System and method for waterproofing electronic device

Abstract

Devices and methods for a portable electronic device with an improved sealing arrangement are provided. A portable electronic device may include an internal electronic component having a communication module and a battery in electrical communication with the communication module. An internal protective cover that at least partially encloses the internal electronic components may be used to seal and prevent water or other external contaminants from contacting the internal electronic components. A housing having at least two apertures may at least partially enclose the inner protective cover. The inner protective cover may be configured to compress between the housing and the inner electronic component so as to prevent water passing through either of the two apertures from entering the inner protective cover enclosure. The portable electronic device may have fewer design constraints and improved functionality, among other advantages, by relying on an internal protective cover to seal the plurality of apertures.

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Patent Application No. 18 / 465,428, filed September 12, 2023, which is incorporated herein by reference in its entirety. Background Technology

[0002] Communication devices play a crucial role in ensuring effective and efficient communication among individuals performing various tasks, including emergency responders (e.g., firefighters). For example, emergency responders typically utilize communication devices for real-time communication and coordination among team members, enabling them to share critical information, coordinate their actions, and make informed decisions on-site. In many such emergencies, clear and reliable communication is essential for the safety and success of numerous emergency response operations.

[0003] Typically, communication devices are used to provide a lifeline for emergency responders working in hazardous environments. These devices, often handheld or attached to the responder's equipment or clothing, allow the user to maintain contact with the incident command center, providing crucial updates on their location, progress, and potential hazards. This two-way communication between the command center and individual responders ensures that commanders can closely monitor the situation, provide guidance, and deploy necessary resources in a timely manner. Furthermore, in cases of distress or injury, personal communication devices allow emergency responders to seek assistance, thereby enhancing their personal safety.

[0004] Given their specialized purpose, emergency response communication devices typically include dedicated features designed for their specific needs. For example, communication devices may include noise cancellation technology to minimize background noise and enhance clarity, and may also integrate with other equipment such as thermal imaging cameras or air supply systems. In particular, because emergency response communication devices often endure extreme conditions, they are typically designed with increased durability against temperature variations and water exposure, ensuring they remain operational under challenging conditions encountered by first responders. Various jurisdictions have established specific testing requirements for emergency responders, which typically subject devices to high temperatures, water exposure, or both, and then test their ability to maintain function and provide clear communication. Emergency response communication devices generally rely on heat-resistant materials and specially designed seals to meet these durability requirements. Summary of the Invention

[0005] This invention provides systems and methods for electronic devices, such as communication devices, which can be sealed and waterproofed using an internal protective shield. In some aspects, a single internal protective shield seals internal electronics at multiple potential leakage points (e.g., speakers, buttons, charging ports). By relying on a single component to seal multiple leakage points, rather than including separate seals for each interaction point, the electronic device can achieve numerous structural and functional improvements. For example, in addition to other advantages achieved by utilizing an internal protective shield, the compressive forces required to connect the components to the housing of the electronic device can be reduced, allowing for the use of different housing connection types. Furthermore, in some aspects, the internal protective shield can be in a consistent, impermeable form near several potential leakage points (e.g., button, microphone location), which can reduce the total number of actual leakage points the electronic device has. Another advantage of relying on an internal protective shield instead of numerous seals is that it allows for simplified manufacturing, testing, and repair of the electronic device. Moreover, the internal protective shield can allow unwanted water to drain from areas where sound transmission is desired (e.g., the top of a speaker) while remaining within the electronic device, which can allow for reduced water buildup at these points and overall improved sound quality of the electronic device.

[0006] In one aspect, this disclosure provides a portable electronic device. The electronic device may include internal electronic components, an internal protective shield at least partially enclosing the internal electronic components, and a housing at least partially enclosing the internal protective shield, the housing having at least two openings, wherein the internal protective shield is configured to compress to prevent at least one of water or another contaminant from passing through the at least two openings and entering the internal protective shield housing.

[0007] In another aspect, this disclosure provides a portable electronic device. The electronic device may include internal electronic components, including a switch configured to receive input from a user. The electronic device may also include an internal protective cover that at least partially encloses the internal electronic components, the internal protective cover having a button section having a top surface and a bottom surface, wherein the button section is configured to receive a downward force from the user on the top surface and to apply the force through the bottom surface to contact and activate the switch. The electronic device may further include a housing that at least partially encloses the internal protective cover, wherein the internal protective cover is configured to compress to prevent at least one of water or another contaminant from entering the internal protective cover housing.

[0008] In one aspect, this disclosure provides a portable electronic device. The electronic device may include internal electronic components including a communication module, a battery electrically in communication with the communication module, and a speaker configured to provide an audio signal to a user based on communication signals received by the communication module. The electronic device may further include an internal protective cover that at least partially encloses the internal electronic components, wherein the internal protective cover has a speaker aperture configured to provide acoustic energy transmission to the speaker. The electronic device may additionally include a housing that at least partially encloses the internal protective cover, and wherein the internal protective cover is configured to allow water to drain from the speaker aperture between the internal protective cover and the housing.

[0009] In another aspect, this disclosure provides a method for assembling a portable electronic device. The method may include: assembling internal electronic components; enclosing the internal electronic components within an internal protective cover by inserting them into openings in the cover; and enclosing the internal protective cover within a housing, wherein the internal protective cover is configured to compress to prevent at least one of water or another contaminant from entering the housing. Attached Figure Description

[0010] Figure 1A It is a perspective view depicting an electronic device.

[0011] Figure 1B It is a description Figure 1A An exploded view of the right side of the electronic device, depicting the internal electronic components, internal protective shield, and outer casing.

[0012] Figure 1C It is a description Figure 1A -A diagram of the exploded left side view of the electronic device of the B, which depicts the internal electronic components, internal protective cover, and outer casing.

[0013] Figure 2A It is a description Figure 1A-1C A front view of the casing of an electronic device.

[0014] Figure 2B It is a description Figure 1A-1C A diagram showing the right-side view of the casing of an electronic device.

[0015] Figure 2C It is a description Figure 1A-1C A diagram showing the left-side view of the casing of an electronic device.

[0016] Figure 2D It is a description Figure 1A-1C A top perspective view of the casing of an electronic device.

[0017] Figure 2E It is a description Figure 1A-1C A bottom perspective view of the casing of an electronic device.

[0018] Figure 2F It is a description Figure 1A-1C A diagram showing the rear view of the casing of an electronic device.

[0019] Figure 3 It is a description Figure 1A-1C A partially exploded view of the housing of an electronic device, showing four threaded fasteners at a distance from four corresponding openings in the housing.

[0020] Figure 4 It is a description of positioning. Figure 1A-1C A cross-sectional view of the internal protective cover inside the outer shell.

[0021] Figure 5A It is a description Figure 1A-1C A front view of the internal protective cover.

[0022] Figure 5B It is a description Figure 1A-1C A diagram showing the rear view of the internal protective cover.

[0023] Figure 5C It is a description Figure 1A-1C A front perspective view of the internal protective cover.

[0024] Figure 5D It is a description Figure 1A-1C A perspective view of the right side of the internal protective cover.

[0025] Figure 6A It is a description Figure 1A-1C A front perspective view of the internal electronic components.

[0026] Figure 6B It is a description Figure 1A-1C A rear perspective view of the internal electronic components.

[0027] Figure 6C It is a description Figure 1A-1C A diagram showing an exploded view of the internal electronic components.

[0028] Figure 7 It is a diagram depicting a partial cross-sectional view of the microphone aperture in an electronic device.

[0029] Figure 8A It is a diagram depicting the arrangement of buttons in an electronic device in an uncompressed (i.e., inactive) state.

[0030] Figure 8B It is a diagram depicting the arrangement of buttons in an electronic device in a compressed (i.e., activated) state.

[0031] Figure 9A It is a description Figure 1A-1C A cross-sectional view of the electronic device (including the loudspeaker subsystem).

[0032] Figure 9B It is a description Figure 9A A cross-sectional view of the loudspeaker subsystem.

[0033] Figure 10 This is a flowchart depicting a method for manufacturing portable electronic devices. Detailed Implementation

[0034] Traditional molded enclosures used in electronic devices (such as communication devices) rely on various techniques to seal their enclosures and thus prevent water and other contaminants (e.g., smoke, dust, dirt, etc.) from contacting the internal electronics. While some joining methods (e.g., ultrasonic welding) are effective in forming a strong seal, they also prevent the device from being reopened for factory repair or maintenance (e.g., replacing a damaged button). Therefore, because it is advantageous to make electronic devices maintainable in many applications, peripheral gaskets are typically provided between two or more molded enclosure components (e.g., molded housings), where the gaskets are compressed into a sealing engagement by threaded fasteners or similar hardware.

[0035] Unfortunately, among other drawbacks, the peripheral gasket design approach requires a relatively large peripheral volume, which may limit the area available for internal electronics or necessitate an additional increase in device size. Furthermore, many devices have multiple interaction points (e.g., buttons, microphones, speakers, battery inputs, peripheral connectors, etc.) that can become potential entry points for water or other contaminants, causing damage. In conventional devices, each of these interaction points must be sealed if the device is to function properly after contact with water or contaminants. All these seals, including those for each interaction point, can limit design flexibility, add undesirable volume, and complicate the process of preventing leaks during the manufacture and use of the electronics. These problems are often exacerbated when specifically designed for emergency response communication devices (such as those described above), as these devices need to withstand significantly more contact with water and contaminants than other electronic devices.

[0036] To address these shortcomings, this disclosure partially provides systems and methods utilizing alternative sealing technologies. In some aspects, an internal protective shield can be positioned between the housing and internal electronics to seal multiple interaction points within the electronics. As discussed above, this approach offers numerous potential advantages compared to devices employing individual seals for each potential leakage point. For example, the internal protective shield can provide a sealing solution with a smaller peripheral volume, allowing for improvements in device size and electronic functionality. This sealing arrangement also enables various structural and functional enhancements to the electronic device. For instance, by relying on multiple seals for a single component, the compressive forces required for the device housing can be reduced, thereby improving design options. Additionally, the internal protective shield can allow for the redesign of button and microphone locations so that they are no longer potential leakage points, reducing the risk of leakage and further simplifying design considerations while maintaining functionality. Furthermore, the internal protective shield can facilitate the drainage of unwanted water from areas where sound transmission is desired (e.g., the top of a speaker). This feature can help prevent water buildup at these points, thereby improving the sound quality of the device. Moreover, utilizing an internal protective shield instead of multiple seals simplifies the manufacturing, testing, and repair processes for the electronic device. As will be discussed further, these are only a few of the advantages provided in this disclosure, and those skilled in the art will readily recognize the further benefits of employing the systems and techniques described herein.

[0037] Although the example systems and methods discussed herein primarily relate to handheld emergency response communication devices, those skilled in the art will readily understand that the techniques described herein can be applied to other electronic devices, including but not limited to communication devices (e.g., cellular phones, two-way radios, pagers), medical devices (e.g., implantable medical devices, surgical devices, insulin pumps), or other personal electronic devices that require sealing to prevent damage from water or other contaminants (e.g., computers, tablets, drones, smartwatches, cameras, speakers, calculators, diving watches).

[0038] Figure 1A-1C Depicts a handheld communication device 100. (e.g.) Figure 1B-1CAs shown, the handheld electronic device 100 is typically formed of three sub-sections: a housing 200, an inner protective cover 300, and an internal electronic assembly 400. As will be further described, the inner protective cover 300 may at least partially enclose the internal electronic assembly 400, which may include multiple electronic components that help provide the functionality of the electronic device 100. The housing 200 may at least partially enclose both the inner protective cover 300 and the internal electronic assembly 400. As shown, the housing 200 may have several openings that act as interaction points, and the inner protective cover 300 may be configured to compress at each point to prevent water or other contaminants from passing through the openings and entering the inner protective cover 300. For example, the inner protective cover 300 may be configured to compress between the housing 200 and the internal electronic assembly 400. In this way, the inner protective cover 300 can be used to seal the internal electronic assembly 400, thereby preventing undesirable exposure.

[0039] Figures 2A-2F A more detailed description Figure 1A-1C The electronic device 100 has a housing 200. As shown, the housing 200 may have a top shell 202 and a bottom shell 204. The top shell 202 and bottom shell 204 may interact and connect to define an enclosed space in which an internal protective cover 300 and internal electronic components 400 are located. The top shell 202 and bottom shell 204 may be formed of several walls or surfaces and may be specifically sized and constructed to be easily and securely held by a user. For example, the housing 200 may be specifically sized for a handheld device and may have a length, width, and height all less than eight inches. The top shell 202 may have similar dimensions and shapes to the bottom shell 204, at least near the points of their interaction, which may facilitate the connection of these two sub-components to each other. Although the top shell 202 and bottom shell 204 are depicted, it should be readily understood that other forms of housings (e.g., left and right shells, three-component arrangements, etc.) may be utilized.

[0040] The top shell 202 and bottom shell 204 may include surfaces configured to contact each other. The outer shell 200 may be formed of a rigid material, such as plastic or composite material. The top shell 202 may be configured to interact with the bottom shell 204 in a manner where the connection point between them is not waterproof or contaminant-proof (i.e., the connection point allows liquids to pass freely between the two shells). In other words, the connection between the top shell 202 and the bottom shell 204 may be specifically designed to be non-waterproof or non-airtight, and the electronic device 100 may alternatively rely primarily on the internal protective cover 300 to prevent water or contaminants from entering the internal electronic components 400.

[0041] Housing 200 may include multiple interaction points (also referred to herein as “leakage points” or “access points”), including one or more speaker apertures 206 configured to provide audio access to a speaker subsystem (not depicted) of internal electronics 400. As shown, speaker apertures 206 may be in the form of apertures within a top housing 202. In the depicted example, three sections of the top housing 202 are positioned above speaker apertures 206 to help prevent damage to the speaker subsystem located within electronics 100. Housing 200 may also include six microphone apertures, including an upper left microphone aperture 210, a top center microphone aperture 212, an upper right microphone aperture 214, a lower left microphone aperture 216, a bottom center microphone aperture 218, and a lower right microphone aperture 220. Similar to speaker apertures 206, microphone apertures 210-218 may be used to provide audio access through housing 200.

[0042] The housing 200 may also include a number of components that allow physical interaction between the user and the electronic device 100. For example, the housing 200 may include a number of buttons or button openings, such as an upper left button opening 230, an upper right button opening 232 and a main side button 234, a top center opening 236, and a front opening 238. Although not depicted, each button opening may include a button cover that may be integrated with the housing 200. The buttons and button openings 230-238 may allow the user to interact with the electronic device by, for example, turning on the power to the electronic device 100, adjusting the device volume, adjusting the communication channel, activating a transmit mode, activating a receive mode, and / or sending an emergency alarm signal. The housing 200 may also include many other interaction points, including a charging port opening 240, an attachment connector 242, a physical interface port 244 (e.g., a USB port), and an optical port 246. To provide a mechanism for attaching the top shell 202 to the bottom shell 204, the shell may include various attachment devices, such as the upper left fastener hole 250, the upper right fastener hole 252, the lower left fastener hole 254, and the lower right fastener hole 256.

[0043] Figure 3 Depicting Figure 1A-1CThe electronic device 100 has a housing 300, in which four threaded fasteners 260, 262, 264, 266 are shown spaced apart from four corresponding openings 250, 252, 254, 256 in the housing 200. These threaded fasteners are used to securely connect the top housing 202 to the bottom housing 204. Although threaded fasteners are depicted, since the electronic device primarily relies on the internal protective cover 300 for sealing purposes, alternative connection technologies can be used, including those providing less robust attachments. For example, clamp connectors, hook connectors, or other mechanical connectors can be utilized. The connection device can be positioned at or near the contact point between the top housing 202 and the bottom housing 204. Furthermore, since the requirement for uniform pressure around the contact point between the top housing 202 and the bottom housing 204 is less critical for this design, the number of threaded fasteners can be reduced. For example, four or fewer attachment mechanisms can be specifically present for connecting the top housing 202 to the bottom housing 204.

[0044] Figure 4 This is a cross-sectional view depicting an inner protective shield 300 positioned within housing 200. As shown, the inner protective shield 300 serves as a barrier, preventing water or other contaminants that have penetrated housing 200 from contacting the internal electronic components 400. Similar to housing 200, the inner protective shield 300 may be formed by several outer walls defining an enclosed space. As shown, the inner protective shield 300 may adopt a geometry substantially matching housing 200, which can help maximize the enclosed space in which the internal electronic components 400 are positioned. The inner protective shield 300 may typically have a hexagonal geometry. The volume of the space enclosed by the inner protective shield 300 may specifically be at least 70%, at least 80%, or at least 90% of the volume of the space enclosed by housing 200. The inner protective shield 300 may be configured to have dimensions that allow it to contact housing 200 at various locations, which can help prevent internal movement or rotation of the inner protective shield 300 or the internal electronic components 400. To maximize the volume of the enclosure in which the internal electronic components 400 can be located, the internal protective cover 300 may have an average wall thickness of less than 1 mm, less than 0.8 mm, or specifically about 0.5 mm.

[0045] Figures 5A-5D A more detailed description Figure 1A-1CAn internal protective cover 300 is provided for the electronic device 100. The internal protective cover 300 can be configured to compress to provide a seal against the housing 200, internal electronic components 400, or both. As shown, the internal protective cover 300 may include a plurality of orifices, at least some of which may be specifically designed to at least partially overlap with orifices in the housing 200. Specifically, the internal protective cover may include a speaker orifice 206, a charging port orifice 340, and a physical interface port 344, corresponding to the speaker orifice 206, charging port orifice 240, and physical interface port 244 of the housing 200, respectively. The internal protective cover may also include a battery orifice 348. Therefore, the internal protective cover 300 may have significantly fewer leakage points than the housing 200. Specifically, the internal protective cover 300 may have fewer than six, fewer than five, fewer than four, or specifically fewer than three orifices or water / contaminant ingress points.

[0046] The internal protective shield 300 may be formed from a single component body (e.g., a wall shell or housing having an enclosed internal volume). The internal protective shield 300 may specifically include an elastomer. For example, the internal protective shield 300 may include, be substantially composed of, or be composed of silicone. To allow light transmission, the internal protective shield may be at least partially translucent. For durability, which is particularly useful for emergency responder applications, the internal protective shield 300 may be formed from a material with heat-resistant properties and may be specifically configured to substantially maintain its intended geometry at temperatures up to at least 350 degrees Fahrenheit.

[0047] As will be further described, the inner protective shield 300 may provide a uniform wall (i.e., a wall without openings) near some interaction points, and alternatively relies on the transmission of sound, light, or physical force through the inner protective shield 300 itself to provide the desired interaction. For example, as Figures 5A-5D As shown, the inner protective cover 300 may have a continuous, impermeable surface near several openings in the housing 200, including microphone holes, button holes, and light holes. Such continuous surface sections may be particularly suitable for transmitting light, sound, or physical forces in a consistent manner.

[0048] The inner protective cover 300 may have a specific geometry that allows the top shell 202 to be attached to the bottom shell 204. For example, the inner protective cover 300 may have a number of recesses 350, 352, 354, 356, in which fastener openings 250, 252, 254, 256 are respectively positioned. In this way, the inner protective cover 300 can avoid having any openings within its uniform body for attaching the top shell 202 to the bottom shell 204.

[0049] Figures 6A-6C A more detailed description Figure 1A-1CThe internal electronic component 400 of the electronic device 100. As shown in this example electronic device 100, the internal electronic component 400 may be at least partially surrounded or enclosed by an internal protective cover 300. For example, the internal protective cover 300 may at least partially surround three, four, five, or specifically all six geometric sides of the internal electronic component 400. The internal electronic component 400 may be specifically configured to be assembled within a shell created by the internal protective cover 300. Furthermore, the internal electronic component 400 may be configured to be inserted into an opening (e.g., a battery opening 348) in the internal protective cover 300, which may allow for simplified assembly.

[0050] The internal electronic component 400 may include at least one printed circuit board (PCB) 402 or similar circuit system. The PCB 402 may include various components that implement the functions of the electronic device 100. Among other components, the PCB 402 may be connected to a speaker 404, various sensors (e.g., a microphone), a battery 406, and button components (e.g., a push-button switch). For example, the internal electronic component 400 may include an upper left button 430, an upper right button 432, a main side button 434, a top center button 436, and a front button 438, which may correspond to the upper left button opening 230, upper right button opening 232, main side button 234, top center opening 236, and front opening 238 of the housing 200, respectively. Similarly, the charging connector 440 and the physical interface hub 444 may be positioned directly adjacent to the charging port opening 240 and the physical interface port 244 of the housing 200, respectively. The internal electronic component 400 may have various structural features configured to maintain the correct positioning of these components relative to each other. For example, as shown, the internal electronic component 400 may include a structural housing 408, which may be held together using a plurality of threaded fasteners 410. It will be readily understood that the internal electronic component 400 may include alternative components configured to provide different functions depending on the intended application of the electronic device 100.

[0051] The internal electronic component 400 may also include a communication module 412, which can electrically communicate with the battery 406 and other components of the internal electronic component 400, such as the PCB 402. The communication module 412 may be configured to transmit and / or receive wireless communication signals, or, if the electronic device 100 is currently attached to a direct communication line, to provide communication signals via that direct communication line. Specifically, the communication module 412 may include a transmitter configured to wirelessly transmit communication signals to at least one second electronic device and a receiver configured to receive communication signals from the second electronic device. The communication module 412 may be specifically configured to transmit and receive radio frequency signals, but alternative forms of communication are also possible.

[0052] Figure 7 A partial cross-sectional view of a microphone aperture 722 in an electronic device is depicted. As shown, the microphone aperture 722 can be positioned within a housing 720 of the electronic device. An internal protective cover 730 can be positioned between the housing 720 and an internal microphone sensor 740. To facilitate sound transmission through the internal protective cover 730, the internal protective cover 730 may include a microphone recess 732, which creates a thinner wall within the internal protective cover, thus resulting in a shorter distance that sound waves must travel through the internal protective cover 730. As shown, the recess 732 can be directly adjacent to the microphone aperture 722 and can completely cover the internal space directly inward from the microphone aperture 722. This arrangement allows the internal protective cover 730 to maintain a uniform waterproof layer near the microphone aperture 722 while still providing sufficient transmission of sound waves through the microphone aperture 722 to the microphone sensor 740. The internal protective cover 730 may specifically have a thickness of less than 0.8 mm, less than 0.5 mm, or specifically about 0.3 mm at the microphone recess 732.

[0053] Similar to a microphone recess, the internal protective housing described in the systems and methods herein may include other recesses or features configured to control the transmission of sound or light through the internal protective housing. For example, instead of the microphone sensor 740, the internal electronic components may include light-emitting elements (e.g., light-emitting diodes), which may be configured to, for example, provide information to a user of the device. Alternatively or additionally, the internal electronic components may include light-receiving elements (e.g., light sensors) that allow the device to adjust device settings (e.g., modify screen brightness levels). The housing may include adjacent light apertures similar to the microphone recess 732. Interposed between the housing and the internal electronic components may be a section of the internal protective housing including a light recess.

[0054] The light recess can be at least partially positioned between the light-emitting or light-receiving component and the light aperture, and can be configured to transmit a visible amount of light emitted from the light-emitting component or to transmit ambient light to the light-receiving component. Compared to a flat surface without a recess, the light recess can have a form that allows controlled light emission. For example, the light recess can have at least one sidewall that is substantially orthogonal to the surface of the inner protective cover adjacent to the light recess. At least one sidewall can help prevent light leakage, thereby providing controlled light transmission through the inner protective cover. The inner protective cover may specifically have a thickness of less than 0.8 mm, less than 0.5 mm, or specifically about 0.3 mm at the light recess.

[0055] Instead of a recessed area, the inner protective cover may include a light-emitting tab (i.e., a thicker area) at least partially located between the light-emitting or light-receiving component and the light aperture, and may be configured to transmit a visible amount of light emitted from the light-emitting component or to transmit ambient light to the light-receiving component. The light-emitting tab can allow for greater light diffusion, particularly when emitted from the light-emitting component. The light-emitting tab can be sized and shaped to extend through the aperture of the housing, thereby simplifying light transmission to or from the device. For example, the light-emitting tab may have a protruding safety triangle shape and may extend at least partially through a triangular aperture of the housing. Relatedly, to control the transmission of light through the inner protective cover, the light-emitting tab may have at least one sidewall that is substantially orthogonal to the surface of the adjacent recessed area of ​​the inner protective cover. Therefore, the light-emitting tab can allow for greater control over the transmission of light through the inner protective cover.

[0056] Figure 8A A button arrangement 800 in an electronic device in an uncompressed (i.e., inactive) state is depicted. The button arrangement 800 can be configured to receive input from a user. As shown, an external button cover 820 (also referred to as a "button cap"), which can be attached to and is part of a housing, can be positioned adjacent to a button sensor 840 (i.e., a switch), with an internal protective cover 830 inserted therebetween. The button sensor 840 can be a momentary operating switch, a push-button switch, a dome switch, or a similar component. The button cover 820 can take various forms, such as a hinged surface, provided that it is configured to move in the direction of the button sensor 840 when subjected to an actuating force (e.g., a finger pushing down on it).

[0057] Figure 8B A button arrangement 800 in an electronic device in a compressed (i.e., activated) state is depicted. Figure 8A In contrast, the button cover 820 (i.e., the button cap) has moved inward, thereby forcing the adjacent section of the inner protective cover 830 to bend and also move inward toward the button sensor 840. The inner protective cover 830 is shown as contacting the button sensor 840, which can activate the button sensor, thereby allowing the user to interact with the electronics via the button arrangement 800. Therefore, the inner protective cover 830 may have a button section having a top surface and a bottom surface, and the button section may be configured to receive a downward force from the user on the top surface and apply that force through the bottom surface to contact and activate the internal button switch or sensor 840. To prevent water or contaminants from penetrating into the internal electronics area, the button section of the inner protective cover 830 may be a solid surface without openings, as shown.

[0058] The button cover 820 and / or the inner protective cover 830 may have a form that allows easy contact with the button sensor 840. For example, the inner protective cover 830 may have a protrusion or increased thickness in the section between the button cover 820 and the button sensor 840. For example, instead of having a flat surface as shown, the protrusion may extend from the bottom or top surface of the inner protective cover 830. After the button sensor 840 is activated, the inner protective cover 830 and the button cover 820 may be configured to return to their original uncompressed position. The inner protective cover 830 may help facilitate this return movement through material elasticity (i.e., the inner protective cover 830 may naturally exist in the uncompressed state and have material memory configured to return to that state). The button cover 820 may return to this initial state by interacting with the inner protective cover 830, or alternative mechanical techniques may be used, such as by utilizing a spring or similar component. The button sensor 840 itself may specifically not include a mechanical spring.

[0059] It should be readily understood that the electronic device described herein may include many different button arrangements. For example, the electronic device may include a number of push-button switches within its internal electronic components, each push-button switch being configured to receive input from a user. For each push-button switch, the internal protective cover may have a corresponding button segment, wherein each button segment has a top surface and a bottom surface, said top surface and said bottom surface being configured to receive a downward force from the user on the top surface and apply a force to contact and activate the adjacent switch. These various button segments of the internal protective cover may be positioned on different geometric surfaces, and / or they may be positioned adjacent to and on the same geometric surface of the internal protective cover.

[0060] Figure 9A Depicting Figure 1A-1C The cross-section of the electronic device 100 (including a speaker subsystem 438 associated with internal electronic components (not depicted) and an internal protective enclosure 300). The speaker subsystem 438 can be configured to provide controlled sound to a user based on communication signals or device commands received, for example, by a communication module. Figure 9B A cross-sectional view of a loudspeaker subsystem 438 is depicted, which may include a loudspeaker diaphragm segment 439 having a top surface 441 and a side surface 443. Relatedly, the inner protective cover 300 may include a gasket 372 configured to provide a seal between the side surface 443 and the inner protective cover 300.

[0061] Because the electronic device 100 can be designed to allow water to permeate the housing 200, the top surface 441 of the speaker diaphragm section 439 can limit the maximum height to which water can accumulate on the speaker subsystem 438. The inner protective cover and housing can be configured to provide gaps so that water can drain from the speaker orifice once it exceeds the top surface 441. In other words, the inner protective cover 300 can be configured to allow water to drain from the speaker subassembly 438 while remaining within the housing 200. Specifically, the inner protective cover 300 may include one or more channels or structural features on its outer surface to facilitate water drainage from the speaker subsystem 438. The height between the lowest point where water can accumulate on the speaker diaphragm 439 and its top surface 441 can be less than 10 mm, less than 8 mm, or specifically less than 5 mm. Advantageously, this allows less water to accumulate on the speaker subsystem 438 compared to a situation where water is forced to reach the height of the housing before drainage.

[0062] Pressure differences between the internal electronic enclosure (i.e., the sealed portion) of an electronic device and its surrounding environment can cause various problems, including degraded sound quality of the device's speakers. To address this issue, in some aspects, the internal protective enclosure of the systems and methods described herein may include intentionally enlarged sections. These enlarged sections can allow for changes in the enclosure volume of the internal protective enclosure to reduce the pressure difference relative to the device's surrounding environment. In other words, the enlarged sections can allow the enclosure volume of the protective enclosure to passively expand or contract. The enlarged sections can come in various forms; for example, the enlarged sections may have a wall thickness thinner than the surrounding walls of the internal protective enclosure and can be configured to increase or decrease the enclosure volume of the internal protective enclosure to reduce pressure variations within the internal protective enclosure. Alternatively, the enlarged sections may take the form of a dome, bellows, or corrugated structure.

[0063] The electronic devices described herein can be specifically configured to withstand various temperature, pressure, and mechanical tests. As discussed above, emergency response communication devices are particularly prone to exposure to high temperatures and large amounts of water. Therefore, specific materials and design techniques can be used to construct the electronic devices described herein to maintain operation under extreme conditions. The electronic devices can be configured to meet the thermal and immersion requirements outlined in Section 8.3 of NFPA 1802 and / or the drainage requirements outlined in Section 8.13 of NFPA 1802 (2021 edition).

[0064] Figure 10 A method 1000 for manufacturing a portable electronic device (such as the electronic device described herein) is depicted. At 1002, internal electronic components may be assembled, which may include a communication module and a battery in electrical communication with the communication module.

[0065] At point 1004, the internal electronic components can be enclosed within the internal protective cover by inserting them into an opening in the internal protective cover. The internal protective cover may comprise a deformable material, and inserting the internal electronic components may include a section of the internal protective cover that stretches over the internal electronic components. Therefore, to allow for this manufacturability, the internal protective cover may include at least one opening or section (e.g., a battery access opening) through which the internal electronic components can be inserted.

[0066] At position 1006, the internal protective cover may be enclosed within the housing. The internal protective cover may be configured to compress between the housing and internal electronic components to prevent water or other contaminants from entering the internal protective cover enclosure. The housing may include a top housing and a bottom housing, and enclosing the internal protective cover within the housing may include connecting the top and bottom housings using multiple threaded fasteners.

[0067] Method 1000 may include additional steps related to testing the electronic device. For example, the internal electronic components may include one or more switches configured to receive input from a user, and method 1000 may further include testing one or more switches to ensure they are operable before enclosing the internal electronic components within an internal protective enclosure. Advantageously, if any switches or other components within the electronic components are found to malfunction during testing, any such problems can be addressed before enclosing the device within the internal protective enclosure and housing. In devices that rely on, for example, overmolding or alternative direct sealing techniques, the internal electronic components may not be easily removed or tested in this manner, thus limiting the manufacturer's ability to properly test functionality early in the assembly process.

[0068] Therefore, in one aspect, this disclosure provides a portable electronic device that may include internal electronic components, an internal protective shield at least partially enclosing the internal electronic components, and a housing that at least partially encloses the internal protective shield. The housing may have at least two openings, and the internal protective shield may be configured to compress to prevent at least one of water or another contaminant from entering the internal protective shield housing through the at least two openings. The internal protective shield may include no more than four openings. The internal protective shield may be configured to substantially maintain its intended geometry at temperatures up to at least 350 degrees Fahrenheit.

[0069] In this regard, the electronic device may further include a light-emitting component as part of an internal electronic assembly, and a light aperture in the housing. The electronic device may also include a light recess within an internal protective cover, the light recess being at least partially positioned between the light-emitting component and the light aperture. The light recess may be configured to transmit a visible amount of light emitted from the light-emitting component. The internal protective cover may have a thickness of 0.5 mm or less at the light recess. The electronic device may also include a light protrusion projecting from the internal protective cover and at least partially positioned within the light aperture, wherein the light protrusion may be configured to transmit a visible amount of light emitted from the light-emitting component. The light protrusion may have at least one sidewall substantially orthogonal to the surface of the internal protective cover adjacent to the light recess. The internal protective cover may have a thickness of 1 mm or greater at the light protrusion. Furthermore, the electronic device may also include: a light-receiving component as part of an internal electronic assembly; a light aperture in the housing; and a light recess within an internal protective cover. The light recess may be at least partially positioned between the light-receiving component and the light aperture, wherein the light recess may be configured to transmit a visible amount of light to the light-receiving component.

[0070] Additionally, the internal protective enclosure of the electronic device may have an enlarged section, and the enlarged section may have a wall thickness thinner than the surrounding wall thickness of the internal protective enclosure. The enlarged section may be configured to increase or decrease the enclosure volume of the internal protective enclosure in order to reduce pressure variations within the internal protective enclosure. The housing of the electronic device may include a top housing and a bottom housing. The top housing and bottom housing may be connected by a clamping connection. Alternatively or additionally, the top housing and bottom housing may be connected by a connection type selected from the following: threaded fasteners, snap-fit, interference fit, thermoplastic joint, welded joint, rivets, and adhesive bonding. The connection point between the top housing and the bottom housing may not be waterproof. The electronic device may be configured to meet the thermal and immersion requirements outlined in Section 8.3 of National Fire Protection Association (NFPA) 1802.

[0071] In another aspect, this disclosure provides a portable electronic device that may include: an internal electronic component including a switch configured to receive input from a user; an internal protective cover at least partially enclosing the internal electronic component, the internal protective cover possibly having a button section having a top surface and a bottom surface, wherein the button section may be configured to receive a downward force from the user on the top surface and apply the force through the bottom surface to contact and activate the switch; and a housing that at least partially encloses the internal protective cover, wherein the internal protective cover may be configured to compress to prevent at least one of water or another contaminant from entering the housing. The button section of the internal protective cover may be a solid surface without openings. The button section of the internal protective cover may include a protrusion extending from the internal protective cover, wherein the top surface of the button section may be positioned on the protrusion.

[0072] In this respect, the electronic device may also include: a second switch included in the internal electronic components, the second switch being configured to receive input from a user; and a second button section having a top surface and a bottom surface, wherein the second button section may be configured to receive a downward force from the user on the top surface and apply force through the bottom surface to contact and activate the second switch. The second button section may be positioned on a different geometric surface of the inner protective cover compared to the first button section. The second button section may be positioned adjacent to and on the same geometric surface of the inner protective cover compared to the first button section. The housing may include a button cover positioned above the second surface of the button section of the inner protective cover, wherein at least a portion of the button cover may be configured to receive a downward force from the user and transmit this downward force to the second surface of the button section. The switch may be a momentary operating switch. Alternatively, the switch may be a push-button switch. Alternatively, the switch may be a dome switch. The switch may specifically not include a mechanical spring. The button section of the inner protective cover may include silicone. The inner protective cover may be formed from a single component body. The inner protective cover may include an elastomer. An internal protective shield may at least partially surround each geometric side of the internal electronic components. The internal electronic components may also include a communication module and a battery in electrical communication with the communication module. The communication module may include: a transmitter configured to wirelessly transmit communication signals to a second device; and a receiver configured to receive communication signals from the second device. The transmitter may be configured to transmit radio frequency signals, and the receiver may be configured to receive radio frequency signals.

[0073] In another aspect, this disclosure provides a portable electronic device that may include internal electronic components having a communication module, a battery in electrical communication with the communication module, and a speaker configured to provide an audio signal to a user based on communication signals received by the communication module. The electronic device may further include: an internal protective cover that at least partially encloses the internal electronic components, wherein the internal protective cover may have a speaker aperture configured to provide acoustic energy transmission to the speaker; and a housing that at least partially encloses the internal protective cover, wherein the internal protective cover may be configured to allow water to drain from the speaker aperture between the internal protective cover and the housing.

[0074] In this respect, the inner protective cover and the outer shell can be configured to provide a gap to allow water to drain from the speaker opening. The inner protective cover may include channels on its outer surface, which may be configured to drain water from the speaker gap. The speaker may include a speaker diaphragm having a top surface and side surfaces, and the inner protective cover may include gaskets configured to contact the side surfaces of the speaker diaphragm to provide a seal between the speaker and the inner protective cover. The gaskets and the outer shell may be configured to provide a gap to allow water to drain from the speaker opening. The height between the lowest point on the outer surface of the diaphragm and the top surface of the diaphragm may be less than 10 mm. The outer shell may include a speaker opening configured to provide acoustic energy transmission to the speaker. The inner protective cover may be configured to compress between the outer shell and the speaker to prevent water from entering the inner protective cover enclosure. The inner protective cover may be formed from a single component body. The inner protective cover may include an elastomer. The inner protective cover may include silicone. The internal electronic components may also include a communication module and a battery in electrical communication with the communication module. The communication module may include: a transmitter configured to wirelessly transmit communication signals to a second device; and a receiver configured to receive communication signals from the second device. The transmitter may be configured to transmit radio frequency signals, and the receiver may be configured to receive radio frequency signals.

[0075] Although this disclosure has been described in detail and with reference to specific embodiments thereof, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the embodiments. Therefore, this disclosure is intended to cover modifications and variations thereof, provided that they fall within the scope of the appended claims and their equivalents.

Claims

1. A portable electronic device comprising: an internal electronic assembly; an internal protective cover at least partially enclosing the internal electronic assembly; and a housing at least partially enclosing the internal protective cover, the housing having at least two apertures, wherein the internal protective cover is configured to compress to prevent at least one of water or another contaminant from passing through the at least two apertures and into the internal protective cover enclosure.

2. The electronic device of claim 1, wherein the internal protective cover at least partially surrounds each geometric side of the internal electronic assembly.

3. The electronic device of claim 1, wherein the internal protective cover includes at least two apertures, the two apertures of the internal protective cover at least partially overlapping the two apertures of the housing.

4. The electronic device of claim 1, wherein the internal protective cover is configured to compress between the housing and the internal electronic assembly.

5. The electronic device of claim 1, wherein the internal protective cover includes no more than six apertures.

6. The electronic device of claim 1, wherein the internal protective cover is formed from a single component body.

7. The electronic device of claim 1, wherein the internal protective cover includes an elastomer.

8. The electronic device of claim 1, wherein the internal protective cover includes silicone.

9. The electronic device of claim 1, wherein the at least two apertures in the housing include a speaker aperture configured to provide acoustic energy transfer to a speaker of the internal electronic assembly and a charging port aperture configured to provide access to a charging port of the internal electronic assembly.

10. The electronic device of claim 1, further comprising: a microphone as a component of the internal electronic assembly; a microphone aperture in the housing configured to provide acoustic energy transfer to the microphone; and a microphone recess within the internal protective cover at least partially positioned between the microphone and the microphone aperture.

11. The electronic device of claim 10, wherein the internal protective cover has a thickness of 0.5 millimeters or less at the microphone recess.

12. The electronic device of claim 1, further comprising: a light emitting component as a component of the internal electronic assembly; and a light aperture in the housing.

13. The electronic device of claim 12, further comprising: a light recess within the internal protective cover at least partially positioned between the light emitting component and the light aperture, wherein the light recess is configured to transmit a visible amount of light emitted from the light emitting component.

14. The electronic device of claim 13, wherein the light recess has at least one sidewall substantially orthogonal to a surface of the internal protective cover adjacent the light recess.

15. The electronic device of claim 1, wherein the internal electronic assembly comprises: a communication module; and a battery in electrical communication with the communication module. ​ ​ ​ ​ 16. The electronic device of claim 15, wherein the communication module comprises: a transmitter configured to wirelessly transmit a communication signal to a second device; and a receiver configured to receive a communication signal from the second device, wherein the transmitter is configured to transmit a radio frequency signal and the receiver is configured to receive a radio frequency signal.

17. A method of manufacturing a portable electronic device, the method comprising: assembling an internal electronic assembly; enclosing the internal electronic assembly within an internal protective cover by inserting the internal electronic assembly into an orifice of the internal protective cover; and enclosing the internal protective cover within a housing, wherein the internal protective cover is configured to compress to prevent at least one of water or another contaminant from entering the internal protective cover enclosure.

18. The method of claim 17, wherein the internal protective cover comprises a deformable material, and wherein inserting the internal electronic assembly comprises stretching a section of the internal protective cover over the internal electronic assembly.

19. The method of claim 17, wherein the housing comprises a top shell and a bottom shell, and enclosing the internal protective cover within the housing comprises connecting the top shell and the bottom shell.

20. The method of claim 17, wherein the internal electronic assembly comprises a switch configured to receive input from a user, and wherein the method further comprises: testing the switch to ensure it is operable prior to enclosing the internal electronic assembly within the internal protective cover.

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