Open type earphone

Abstract

A flexible arm is configured to be located between an acoustic module of an open headphone and a battery housing of the open headphone and physically and electrically connect the acoustic module to the battery housing. The flexible arm includes a flexible printed circuit extending through the entire original rest length of the flexible arm and including a conductor configured to carry electrical energy between the acoustic module and the battery housing. A first interface structure is coupled to one of the acoustic module and the battery housing. At least one coupling member is pivotally coupled to the first interface structure. A flexible material surrounds at least some of the flexible printed circuit, at least some of the at least one coupling member, and at least some of the first interface structure.

Description

Background Art

[0001] The present disclosure relates to an earphone worn on the ear.

[0002] Open-back headphones usually produce sound close to the ear canal but not in it. Summary of the invention

[0003] All examples and features mentioned below can be combined in any technically possible way.

[0004] In one aspect, the flexible arm is configured to be located between an acoustic module of an open-type earphone and a battery housing of the open-type earphone and to physically and electrically connect the acoustic module to the battery housing. The flexible arm includes a flexible printed circuit that extends through the entire original resting length of the flexible arm and includes a conductor configured to carry electrical energy between the acoustic module and the battery housing. A first interface structure is coupled to one of the acoustic module and the battery housing. At least one coupling member is pivotably coupled to the first interface structure. The flexible material surrounds at least some of the flexible printed circuit, at least some of the at least one coupling member, and at least some of the first interface structure.

[0005] Implementations may include one or any combination of the following features.

[0006] In some implementations, the at least one coupling member is pivotably coupled to the first interface structure via a pivot pin that passes through corresponding holes in the at least one coupling member and the first interface structure.

[0007] In certain implementations, the at least one coupling member inhibits twisting of the flexible arm.

[0008] In some cases, the at least one coupling member includes a plurality of coupling members that are pivotably coupled in series to one another.

[0009] In some cases, the plurality of link members are pivotably coupled to one another via a pivot pin that passes through corresponding apertures defined by the plurality of link members.

[0010] In some examples, the at least one coupling member at least partially surrounds the flexible printed circuit.

[0011] In some examples, the flexible arm further includes a guide member coupled to the at least one coupling member. The flexible printed circuit can pass through a channel in the guide member, thereby coupling the flexible printed circuit to the at least one coupling member.

[0012] In some implementations, the guide member is formed of silicone.

[0013] In certain implementations, the guide member is coupled to the at least one coupling member via an adhesive.

[0014] In some cases, the flexible arm further comprises a second interface structure coupled to the other of the acoustic module and the battery housing.The at least one coupling member can be pivotably coupled to the second interface structure.

[0015] In some cases, the at least one coupling member includes a plurality of coupling members pivotably coupled to one another and arranged in series between the first interface member and the second interface member.

[0016] In some examples, the at least one coupling member includes a motion limiting feature that limits rotational movement of the coupling member.

[0017] In some examples, the at least one coupling member is formed from a rigid plastic.

[0018] In some implementations, the at least one coupling member is formed from metal (eg, spring steel).

[0019] In certain implementations, a flexible material is overmolded over the at least one coupling member, at least some of the flexible printed circuit, and at least some of the first interface structure.

[0020] In some cases, the flexible material comprises the entire outer layer of the flexible arm.

[0021] In some cases, the original rest position of the flexible arm is along a bending axis defining a simple open curve.

[0022] In some examples, the first interface structure includes one or more centering features to help center the first interface structure within the cavity in the battery housing.

[0023] In certain examples, the first interface structure includes one or more guide members that provide a hard stop that abuts the battery housing to limit inward movement of the first interface structure into the cavity in the battery housing during assembly.

[0024] In some implementations, the flexible material defines a gasket that provides a seal between the first interface member and the acoustic module. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Various aspects of at least one example are discussed below with reference to the accompanying drawings, which are not intended to be drawn to scale. The accompanying drawings are included to provide illustration and further understanding of the various aspects and examples, and are incorporated into and constitute a part of this specification, but are not intended to be used as a definition of limitations of the present invention. In the accompanying drawings, the same or nearly the same components illustrated in various figures may be represented by similar reference symbols or numbers. For clarity, not every component is labeled in every figure. In the drawings:

[0026] Figure 1A This is a side view of an open-back headphone. Figure 1B is its rear view, and Figure 1C It is along Figure 1B A cross-sectional view taken along line 1C-1C.

[0027] Figure 1D yes Figure 1A Perspective view of open-back headphones.

[0028] Figure 2A is a front perspective view of an interface structure for a flexible arm, and Figure 2B This is a rear perspective view.

[0029] Figure 3A and Figure 3B It is connected to the battery housing of the open-back headphones Figure 2A and Figure 2B A perspective view of the junction structure.

[0030] Figure 4A , Figure 4B and Figure 4C are various perspective views of another interface structure for a flexible arm.

[0031] Figure 5A , Figure 5B and Figure 5C They are connected to the acoustic modules of open headphones. Figure 4A Perspective and rear views of the junction structure.

[0032] Fig. 6A and Figure 6B They are Figure 1A Front and rear perspective views of a connecting member of an open-type earphone.

[0033] Fig. 7A and Figure 7B is a perspective view of an open-ear headphone with an alternative coupling member design.

[0034] Fig. 8A and Figure 8B They are Fig. 7A Front and rear perspective views of a connecting member of an open-type earphone. DETAILED DESCRIPTION

[0035] Open-ear headphones worn on the ear should provide high-quality sound, be stable on the ear, be comfortable to wear for long periods of time, be unobtrusive, and look stylish. These goals can be difficult to achieve because, in some ways, they are considered mutually exclusive. For example, stability usually means clamping on the outer ear, which may not be comfortable for long-term wear, and may not look stylish. In addition, in order to obtain high-quality sound, the sound must be delivered near the ear canal, but not in the ear canal, which means that the headphone structure needs to cover the ear and is therefore easily visible to others. Moreover, for the best sound quality, the sound should be delivered close to the ear canal opening but not in the ear canal opening.

[0036] The examples of open-back headphones discussed herein are not limited to application to the construction details and component arrangements listed in the following description or illustrated in the accompanying drawings. These headphones can be implemented in other examples and can be operated or performed in various ways. The examples of specific implementations provided herein are for illustrative purposes only and are not intended to be limiting. In particular, the functions, components, elements, and features discussed in conjunction with any one or more examples are not intended to be excluded from similar effects in any other examples.

[0037] The examples disclosed herein may be combined with other examples in any manner consistent with at least one of the principles disclosed herein, and references to "examples," "some examples," "alternative examples," "various examples," "an example," etc. are not necessarily mutually exclusive but are intended to indicate that the particular features, structures, or characteristics being described may be included in at least one example. The appearances of such terms herein do not necessarily all refer to the same example.

[0038] In addition, the words and terms used herein are for descriptive purposes and should not be considered limiting. Any reference to an example, component, element, action, or function of the headphones herein that is referred to in the singular may also cover embodiments including the plural, and any reference to any example, component, element, action, or function herein in the plural may also cover examples that include only the singular. Therefore, references in the singular or plural are not intended to limit the systems or methods disclosed in the present invention, their components, actions, or elements. The use of "including," "comprising," "having," "containing," "involving," and variations thereof herein is intended to cover the items listed thereafter and their equivalents, as well as additional items. References to "or" may be understood to be inclusive, such that any term described using "or" may indicate any of a single, more than one, and all of the terms.

[0039] In some examples herein, an open earphone includes a flexible arm configured to be located between an acoustic module and a battery housing of the earphone and to physically and electrically connect the acoustic module and the battery housing. The flexible arm defines an original resting length and position between the acoustic module and the battery housing. The flexible arm includes a flexible printed circuit extending through the entire original resting length of the flexible arm. The flexible printed circuit includes one or more conductors that carry electrical energy between the acoustic module and the battery housing. The interface structure is connected to the acoustic module or the battery housing. The flexible material surrounds at least some of the flexible printed circuit and at least some of the interface structure. In some examples, the length of the flexible printed circuit within the flexible arm is greater than the original resting length of the flexible arm. Therefore, when the flexible arm is bent from its original resting position, the flexible printed circuit is better able to adapt to tension or compression on the flexible arm.

[0040] In some examples, the original resting position of the flexible arm is along the bend axis. In one example, the bend axis defines a simple open curve. In one example, the bend axis is generally "C" shaped. In one example, the bend axis bisects the flexible arm, and different portions of the first surface of the flexible printed circuit are located on different sides of the bend axis. In one example, the flexible printed circuit defines at least one simple open curve along its length within the flexible arm. In one example, the flexible printed circuit defines a plurality of simple open upward curves and simple open downward curves along its length within the flexible arm. In one example, each simple open downward curve is adjacent to one or more of the simple open upward curves.

[0041] In various examples, the flexible arm may also include a series of pin connectors arranged between the first interface structure and the second interface structure and attached to the first interface structure and the second interface structure in a pivotable manner. The flexible printed circuit may pass through an internal channel formed in the connector, which may provide support and protection to the flexible printed circuit in the area between the interface members. The connector may also resist torsional motion, for example, to inhibit torsion of the flexible arm. The connector may be formed of plastic (e.g., cast polyurethane) or metal (e.g., spring steel), and may be formed in a molding or stamping operation.

[0042] Figure 1A is a side view of the open earphone 100, Figure 1B is the rear view, Figure 1C is a cross-sectional view taken along line 1C-1C, and Figure 1D 1 is a perspective view. The earphone 100 is configured to be worn on the ear of the user so that the distal sound delivery end 102 of its acoustic module 104 is located in the concha of the ear and the battery housing 106 is located behind the ear. The flexible arm 108 is configured to pass over the outer side of the helix, anti-helix and / or earlobe of the ear. The arm 108 has an original or resting position and length, which is Figures 1A to 1D. In some examples, the original position generally defines a "C" shape, as shown in these figures. Arm 108 is configured to flex at least along its length so that the space between acoustic module 104 and battery housing 106 can be slightly increased. This allows the earphone 100 to be put on and taken off the ear without having to push the earphone over the outer ear, but still provides a light clamping force on the ear to help keep the earphone 100 in place on the ear as the user's head moves. Note that Figures 1A to 1D Some interference between the acoustic module 104 and the battery housing 106 is illustrated. However, in most examples, there is actually space between the two, as disclosed, for example, in the patents incorporated by reference. In some examples, the interference is modeled so that when the arm 108 is molded in this shape, it will want to "rest" in this position. This modeling helps to create some preload in the arm.

[0043] Electrical signals need to be carried through the arm 108. In some examples, the electrical signals include or contain power from the battery 110 in the battery housing 106 to any powered circuits and components and the acoustic transducer 112 in the acoustic module 104. In some examples, the electrical signals also include audio signals from wireless reception and processing circuits (not shown), which may be located in one or more of the arm 108, the battery housing 106, and the acoustic module 104. In some examples, these electrical signals are carried by conductors of the flexible printed circuit 114. The flexible printed circuit needs to be able to flex when the arm 108 flexes, and also needs to carry the necessary electrical signals at the same time.

[0044] The flexible printed circuit 114 carries power from the battery 110 to the data receiving and processing circuits on the printed circuit board 116. Power and audio signals are provided from the board 116 to the transducer 112. The transducer 112 generates sound pressure in the front acoustic cavity 118 and the rear acoustic cavity 120. The openings / ports in the acoustic module housing 122 are the paths for the sound to escape the housing 122. The flexible printed circuit 114, the arm interface structures 124 and 126, and the flexible overmold material 128 are further described below.

[0045] Additional details of open-back headphones, including but not limited to details of their construction, operation, and acoustic performance, are disclosed in U.S. Pat. No. 11,140,469, the entire disclosure of which is incorporated herein by reference and for all purposes. Aspects of the present open-back headphones disclosed in that patent will not be further described herein.

[0046] In some examples, the flexible arm 108 includes one or more intersection structures 124, 126. The intersection structure is configured to mechanically connect the arm to one or both of the battery housing and the acoustic module. In some examples, the intersection structure is relatively rigid, but has a certain compliance. The intersection structure can be made of engineering plastics such as nylon or acrylonitrile-butadiene-styrene (ABS), or made of rubber or rubber-like materials. In some examples, the intersection structure is made by injection molding or machining or stamping or 3-D printing. In some examples, they are single components. The intersection structure helps to keep the arm in its bent static position and provides a reinforced reinforcement for the arm. In some examples, the intersection structure also helps anchor a relatively soft overmolding portion covering the entire arm. In some examples, the overmolding portion also covers at least a portion of the battery housing.

[0047] The first interface structure 124 is Figure 2A and Figure 2B The interface structure 124 is a unitary molded plastic component defining a body 202 extending between a proximal end 204 and a distal end 206, wherein a pair of pivot arms 208 are disposed along the distal end 206 of the body 202. Each of the pivot arms 208 includes a pivot pin 130 ( Figure 1C ) hole 209. The body 202 defines an opening 210 extending through its length between the proximal end 204 and the distal end 206. The opening 210 accommodates the flexible printed circuit 114, thereby allowing the flexible printed circuit 114 to pass through the first interface structure 124 and into the battery housing 106.

[0048] The interface structure 124 is configured to couple the flexible arm 108 to the battery housing 106, helping to support and guide the flexible printed circuit 114. Figure 3A and Figure 3B As shown, the body 202 is configured to be coupled to the battery housing 106. In some examples, the body 202 is received in a complementary shaped cavity 302 ( Figure 3B ), and / or the battery housing 106 can be made of two (or more) pieces that snap together or otherwise fit together around the body 202. An adhesive (such as a pressure sensitive adhesive or epoxy) can be used to more permanently attach the interface structure 124 to the battery housing 106.

[0049] A pair of guide members 212 (shown as raised strips) are provided along opposing outer surfaces of the body 202. The guide members 212 provide a hard stop that abuts the battery housing 106 and prevents further inward movement during assembly. The guide members 212 provide a reference surface to help ensure that the interface structure 124 is properly positioned during assembly with the battery housing 106. The interface structure 124 also includes a plurality of centering features 214, shown in the form of raised bumps extending outwardly from the outer surface of the body 202. These centering features 214 engage the surface of the battery housing 106 within the cavity 302 to help ensure that the body 202 is centered within the cavity 302.

[0050] FIG. 4A to FIG. 4C The second interface structure 126 couples the flexible arm 108 to the acoustic module 104. The interface structure 126 is a one-piece molded plastic component that defines a body 402, a middle narrow portion 404, and a terminal expanded portion 406. The body 402 defines a recess 410 for receiving the flexible printed circuit 114.

[0051] The interface structure 126 is configured to couple the flexible arm 108 to the acoustic module 104, help support and guide the flexible printed circuit, and anchor the overmold. The end expansion portion 406 is configured to couple to the acoustic module 104, such as Figure 5A As shown (in FIG. 5A to FIG. 5C 4 (only a portion of the acoustic module is shown in FIG. 4 ). In some examples, portion 406 is received in a complementarily shaped cavity (not shown) in acoustic module 104 and / or acoustic module 104 is made of two (or more) pieces that snap together or otherwise fit together around portion 402. In some examples, an adhesive (such as a pressure sensitive adhesive) is used to more permanently attach interface structure 126 to acoustic module 104.

[0052] The interface structure 126 defines a guide 410 for the flexible printed circuit 114. The guide 410 has a width and thickness that is approximately the same as the width and thickness of the flexible printed circuit so that the flexible printed circuit is guided into the acoustic module through a slot 412 extending through the middle narrow portion 404 and the end expanded portion 406. The guide 410 helps to properly center, align and support the flexible printed circuit. The guide 410 includes a flat surface created by a groove formed in the surface of the body 402,

[0053] In some examples herein, the overmold material 128 surrounds and encloses the flexible printed circuit along at least a majority of, and preferably all of, the original resting length of the flexible arm, as well as some and preferably all of any internal supports and interface structures. In some cases, a sleeve (not shown) may be provided to cover the coupling member 600 prior to overmolding the overmold material 128. The sleeve may help prevent the overmold material 128 (e.g., silicone) from entering or directly contacting the coupling.

[0054] In conjunction with the acoustic module 104 (in FIG. 5A to FIG. 5C Prior to assembly (only a portion of the acoustic module is shown in FIG), the interface structure 126 is overmolded with a flexible overmolding material 128 ( Figure 5B and Figure 5C ). For illustrative purposes, the interface structure 126 is Figure 5A 4 is shown without the overmolding material 128. The overmolding material 128 forms a gasket 502 ( Figure 5B and Figure 5C ), which engages the acoustic module 104 to form a seal therebetween, for example, to inhibit liquid or debris from entering the interior cavity of the acoustic module 104.

[0055] refer to Fig. 6A and Figure 6B , one or more coupling members 600 are disposed between the first interface structure 124 and the second interface structure 126 and are pivotally coupled to the first interface structure and the second interface structure. Each coupling member 600 includes a plurality of coupling arms 602 and one or more bridging members 604 extending therebetween. In the illustrated example, the bridging members 604 are arranged to define a channel 606 between the coupling arms 602 for accommodating the flexible printed circuit 114.

[0056] Each of the link arms 602 includes a pivot pin 130 ( Figure 1C ) of the pivot pin 612, the pivot pin is used to connect the connecting members 600 to each other and to the first and second interfacing structures. Figure 1D In the example illustrated in FIG. 1 including a plurality of coupling members 600 arranged in series, a coupling arm 602 arranged along a distal end 610 of a coupling member 600 is configured to fit around a coupling arm 602 arranged along a proximal end 608 of an adjacent coupling member in the coupling member 600. The coupling arm 602 arranged along the proximal end 608 of a first coupling member 600 in the series is configured to fit around a pivot arm 208 ( Figure 2A and Figure 2B) and the coupling arm 602 disposed along the distal end 610 of the last coupling member 600 in the series is configured to fit around a pair of pivot arms 414 on the second interface structure 126. The pivot pin 130 ( Figure 1C ) extends through a hole in the connecting arm 602 to pivotally connect the connecting members 600 together. Similarly, the pivot pin 130 extends through holes in the first and last connecting members 600 and the first and second intersection structures 124, 126, respectively, to pivotally connect the connecting members 600 to the battery housing 106 and the acoustic module 104. In some cases, each of the connecting members 600 may also include a motion limiting feature, such as a protrusion or wedge extending outward from one of the bridging members 606, which provides a mechanical limit to the rotation of the connecting member 600. The connector may be formed of a plastic (e.g., cast polyurethane).

[0057] The flexible printed circuit 114 is connected to the connecting member 600, the connecting structure 124 and the connecting structure 126 in a manner as follows: Figure 1C and Figure 1D The first end 132 of the flexible printed circuit 114 is configured to be connected to the battery 110 ( Figure 1C ) of the printed circuit board, and the second end 136 is configured to be connected to the printed circuit board (such as printed circuit board 116, Figure 1C ) intersection. In order to accommodate the flexing of the arm 108 while reducing the stress on the flexible printed circuit 114, the flexible printed circuit 114 may have a longer length in the arm 108 than the nominal resting length of the arm 108. The additional length can be achieved by maintaining one or more curves in the flexible printed circuit in the flexible arm 108. Such additional length can be accommodated in the curves formed in the flexible printed circuit 114. In some examples, the curve 138 is maintained in place via an associated pivot pin in the pivot pin 130. The coupling member 600 surrounds and serves to protect the flexible printed circuit board 114. In addition, the coupling member 600 inhibits torsion of the flexible arm 108. The coupling member 600 can be made by injection molding or machining or stamping.

[0058] Other specific implementations

[0059] exist Fig. 7A , Figure 7B , Fig. 8A and Figure 8B, different specific implementations for connecting members are illustrated in FIG. The connecting member 800 can be made by injection molding or machining or stamping. In some examples, the connecting member 800 can be formed (e.g., stamped) by spring steel. The connecting member 800 includes a pair of connecting arms (a first connecting arm 802 and a second connecting arm 804) connected together via a bridging member 806. The third connecting arm 808 extends from the middle portion of the bridging member 806. The connecting arms 802, 804, 808 are provided with a hole 814 for receiving a pivot pin 130. The third connecting arm 808 is configured to fit between the first connecting arm 802 and the second connecting arm 804 of the adjacent connecting member 800. The pivot pin 130 connects the connecting member 800 together in a pivotable manner. The connecting arms 802, 804, 808 can be similarly connected to the pivot arms 208, 414 on the first and second interfacing structures 124, 126 via the pivot pin 130 in a pivotable manner.

[0060] The coupling member 800 may also include a motion limiting feature 820 that limits the amount of relative rotational movement. This may help inhibit over-extension of the flexure joint. Fig. 8A and Figure 8B In the example illustrated in , the motion limiting feature 820 is in the form of a tab extending outwardly from a bridge member between the first link arm 802 and the second link arm 804 .

[0061] Before the limiting features 820 contact the adjacent link members 800, the link members 800 can rotate freely relative to each other. Once the limiting features 820 on each link contact the adjacent link members 800, any further rotation will result in flexure of the link members 800 and thereby provide a relatively rigid resistance as feedback to the user to inhibit (e.g., prevent) any additional rotation that could damage other plastic components or the flexible printed circuit 114.

[0062] In some cases, guide member 822 may be disposed on one or more of coupling members 800. Guide member 822 defines a channel 824 ( Figure 8B ). The guide member 822 may be formed of silicone and may be secured to the coupling member 800, for example, via an adhesive or interlocking mechanical features.

[0063] Having described several aspects of at least one example above, it should be understood that various changes, modifications and improvements will be readily apparent to those skilled in the art. Such changes, modifications and improvements are intended to be part of this disclosure and are intended to fall within the scope of the present invention. Therefore, the above description and drawings are only exemplary, and the scope of the present invention should be determined by the appropriate construction of the appended claims and their equivalents.

Claims

1. A flexible arm configured to be located between an acoustic module of an open-ear headphone and a battery housing of the open-ear headphone and to physically and electrically connect the acoustic module to the battery housing, the flexible arm comprising: a flexible printed circuit extending through the entire original resting length of the flexible arm and including conductors configured to carry electrical power between the acoustic module and the battery housing; a first interface structure coupled to one of the acoustic module and the battery housing; at least one coupling member pivotably coupled to the first interface structure; as well as A flexible material surrounds the at least one coupling member, at least some of the flexible printed circuit, and at least some of the first interface structure.

2. The flexible arm of claim 1, wherein the at least one connecting member is pivotally connected to the first interface structure via a pivot pin, the pivot pin passing through corresponding holes in the at least one connecting member and the first interface structure.

3. The flexible arm of claim 1, wherein the at least one coupling member inhibits twisting of the flexible arm. 4 . The flexible arm of claim 1 , wherein the at least one coupling member comprises a plurality of coupling members that are pivotably coupled to one another in series.

5. The flexible arm of claim 4, wherein the plurality of link members are pivotally coupled to one another via a pivot pin that passes through corresponding holes defined by the plurality of link members.

6. The flexible arm of claim 1, wherein the at least one coupling member at least partially surrounds the flexible printed circuit.

7. The flexible arm of claim 1, further comprising a guide member coupled to the at least one coupling member, wherein the flexible printed circuit passes through a channel in the guide member, thereby coupling the flexible printed circuit to the at least one coupling member.

8. The flexible arm of claim 7, wherein the guide member is formed of silicone.

9. The flexible arm of claim 7, wherein the guide member is coupled to the at least one coupling member via an adhesive.

10. The flexible arm of claim 1, further comprising a second interface structure coupled to the other of the acoustic module and the battery housing, wherein the at least one coupling member is pivotably coupled to the second interface structure.

11. The flexible arm of claim 10, wherein the at least one coupling member comprises a plurality of coupling members pivotably coupled to one another and arranged in series between the first interface member and the second interface member.

12. The flexible arm of claim 1, wherein the at least one coupling member includes a motion limiting feature that limits rotational movement of the coupling member.

13. The flexible arm of claim 1, wherein the at least one coupling member is formed of a rigid plastic.

14. The flexible arm of claim 1, wherein the at least one coupling member is formed of metal.

15. The flexible arm of claim 1, wherein the flexible material is overmolded over the at least one coupling member, at least some of the flexible printed circuit, and at least some of the first interface structure.

16. The flexible arm of claim 1, wherein the flexible material comprises an outer layer of the entire flexible arm.

17. The flexible arm of claim 1, wherein the original resting position of the flexible arm is along a bending axis defining a simple open curve.

18. The flexible arm of claim 1, wherein the first interface structure includes one or more centering features to help center the first interface structure within the cavity in the battery housing.

19. A flexible arm according to claim 1, wherein the first interface structure includes one or more guide members, and the one or more guide members provide a hard stop member, which is tightly attached to the battery housing to limit the first interface structure from moving inward into the cavity in the battery housing during assembly.

20. The flexible arm of claim 1, wherein the flexible material defines a gasket that provides a seal between the first interface member and the acoustic module.

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