point 742 of a first shaft 744 along a first axis about which the bistable hinge 740 rotates, and a second pivot point 746 of a second shaft 748 along a second axis about which the bistable hinge 740 rotates. The relative positions between the first shaft 744 and the second shaft 748 can be fixed such that the first shaft 744 and the second shaft 748 are positioned a certain distance apart from each other. The axis intersecting the first pivot point 742 and the second pivot point 746 can define a neutral position in which the bistable hinge 740 is not pulled in either direction to open or close the cover 602.

[0123] A first end of a piston rod 750 can be coupled to the second shaft 748 such that when the bistable hinge 740 transitions between open and closed positions, the piston rod 750 can pivot about the second pivot point 746, and a second end of the piston rod 750 opposite its first end can be attached to a stop 752. The stop 752 can include a flange region 754 that is annular in configuration and positioned around a portion of the piston rod 750 and perpendicular to the outer surface of the piston rod 750. The maximum opening angle of the cover 602 can be controlled by faces on the first leaf 741 and the second leaf 743 that hard stop against each other to prevent further movement of the hinge 740. In one particular implementation, the hinge 740 can be designed to span a full open angle of the cover 602 from 110 degrees to 120 degrees, centered at 115 degrees.

[0124] To generate a spring-loaded force for operating the bistable hinge 740, a spring 756 can be implemented between a piston guide 758 and a second pivot point 746. The spring 756 can be a helical spring that wraps around a portion of the piston rod 750 such that it can exert a force on the piston guide 758. In some cases, the spring 756 is tapered, where it is wider at one end and narrower at the opposite end, such that the spring 756 can provide a force distribution during the transition between a compressed state and an extended state. In some embodiments, the tapered spring can be designed to bend when compressed to a certain degree, where the bending is controlled and results in a repeatable hinge torque distribution. The spring 756 can generate a force in a direction along the axis of the piston rod 750 but away from the direction in which the piston guide 758 is guided. When compared to the axis formed by the first and second pivot points 742 and 746, the direction of this force can enable the bistable operation of the hinge 740.

[0125] Figure 7C is a simplified perspective view of a bistable leaf spring hinge 780 that can be incorporated into the cover 602 in some embodiments instead of being incorporated into the hinge 740. The hinge 780 includes a first pivot point 742 through which a shaft 744 extends as described above with respect to the hinge 740. The hinge 780 does not include a connecting rod or a tapered linear spring that encapsulates the connecting rod. Instead, the hinge 780 includes a leaf spring 782 that is connected to the lobe 741 by a first rod 748 and a second rod 788. The design of the leaf spring hinge 780 can provide a number of benefits, including a lower part count, reduced cost due to the lower part count and fewer assembly steps, improved reliability, and a smaller neutral angle range, resulting in a better user experience.

[0126] Body Insert Sub - Assembly

[0127] Figure 8 is a simplified exploded view of the various components that make up the insert subassembly 800 and can be assembled together to form the interior portion of the body 604. As Figure 8 shown, the subassembly 800 includes an earbud carrier 810 and a contact carrier 820. The earbud carrier 810 can be formed from a one-piece structure that is designed to provide a first bowl region 812a and a second bowl region 812b that are spaced apart from each other, with each of the first and second bowl regions being configured to receive a portion of the earbuds 300a, 300b, respectively. Each of the bowl regions 812a, 812b can include a receiving surface that is contoured to receive and match the outer contour of the lower portion of the speaker housing of each earbud. Each of the cavities 812a, 812b opens at the bottom portion of the cavity to a corresponding tubular extension 814a, 814b.

[0128] The contact carrier 820 may include separate first and second contact carriers 820a and 820b, which may be coupled and attached respectively to extensions 814a and 814b of the earbud cradle 810. Each tubular extension is sized and shaped to receive a portion of the stem of its corresponding earbud such that the tubular extension surrounds an upper portion of the stem. A lower portion of each stem (including the electrical contact ( Figure 8 not shown in) positioned at the end of the upper stem) protrudes through its corresponding tubular extension into its corresponding contact carrier. Each of the contact carriers 820a, 820b includes features that enable electrical contacts ( Figure 8 not shown in) within the charging housing 600 to be fixed to the contact carrier when a portion of the contact extends into the interior space of the contact carrier such that the charging housing contacts can be electrically coupled to the earbud contacts. In some embodiments, the contacts may be sealed relative to the external environment to protect them from moisture. For example, a sealing ring may be strategically positioned at the interface region, which is the entry point of the charging housing.

[0129] In some embodiments, the earbud cradle 810 may be configured to seal the internal components of the charging housing 600 relative to the external environment through the top of the housing body 604. Accordingly, a sealing structure (not shown) formed of a flexible material suitable for sealing purposes may be provided between the intersection of the earbud cradle 810 and the body 604. For example, the sealing structure may extend around the perimeter of the upper portion of the earbud cradle 810 and the inner surface of the body 604.

[0130] The main body housing insert subassembly 800 may also include the cap retaining sub-rotator 822, the earbud retaining magnet 824, and the earbud retaining sub-rotator 826 discussed above.

[0131] Skeleton Sub - Assembly

[0132] Figure 9 is a simplified exploded view of the various components that make up the skeleton subassembly 900 and may be attached to the bottom insert subassembly 800 within the body 604. The skeleton subassembly 900 includes an internal frame 910, which may be formed of a one-piece structure designed to provide contours and surface features against which various electronic components within the charging housing 600 may lean and / or attach. That is, the internal frame 910 may provide a structural backbone for some of the internal components of the charging housing 600, and in the Figure 9 embodiment depicted in, the internal frame 910 provides mounting locations for the battery module 920 and the circuit board module 930 as well as the coil subassembly 1100 discussed with respect to Figure 11 . Additionally, the earbud cradle 810 may be mounted to the upper surface of the internal frame 900 such that the extensions 814a, 814b extend through the openings 914a, 914b in the internal frame 910.

[0133] The battery module 920 includes a battery that provides power to the charging case and can be used to recharge the battery of one or both of the earbuds 300a, 300b when the earbuds are stored in the charging case 600. The circuit board module 930 may include a circuit board 932 on which electronic components can be mounted. In some embodiments, the circuit board 932 can be a rigid multi-layer printed circuit board and the electronic components and circuits that provide one or more functions or portions of the functions of the housing communication system 251, the earbud interface 252, the power receiving circuit 253, the computing system 255, and the user interface 256 discussed Figure 2 above. A flexible circuit board 934 may also be coupled to the circuit board 932 to provide an electrical connection to the electrical contacts 936 of the charging case 600, which can be mounted to the contact carriers 820a, 820b, as described above.

[0134] Coil Sub - Assembly

[0135] Figure 10A is a simplified exploded view of the various components of the coil subassembly 1000 that forms the inner surface of the bottom housing cover that can be laminated. In a particular embodiment, the coil subassembly 1000 can be positioned between the battery module 920 and the rear inner surface of the bottom housing 1110 (see Figure 11 ). The coil subassembly 1000 may include a power receiving coil 1010, a coil shield 1012, a button housing 1014, a nanocrystalline shield 1016, a circuit board 1018, and a flexible circuit 1020.

[0136] The coil subassembly 1000 enables the charging case 600 to be inductively charged by a suitable charging device. For example, Figure 10B is a simplified illustration of a wireless power charging device 1050 that includes a power transmitting coil 1052 positioned within a housing 1054. The charging device 1050 also includes a cable 1056 that enables the device 1050 to receive power from an external source. During wireless power transfer, the charging case 600 can be positioned on Figure 10C the charging device 1050 shown, and the transmitter coil 1052 can generate a time-varying magnetic flux that can propagate through the device housing 1054 and through the housing of the charging case 600, where it can be received by the receiving coil 1010. The time-varying magnetic flux interacts with the receiver coil 1010 to generate a corresponding current in the receiver coil 1010. The generated current can be used by the charging case 600 (e.g., by the electronic circuitry on the circuit board 1018) to charge the battery within the battery module 920.

[0137] The magnetic fields generated during charging operations can potentially interfere with or damage the circuitry within the charging housing 600. To prevent such fields from damaging or otherwise undesirably interfering with the circuitry within the charging housing 600, the coil shield 1012 can be positioned directly adjacent to the power receiving coil 1010 such that the coil shield 1012 blocks the coil 1010 and is between the coil and the circuit board 1018.

[0138] The button housing 1014 provides the structure for the user input button 1114 (see Figure 11 ), which in some embodiments allows a user to initiate the process of wirelessly pairing the earbuds 300a, 300b with a host device using a wireless communication protocol such as Bluetooth. In some embodiments, a memory unit in the earbuds or the charging housing stores information about previous pairings, which enables the earbuds to automatically pair with an authorized host device when the earbuds and the authorized host device are within range of each other. In such embodiments, the input button 1114 can be used to initiate the pairing of the earbuds, which have not been previously paired, with a new device.

[0139] To improve charging efficiency, the charging housing 600 can include a permanent magnet array that aligns the receiving coil 1010 with a transmitting coil of a compatible wireless charger, such as the transmitting coil 1052. In some embodiments, the magnet array can include four separate magnets positioned near the corners of the rear surface of the charging housing 600. For example, in some embodiments, the magnet array can include a first pair of magnets 716 disposed within the cover housing 710 (see Figure 6C ) along the rear surface 620 of the charging housing 600 ( Figure 7A ) and a second pair of magnets 1136 disposed within the bottom housing 1110 (see Figure 11 ) along the rear surface 620. DC shields 718 ( Figure 7A ) and 1138 ( Figure 11 ) can be positioned adjacent to each magnet to isolate the electronic components within the charging housing 600 from the magnetic fields generated by the magnets 716, 1136. Due to the compact size of the charging housing 600, to provide proper spacing between the magnets such that the magnets can align with the corresponding magnetic structures in the wireless charger (e.g., Figure 10D the magnet array 1062 shown), in some embodiments, the magnets 716 are positioned in the cover 602 of the charging housing, while the magnets 1136 are positioned in the body 604 of the charging housing.

[0140] In some embodiments, the magnets 716, 1136 are positioned at the outer edges of the charging housing 600 such that the magnets are positioned along the curvature of the cover 602 and the body 604, as shown, for example, in Figure 10E . Moreover, as shown in Figure 10DAs shown, in some embodiments, magnets 716, 1136 are positioned along a radius that is slightly less than the radius of magnet array 1062. When charging housing 600 is positioned on wireless charging device 1050, magnets 716, 1136 align with magnetic array 1062, thereby generating a magnetic field that has a pulling direction downward and toward the inner ring of magnetic array 1062 to center charging housing 600 on wireless charging device 1050. The placement of magnets 716, 1136 along the curvature of the outer housing of charging housing 600 creates a gap or space 1070 between charging housing magnets 716, 1136 and charging device magnet 1062, which can help prevent magnetic particles from getting stuck in the attraction area between the magnets. Bottom shell cover assembly

[0141] Figure 11 is a simplified exploded view of the various components that make up bottom shell cover assembly 1100 according to some embodiments. Sub-assembly 1100 includes bottom shell cover 1110, which defines the outer surface of main body 604 of charging housing 600. Bottom shell cover is complementary to top shell cover 710, and the two components can be coupled together in a flip-open arrangement by a hinge such as hinge 740 or hinge 780. Bottom shell cover 1110 may include one or more cutouts for the various features of charging housing 600. As Figure 11 depicted, cutout 1112 is formed at a central location on the rear surface of shell cover 1110, and button 1114 extends through cutout 1112 such that the outer surface of button 1114 is flush with the outer surface of bottom shell cover 1110. An O-ring 1116 may form a seal between button 1114 and shell cover 1110 to reduce or prevent moisture from entering through cutout 1112. Figure 6C Button 612 shown as such may represent button 1114.

[0142] Shell cover 1110 may also include smaller cutouts ( Figure 11 (not shown in ) opposite cutout 1112 for light guide 1118, which guides light from a transmitter 1120 such as an LED of a VSCEL to the outer surface of charging housing 600, and may include a third cutout ( Figure 11 (also not shown in ) on the bottom surface of shell cover 1110. The third cutout provides an opening for socket connector 1130, which enables a physical connector to be inserted into charging housing 600. As described with respect to Figure 6A , in some embodiments, the physical connector may be Apple's Lightning connector. However, the embodiments are not limited to any particular connector type, and in other embodiments, connector 1130 may be any other suitable small form factor connector, including a USB-C connector, a micro or mini USB connector, etc.

[0143] Figure 11Also shown therein are the magnet 1136 and the DC shield 1138 discussed above. Figure 12 is a simplified exploded view of sub-assemblies 700, 800, 900, 1000, and 1100 arranged together according to some embodiments. As Figure 12 shown, sub-assemblies 800, 900, 1000, and 1100 form the main body portion 604 of the charging housing 600. Sub-assembly 700 generally forms the lid 602 of the charging housing, except for the leaf 743 portion of the hinge 740, which is mounted to the main body 604 so that the hinge can connect the lid 602 to the main body 604.

[0144] For purposes of illustration, the foregoing description uses specific names to provide a thorough understanding of the described embodiments. However, it will be apparent to those skilled in the art that no specific details are required in order to practice the described embodiments. Accordingly, the foregoing description of the specific embodiments described herein is presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the embodiments to the precise forms disclosed. Additionally, while different embodiments of the present invention are disclosed above, the specific details of particular embodiments may be combined in any suitable manner without departing from the spirit and scope of the embodiments of the present invention. Additionally, it will be apparent to those of ordinary skill in the art that, given the teachings above, many modifications and variations are possible.

[0145] Finally, it is well known that the use of personal identification information should follow privacy policies and practices that are generally recognized as meeting or exceeding industry or government requirements for maintaining user privacy. Specifically, personally identifiable information data should be managed and processed so as to minimize the risk of inadvertent or unauthorized access or use, and the nature of the authorized use should be clearly explained to the user.

Claims

1. An earphone, comprising: A device housing having a wall that defines an internal cavity within the device housing; An acoustic port formed through the wall of the device housing and having an opening at an outer surface of the device housing, wherein the wall includes a first edge and a second edge separated by a ledge that extends completely around a perimeter of the acoustic port; An audio driver disposed within the device housing and aligned to emit sound through the acoustic port; and A mesh coupled to the ledge within the acoustic port and having an outer perimeter spaced from the first edge, thereby forming a gap between the first edge and the outer perimeter of the mesh, wherein the mesh forms a portion of an outer surface of the earphone that is recessed from the opening at the outer surface of the device housing.

2. The earphone according to claim 1, wherein, The mesh is recessed from the opening at the outer surface of the device housing within the acoustic port by 0.5 mm to 2.0 mm.

3. The earphone according to claim 2, wherein, The mesh has a convex profile in which an outer edge of the mesh is recessed more from the opening at the outer surface of the housing than a center of the mesh.

4. The earphone according to claim 1, wherein, The ledge defines an acoustic dead zone surrounding the outer perimeter of the acoustic port, and the outer perimeter of the mesh is disposed within the acoustic dead zone.

5. The earphone according to claim 1, wherein, The mesh includes a multi-layer mesh including an outer decorative mesh and an inner acoustic mesh.

6. The earphone according to claim 1, further comprising: A bass port formed through the housing and configured to provide an acoustic path from the driver, the acoustic path allowing air to flow more easily within the acoustic path for low-frequency sounds; And A control leak hole formed through the housing and configured to provide an atmospheric passage between the external environment and the acoustic port, such that when the earphone is worn by a user, the housing does not completely seal the user's ear canal and build up pressure within the ear canal.

7. The earphone according to any one of claims 1 to 6, wherein, The device housing includes a speaker housing and a rod extending away from the speaker housing, wherein the speaker housing and the rod combine to define the internal cavity within the device housing.

8. The earphone according to claim 7, wherein, A user input area is provided along a portion of the rod.

9. The earphone according to claim 8, further comprising a force sensor disposed within the rod adjacent to the user input area.

10. The earphone according to claim 9, further comprising an antenna disposed within the rod.

11. A portable acoustic device, comprising: A device housing that defines an internal cavity within the device housing, the device housing including a speaker housing portion and a rod portion extending away from the speaker housing portion, wherein the speaker housing portion and the rod portion combine to define the internal cavity within the device housing; An acoustic port formed through a wall of the device housing and having an opening at an outer surface of the device housing, wherein the wall includes a first edge and a second edge separated by a ledge that extends completely around a perimeter of the acoustic port; An audio driver, the audio driver being disposed within the device housing and being aligned to emit sound through the acoustic port; and A grille, the grille being coupled to the ledge within the acoustic port and having an outer perimeter spaced from the first edge of the ledge, thereby forming a gap between the first edge of the ledge and the outer perimeter of the grille, wherein the grille forms a recessed portion of the outer surface of the portable acoustic device from an opening at the outer surface of the speaker housing.

12. The portable acoustic device according to claim 11, wherein, The grille is recessed within the acoustic port from an opening at the outer surface of the speaker housing by 0.5 mm to 2.0 mm.

13. The portable acoustic device according to claim 12, wherein, The grille has a convex profile in which the outer edge of the grille is recessed more from the opening at the outer surface of the housing than the center of the grille.

14. The portable acoustic device according to claim 12, wherein, The grille includes a multi-layer grille, the multi-layer grille including an outer decorative grille and an inner acoustic grille.

15. The portable acoustic device according to any one of claims 11 to 14, wherein, The ledge defines an acoustic dead zone surrounding the outer perimeter of the acoustic port, and the outer perimeter of the grille is disposed within the acoustic dead zone.

16. A portable wireless acoustic device, comprising: A device housing, the device housing defining an internal cavity within the device housing, the device housing including a speaker housing portion and a rod portion extending away from the speaker housing portion, wherein the speaker housing portion and the rod portion have walls that combine to define the internal cavity within the device housing; A wireless antenna, the wireless antenna being disposed within the housing; An acoustic port, the acoustic port being formed through the wall of the speaker housing portion and having an opening at the outer surface of the device housing, wherein the wall includes a first edge and a second edge separated by a ledge, the ledge extending completely around the perimeter of the acoustic port; An audio driver, the audio driver being disposed within the device housing and being aligned to emit sound through the acoustic port; A battery, the battery being disposed within the housing; and A grille, the grille being coupled to the ledge within the acoustic port and having an outer perimeter spaced from the first edge, thereby forming a gap between the first edge and the outer perimeter of the grille, wherein the grille forms a recessed portion of the outer surface of the portable wireless acoustic device from an opening at the outer surface of the device housing.

17. The portable wireless acoustic device according to claim 16, wherein, The grille is recessed within the acoustic port from an opening at the outer surface of the speaker housing by 0.5 mm to 2.0 mm.

18. The portable wireless acoustic device according to claim 17, wherein, The housing includes a hard radio frequency (RF) transparent plastic.

19. The portable wireless acoustic device according to claim 18, further comprising a user input area and a force sensor, the user input area being provided along a portion of the rod, the force sensor being disposed within the rod adjacent to the user input area.

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