Earcup

By employing a securing member that aligns electronic components orthogonally within earcup housings and using a cover with a gap portion for radio frequency antennas, the installation challenges and signal interference issues are resolved, enhancing the functionality and usability of headgear.

GB2643485APending Publication Date: 2026-02-25DYSON TECH LTD
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Patent Information

Application Number
GB2024002884
Authority / Receiving Office
GB · GB
Patent Type
Applications
Current Assignee / Owner
Filing Date
2024-02-29
Publication Date
2026-02-25

AI Technical Summary

Technical Problem

The challenge of installing electronic components, such as sensors, in the limited space within earcup housings of headgear is complicated by the need for precise alignment and access, which existing methods often fail to address effectively.

Method used

The use of a securing member that moves orthogonally relative to the housing to align sensors or other electronic components with the housing opening, allowing installation in otherwise inaccessible or hard-to-reach locations, and the provision of a cover with a gap portion to minimize interference with radio frequency signals.

Benefits of technology

This method enables efficient and secure alignment of electronic components within earcup housings and enhances signal reception by reducing interference, thereby improving the functionality and usability of headgear.

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Abstract

Headgear, preferably headphones, comprises at least one earcup. The earcup comprises a housing 600 comprising a non-metallic material e.g., plastic. The earcup housing comprises a radio frequency an
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Description

BACKGROUND A variety of headgears are available on the market, often with some form of housing attached, such as a housing of an earcup for housing a speaker in headphones. The housings are often required to house a number of different electronic components performing different functions. Space is often limited within the housings of the earcup, which can make assembly difficult, and the function of some electronic components may be dependent on the position of said electronic components in the housing. SUMMARY According to a first aspect, there is provided an earcup for headgear, the headgear for wearing on a wearer’s head, the earcup comprising: a housing having a housing wall with an opening; a sensor or sensors aligned with the opening on an alignment axis; a securing member secured between the housing and the sensor or sensors to hold the sensor or sensors in alignment with the opening; wherein, during assembly, the securing member and housing are arranged to force the sensor or sensors into alignment with the opening by movement of the securing member relative to the housing along or about an assembly axis, the assembly axis being substantially orthogonal to the alignment axis. In the first aspect, there is provided an earcup for headgear, the headgear for wearing on a wearer’s head, the earcup comprising: a housing having a housing wall (e.g., including an opening); an electronic component or components (e.g., a sensor or sensors) aligned with a portion of the housing wall (e.g., the opening) on an alignment axis; a securing member secured between the housing and the electronic component(s) (e.g., the sensor(s)) to hold the electronic component(s) (e.g., the sensor(s)) in alignment with the portion of the housing wall (e.g., the opening); wherein, during assembly, the securing member and housing are arranged to force the electronic component(s) (e.g., the sensor(s)) into alignment with the portion of the housing wall (e.g., the opening) by movement of the securing member relative to the housing along or about an assembly axis, the assembly axis being substantially orthogonal to the alignment axis. In an embodiment, the electronic component(s) (e.g., the sensor(s)) is aligned with an opening in the housing wall. In other words, the electronic component(s) (e.g., the sensor(s)) may be exposed to the external environment outside of the housing by way of the opening. The alignment axis may be aligned with a centre of the opening. In another embodiment, the electronic component(s) (e.g., the sensor(s)) is aligned with a portion of the housing wall, but which does not necessarily include an opening. In this case, the alignment axis may be aligned with the portion of the housing wall. In an embodiment, the electronic component is a sensor. In an alternative embodiment, the electronic component is an electronic component other than a sensor, such as an LED, a speaker and the like. For the purposes of illustration, the examples below are described with reference to an opening in the housing wall and a sensor. However, it will be understood that the below embodiments may apply equally to any portion of the housing wall without an opening and any electronic component other than a sensor. There is provided a means of installing an electronic component, such as a sensor, within a housing with limited access. In some housings, it may not be possible to install a component in a direction parallel to the direction in which the component needs to be secured. By providing a securing member and housing arranged to secure the sensor in a direction substantially orthogonal to the direction in which the sensor is installed, the sensor may be installed in difficult to reach locations without reducing the effectiveness of the securing. For example, by aligning the sensor with the alignment axis of the opening, the sensor may be brought near or adjacent to, and facing, the opening. The alignment axis may be defined as substantially orthogonal to a plane of the portion of the housing wall that includes the opening. By providing a securing member adapted to translate a movement along an assembly axis (for example, directed in an easily accessible direction) into a movement along an alignment axis, components may be installed in the housing at positions that would have been otherwise inaccessible or harder to access. Put another way, there is provided an improved apparatus for installation of a sensor into a restricted space where the direction of alignment with the portion of the housing wall is not the same as the direction in which the apparatus assembled. The housing may be supported over an ear of the wearer, for example, to cover an ear of the wearer when supported over the wearer’s ear. The housing may further comprise an ear cup adapted to contact the wearer’s head around the ear. The ear cup may be made from a flexible, or pliable, material. The sensor may be any suitable type of sensor. In some examples, the sensor may be a microphone sensor. Securing the securing member between the housing and the sensor may comprise inserting the securing member into the housing between the sensor and the housing so as to progressively force the sensor into alignment with the alignment axis. Securing the securing member between the housing and the sensor may comprise a translational and / or a rotational movement. The alignment axis may be aligned, for example, with a normal to a surface of the housing at the portion of the housing wall, the surface being the portion of the housing wall where the sensor is to be secured, which may include an opening. The surface of the housing may be an internal surface of the housing wall, which may be provided on a face of the housing wall opposite to an external surface The surface of the housing may be an internal surface of the housing wall that defines at least part of a perimeter of the housing and / or the earcup. The alignment axis is substantially orthogonal to the assembly axis. For example, an angle between the alignment axis and the assembly axis may be between 80 and 100 degrees, such as between 85 to 95 degrees, and for example 90 degrees (90°). The securing member may wedge the sensor against the housing. The securing member may be generally arcuate. The securing member and housing may comprise substantially similar structural properties, such as a similar or the same material composition. In other words, the securing member may be adapted to secure the sensor in a difficult to reach location, such as between two walls of the housing, by wedging the sensor in place. In this way, the sensor may be secured without having to locate the sensor itself in a difficult position, but by moving the sensor to the portion of the housing wall using the securing member. The securing member may abut a further housing wall such that the securing member is wedged between the further housing wall and the sensor, such that the sensor is forced against the opening. In this way, the sensor may be installed on the sidewall of a channel, the channel comprising a base connected to two opposing sidewalls. The further housing wall may comprise an angled face arranged to translate movement of the securing member along the assembly axis to movement of the sensor along the alignment axis. In this way, the further housing wall may be shaped to translate a force or movement along one axis, such as the assembly axis, to another axis, such as the alignment axis. The securing member may comprise an angled face arranged to translate movement of the securing member along the assembly axis to movement of the sensor along the alignment axis. In this way, the securing member may be shaped to translate a force or movement along one axis, such as the assembly axis, to another axis, such as the alignment axis. The angled face may be angled with respect to the assembly axis, for example, by an angle of less than or equal to 30 degrees (30°). In this way, the component of the movement of the securing member along the assembly axis that is translated into the force against the sensor along the alignment axis may be controlled. Further, any force or impact incident on the sensor in the direction of the alignment axis will result in only a small component force being generated against the securing member along the assembly axis. The angle between the angled face and the assembly axis may be less than or equal to 30°, such as less than or equal to 20°, for example less than or equal to 10°. The earcup may further comprise a sensor housing arranged to receive the sensor, and wherein the securing member abuts the sensor housing to force the sensor received by the sensor housing into alignment with the alignment axis. In this way, the sensor may be held within a sensor housing, thereby providing additional protection to the sensor. The sensor housing and the securing member may define contact surfaces arranged to contact each other when the securing member abuts the sensor housing, and wherein the contact surfaces are parallel. In this way, the transfer of force from the assembly axis to the alignment axis may be distributed more evenly from the securing member to the sensor housing. The contact surfaces may be angled such that, when the contact surfaces engage, the contact surfaces translate movement of the securing member along the assembly axis to movement of the sensor along the alignment axis. In this way, the contact surfaces may be shaped to translate a force or movement along one axis, such as the assembly axis, to another axis, such as the alignment axis. By controlling the size of the angle of the contact surfaces, the component of the movement of the securing member along the assembly axis that is translated into the force against the sensor along the alignment axis may be controlled. Further, any force or impact incident on the sensor in the direction of the alignment axis will result in only a small component force being generated against the securing member along the assembly axis. The angle between the contact surfaces and the assembly axis may be less than or equal to 30°, such as less than or equal to 20°, for example less than or equal to 10°. The contact surfaces may be aligned with a direction of the alignment axis. The contact surfaces may be aligned to be substantially orthogonal to the alignment axis. The sensor housing may comprise a compressible portion arranged between to abut the housing wall, wherein during assembly, the compressible portion is compressed against the housing wall as the sensor is forced into alignment with the opening. The earcup may further comprise a retention member arranged to inhibit movement of the securing member along, or about, the assembly axis. In this way, movement of the securing member along the assembly axis may be inhibited, or stopped, thereby holding the sensor in place. The retention member may be releasably secured to the housing. The earcup comprises a plurality of further electronic components, each aligned with a respective portion of the housing wall along a respective alignment axis, and wherein, during assembly, the securing member and housing are arranged to force each of the plurality of further electronic components into alignment with the respective portion of the housing wall by movement of the securing member relative to the housing along or about an assembly axis, the assembly axis being substantially orthogonal to one or more of the respective alignment axes. In this way, multiple electronic components may be installed in the housing and secured using a single securing member. The sensor may be a microphone sensor. The earcup may further comprise a sensor cover secured between the sensor and the housing, and wherein the sensor cover protrudes into the opening. In an embodiment, the sensor cover is provided between the sensor housing and the opening. The sensor cover may extend through the opening, for example fully through but not out of the opening, for example such that the sensor cover is flush with an external surface of the housing. The sensor cover may be perforated. In this way, the sensor may be protected by the sensor cover whilst still provided access to the environment external to the housing for the sensor. The earcup may further comprise a compressible seal provided between the sensor cover and the housing, wherein the compressible seal at least partially surrounds the opening. In this way, the ingress of debris into the housing through the opening may be prevented. The compressible seal may fully surround the opening. The compressible seal may be formed of or comprise foam, such as a closed cell foam, such as foam formed of or comprising Ethylene Propylene Diene Monomer (EPDM). When the sensor is a microphone sensor, the compressible seal may enable an air-tight seal to be provided when the securing member is secured. The earcup may further comprise an adhesive tape arranged between the sensor and the housing wall. The adhesive tape may be double-sided, such that each side of the tape comprises adhesive for adhering to another component or components. In some embodiments, the adhesive tape is arranged between the sensor housing and the housing wall. In some embodiments, the adhesive tape is arranged between the compressible seal and the housing wall. In some embodiments, the adhesive tape may be arranged between the compressible seal and the sensor housing. The housing wall may comprise a plurality of openings, and the earcup may further comprise: a plurality of sensors aligned with the opening each on an alignment axis aligned with the opening on an alignment axis; wherein the securing member secured between the housing and the sensor is to hold the plurality of sensors in alignment with the opening; and wherein, during assembly, the securing member and housing are arranged to concurrently force the plurality of sensors into alignment with each of the corresponding openings by movement of the securing member relative to the housing along or about an assembly axis, the assembly axis being substantially orthogonal to each respective alignment axis. In this way, multiple sensors may be secured within the housing, each sensor being secured at a respective position, such as a respective opening, using a single, common securing member. In alternative examples, multiple securing members may be used to secure the plurality of sensors. The plurality of sensors may be the same type of sensor, such as microphones, or may be different sensors, such as a microphone, an environmental sensor configured to measure a condition of the environment (such as at least one of: a particulate sensor, a humidity sensor, a temperature sensor, and a gas sensor (e.g. a carbon dioxide sensor)), and / or an accelerometer. According to a second aspect, there is provided a headgear comprising the earcup of the first aspect. The headgear may further comprise a headband adapted to contact a head of the wearer and to support the housing over the ear of the wearer. The headgear may further comprise a speaker housed by the housing. According to a third aspect, there is provided method of installing a sensor in a housing of an earcup for headgear, the headgear for wearing on a wearer’s head, the method comprising: inserting the sensor into the housing, the housing having a housing wall with an opening; and securing a securing member between the housing and the sensor, thereby forcing the sensor into alignment with the opening on an alignment axis by movement of the securing member relative to the housing along or about an assembly axis to hold the sensor in alignment with the opening, the assembly axis being substantially orthogonal to the alignment axis. According to a fourth aspect, there is provided an earcup for headgear, the headgear for wearing on a wearer’s head, the earcup comprising: a housing assembly to be supported over an ear of the wearer, the housing assembly comprising: a housing; a radio frequency antenna housed by the housing; and a cover coupled to the housing, the cover comprising a gap portion; wherein the cover is coupled to the housing to partially cover the housing such that the radio frequency antenna is uncovered by the cover due to the presence of the gap portion. There is provided a means of providing a radio frequency antenna in a housing having a cover provided on a housing such that interference of the cover on the radio frequency signals emitted from, and received at, the radio frequency antenna is minimised. Put another way, the radio frequency antenna may be provided in a portion of the housing that is not covered by the cover in order to prevent the radio frequency signals travelling to and from the antenna from being blocked by the cover. The cover is provided on the housing so as to change the appearance of a substantial part of the housing. By providing the radio frequency antenna within a portion of the housing that aligns with a gap portion of the cover, the field of view of radio frequency antenna that does not include the cover is widened, thereby improving the signal reception of the radio frequency antenna of the earcup. The cover may be referred to as a facade, for example a housing facade. The cover may be understood to be an element for covering an external surface of the housing. The cover may be any suitable face, facing, case for covering an external surface of the housing. The cover may contain no active elements, for example, no electronic components, related to the electronic function of the earcup and / or headgear. Put another way, the cover may be an unpowered feature of the earcup. The cover is attachable directly to the housing. Put another way, the cover is attachable to the housing without any intervening components that do not form part of the cover or the housing themselves being provided therebetween. The housing may be a chassis for housing a speaker driver for driving a speaker. The housing may cover an ear of the wearer when supported over the wearer’s ear. The housing may further comprise an ear cup adapted to contact the wearer’s head around the ear. The ear cup may be made from a flexible, or pliable, material. The housing may comprise one or more external surfaces of the earcup, and wherein the cover covers a majority of the one or more external surfaces of the housing. The external surface may include surfaces that are exposed to the environment surrounding the earcup and / or headgear during use. The external surface may exclude surface that are covered by the wearer in use. The external surfaces of the housing may be any surface of the housing arranged to contact the cover. The external surfaces of the housing may be any surface of the housing arranged to not contact the ear of the wearer. The housing may comprise one or more internal surface, facing a space at least partially enclosed by the housing, and the wall of the housing may comprise the one or more internal surfaces on one side and the one or more external surfaces on the other. The cover may cover a majority of the one or more external surfaces of the housing, for example more than 50% of the one or more external surfaces of the housing. A majority of the one or more external surfaces of the housing may be more than 50% of the one or more external surfaces of the housing, such as more than 60% of the one or more external surfaces of the housing, such as more than 70% of the one or more external surfaces of the housing, such as more than 80% of the one or more external surfaces of the housing, such as more than 90% of the one or more external surfaces of the housing. The gap portion may comprise a notch for exposing the housing through the gap portion of the cover. The notch may be any shaped indent, cut-away, aperture, window, opening, hole or the like in the cover through which at least a portion of the housing is exposed. The notch may be formed at an edge of the cover. The housing may comprise a projection portion projecting through the gap portion of the cover, and wherein the radio frequency antenna is housed within the projection portion. In this way, the interference of the cover on the signals travelling to and from the antenna may be further reduced. The projection portion may project away from a base of the hosing in a direction away from the ear of the wearer. Put another way, the protrusion portion may project along a longitudinal axis of the housing away from the base of the housing. The base of the housing may be a portion covered by a portion of the cover, for example an outer portion of the cover or a portion of the cover proximate to the ear of the wearer, when worn, compared to a remaining portion of the cover. In this way, the interference of the cover on the signals travelling to and from the antenna may be further reduced. The projection portion may be arcuate along a length of the projection portion. In this way, the uninterrupted field of view of the radio frequency antenna receiving the projection portion may be increased. The projection portion may define at least part of a perimeter of the housing. In this way, the interference of the cover, which may be a cover entirely or partially comprising a metal material, on the signals travelling to and from the antenna may be further reduced. The projection portion may define a channel having walls, and wherein the radio frequency antenna is provided on one of the walls of the channel. In this way, the interference of the cover on the signals travelling to and from the antenna may be further reduced. The wall of the channel may comprise two opposing sidewalls separated by, and extending from, a base. The radio frequency antenna may be provided on either of the two opposing side walls or on the base of the channel. The radio frequency antenna may be housed by a portion of the housing that is formed of or comprises a non-metal material. In this way, the interference of the housing on the signals travelling to and from the antenna may be further reduced. In some examples, the projection portion may be formed of or comprise a non-metal material (i.e. a non-metal projection portion). In some examples, the entire housing may be formed of or comprise a non-metal material (i.e. a non-metal housing). The projection portion may substantially fill the gap portion. In this way, vibrations caused by movement between the cover and the housing may be reduced. In use, the projection portion may sit towards a rear portion of the ear of the wearer. In some embodiments, the projection portion may sit towards a lower portion of the ear of the wearer. In some embodiments, the projection portion may sit behind and below the ear of the wearer. The radio frequency antenna may occupy over half of an interior length of the projection portion. By providing a projection portion that is the same, or a similar, length as the radio frequency antenna, the interference of the cover on the signals travelling to and from the antenna may be further reduced. For example, the length of the antenna may be commensurate with an interior length of the projection portion. The antenna may be coiled, or wound, such that the total length of the antenna is longer than the space within the projection portion that the antenna occupies. The cover may be removably coupled to the housing. In this way, the wearer may remove and replace the cover on the housing, for example to customise an appearance of the earcup. The cover may be formed of or comprise a metal material. In this way, the housing may be covered by a metal cover (i.e. a cover entirely or partially comprising a metal material) without interfering with the signals passing to and from the radio frequency antenna by virtue of the gap portion in the cover. The metal material may comprise aluminium. According to a fifth aspect, there is provided a housing of an earcup for a headgear, the headgear for wearing on a wearer’s head, the housing comprising a projection portion for housing a radio frequency antenna, wherein the housing is releasably couplable with a cover for covering the housing except at the projection portion. In an embodiment, the projection portion projects away from the ear of the wearer. In an embodiment, the projection portion is arcuate along a length of the projection portion. In an embodiment, the projection portion defines at least part of a perimeter of the housing. In an embodiment, the projection portion defines a channel having two opposing side walls extending from a base, and wherein the radio frequency antenna is provided on the base of the channel. In an embodiment, the projection portion is formed of a non-metal material. In an embodiment, in use, the projection portion sits behind and below the ear of the wearer. In an embodiment, wherein a length of the radio frequency antenna is commensurate with a length of the projection portion. In an embodiment, the housing is formed from a non-metal material. According to a sixth aspect, there is provided a cover releasably couplable to a housing of an earcup for headgear, the headgear for wearing on a wearer’s head, the cover for covering the housing, the cover comprising a gap portion for uncovering a portion of the housing for housing a radio frequency antenna. In an embodiment, the gap portion comprises a notch for exposing the housing through the cover. In an embodiment, the cover is formed from a metal material. Any feature of any of the aspects described above may be combinable with any feature of any other aspect described above. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 shows a schematic representation of an earcup; Figure 2 shows a perspective view of a headgear for wearing on a wearer’s head; Figures 3a and 3b show a sensor housing arranged to receive the sensor; Figure 4 shows a cross section of a housing with a microphone sensor received in a sensor seat of the sensor housing shown in Figure 3; Figure 5 shows an exterior elevation view of the housing shown in Figure 4; Figures 6a to 6f show schematic representations of different arrangements of the sensor housing, securing member and sensor cover; Figure 7 shows an elevation view of the headgear of Figure 2; Figure 8 shows a schematic representation of a housing that houses a radio frequency antenna; and Figure 9 shows a schematic cross-section of the housing of Figure 8. DETAILED DESCRIPTION Figure 1 shows an earcup 101 for headgear, the headgear for wearing on a wearer’s head. The earcup 101 comprises a housing 100 of a headgear, the headgear for wearing on a wearer’s head. The housing 100 includes a housing wall 110 with an opening 120. The earcup 101 includes a sensor 130 aligned with the opening 120 on an alignment axis 140. In the example shown in Figure 1, the alignment axis 140 is aligned with the centre of the opening 120. The earcup 101 further includes a securing member 150 secured between the housing 100 and the sensor 130 to hold the sensor in alignment with the opening 120, i.e., along the alignment axis 140. During assembly, the securing member 150 and housing 100 are arranged to force the sensor 130 into alignment with the opening 120 by movement of the securing member 150 relative to the housing 100 along or about an assembly axis 160, the assembly axis 160 being substantially orthogonal to the alignment axis 140. In the axis shown, the assembly axis 160 is a translation axis along which the securing member 150 moves. In other examples, the assembly axis 160 may be a rotational axis about which the securing member 150 rotates. Indeed, a method for installing the sensor 130 into the housing 100 may begin by inserting the sensor 130 into the housing 100 such that the sensor is aligned, or at least partially aligned or in place to be aligned, with the opening 120 in the housing wall 110. The securing member 150 is then secured between the housing 100 and the sensor 130, thereby forcing the sensor 130 into alignment with the opening 120 on the alignment axis 140 by movement of the securing member 150 relative to the housing 100 along or about the assembly axis 160 to hold the sensor 130 in alignment with the opening 120. Figure 2 shows a perspective view of a headgear 200 for wearing on a wearer’s head. In the example shown in Figure 2, the headgear 200 is a pair of headphones having a pair of earcups 101,105 supported over each ear of the wearer by a headband 210. Each earcup 101, 105 is covered by a respective cover 120, 125. Each earcup 101, 105 comprises a respective housing, each of which is covered by one of the respective covers 120, 125, such that the respective housings are not visible in Figure 2 apart from the projection portion 112 of one of the housings, which protrudes through the cover 120. The projection portion 112 is described in further detail below. Each earcup 101, 105 comprises a respective cushion, or earpad, 220, 225 provided between the earcups 101, 105 and the side of the wearer’s head. In the example shown in Figure 2, the headgear 200 includes a pair of speakers (one speaker 320 of the pair of speakers is shown in Figure 2), each directed towards a respective ear of the wearer. The speakers are each housed by one of the respective housings of the earcups 101, 105. The speakers are driven by speaker drivers housed by the earcups 101, 105. Each housing of the earcups 100, 105 includes a respective projection portion 112 that projects through a gap portion in the respective cover 120, 125. In use, the projection portion 112 sits towards a rear portion of the ear of the wearer. Figures 3a and 3b show a sensor housing 300 arranged to receive the sensor 130. In the examples shown in Figures 3a and 3b, the sensor housing 300 comprises a sensor seat 310 into which the sensor 130, which may be a microphone sensor, may be slotted. The sensor seat 310 is sized and shaped to receive the intended sensor. In addition, the sensor housing 300 shown in Figure 3a includes a sensor window 320, which uncovers the sensor seat 310, and the sensor 130 received in the sensor seat 310. The sensor window 320 may align with the opening 120 in the housing wall 110, for example, the centre of the sensor window 320 may align with the alignment axis 140. Accordingly, an uninterrupted path is provided between the sensor 130 received in the sensor seat 310 and the environment external to the housing 100, by way of the opening 120 in the housing wall 110 and the sensor window 320. The sensor housing 300 shown in Figure 3b comprises a contact surface 330 adapted to abut a securing member 150 as described in further detail below with reference to Figure 4. Figure 4 shows a cross section of a housing 400 with a microphone sensor 430 received in the sensor seat 310 of the sensor housing 300 shown in Figure 3. The sensor housing 300 is wedged against the housing wall 410 by the securing member 450, such that the sensor window 320 is aligned with the opening 420 in the housing wall 410 along the alignment axis 140. The alignment of the microphone sensor 430 with the sensor window 320 and the opening 420 in the housing wall 410 greatly improves the accuracy of the signals captured by the microphone sensor 430, as the alignment provides an unobscured path for the sound waves to reach the microphone sensor 430 from the environment outside the housing 400. As shown in Figure 4, the securing member 450 abuts the sensor housing 300 to force the sensor 430 received by the sensor housing 300 into alignment with the alignment axis 140 as the securing member 450 is moved along the assembly axis 160. The securing member 450 abuts a further housing wall 470 such that the securing member 450 is wedged between the further housing wall 470 and the sensor housing 300. The housing wall 410 and the further housing wall 470 define a channel, with the housing wall 410 and the further housing wall 470 defining two opposing sidewalls extending from a base 480 of the channel. A radio frequency antenna 500, which is described in further detail below with reference to Figures 7 and 8, is provided towards the base 480 of the channel. In example shown in Figure 4, the channel is formed in the projection portion 412 of the housing 400. The securing member 450 comprises an angled face 455 arranged to translate movement of the securing member 450 along the assembly axis 160 to movement of the sensor housing 300 along the alignment axis 140. In alternative examples, the further housing wall may comprise such an angled face. The angled face 455 of the securing member 450 is angled with respect to the assembly axis 160 by an angle of 5°. The angled face 455 of the securing member 450 defines one of two parallel contact surfaces, the other being the contact surface 330 of the housing member 300, which are arranged to contact each other when the securing member 450 abuts the sensor housing 300. The parallel contact surfaces 330, 455 provide a uniform distribution of the securing force applied by the securing member 450 to the sensor housing 300. In the example shown in Figure 4, a perforated sensor cover 490 is secured between the sensor housing 300 and the housing wall 410. The sensor cover 490 protrudes into the opening 420 in the housing wall 410 such that an outer surface of the sensor cover 490 sits flush with an outer surface of the housing wall 410. Figure 5 shows an exterior elevation view of the housing 400 described with respect to Figure 4. Figure 5 shows the sensor cover 490 held in place at the opening 420 in the housing wall 410 of the projection portion 412 of the housing 400. Figure 5 also shows a button 510 projecting through a further opening in the housing wall 410. The button is held in place using a component housing, similar to the sensor housing 300, and the securing member 450, which extends the length of the channel formed within the projection portion 412. The securing member secures a plurality of further electronic components, including the sensor 430, in place within the channel formed within the projection portion 412. Figures 6a to 6f show schematic representations of different arrangements of the sensor housing 300, securing member 450 and sensor cover 490. Figure 6a shows the sensor housing 300 secured against the housing wall 410 by the securing member 450. The sensor cover 490 is provided between the sensor housing 300 and the housing wall 410 and protrudes into the opening 420 in the housing wall 410. An air gap 491 is provided between the sensor housing 300 and the sensor cover 490 to provide an uninterrupted path from the sensor 430 to the external environment through the sensor housing 300, by way of the sensor window 320, and the sensor cover 490. A compressible seal 520 is provided between the sensor cover 490 and the housing wall 410. The compressible seal surrounds the opening 420 in the housing wall 410. When the securing member 450 is installed in the housing 400, the compressible seal 520 is compressed against the housing wall 410 as the sensor housing 300 moves along the alignment axis 140 towards the housing wall 410, thereby providing a tight seal about the opening 420. Figure 6b shows an example where the compressible seal 520 is provided between the sensor housing 300, and the sensor cover 490, and the housing wall 410. In the example shown in Figure 6b, an adhesive tape 530 is provided between the compressible seal 520 and the sensor housing 300 and the sensor cover 490. Figure 6c shows an example where the compressible seal 520 is provided between the sensor housing 300, and the sensor cover 490, and the housing wall 410. In the example shown in Figure 6c, adhesive tape 530 is provided between the compressible seal 520 and the housing wall 410 and between the compressible seal 520 and the sensor housing 300 and the sensor cover 490. Figure 6d shows an example where the compressible seal 520 is provided between the sensor housing 300 and the housing wall 410. In the example shown in Figure 6d, adhesive tape 530 is provided between the compressible seal 520 and the sensor cover 490 and between the sensor housing 300 and the housing wall 410. Figure 6e shows an example where the compressible seal 520 is provided between the sensor cover 490 and the housing wall 410. In the example shown in Figure 6e, adhesive tape 530 is provided between the compressible seal 520 and the sensor cover 490, between the sensor cover 490 and the sensor housing 300 and between the sensor housing 300 and the compressible seal 520 and the housing wall 410. Figure 6f shows an example where the sensor housing 300 includes a compressible portion 305 arranged receive the sensor cover 490 such that compressible portion 305 is arranged between the sensor cover 490 and the housing wall 410. During assembly, the compressible portion 305 is compressed against the housing wall 410 as the securing member 450 is moved along the assembly axis 160 and the sensor 430 is forced into alignment with the opening 420. In the examples shown in Figures 6a to 6f, the adhesive tape 530 may perform several functions. For example, adhesive tape 530 provided between the sensor housing 300 and / or the sensor cover 490 and the housing wall improves the lifespan of the sealing of the housing 400 by acting against degradation of the compressible seal 520 overtime. By way of a further example, adhesive tape 530 provided between the sensor cover 490 and the sensor housing 300 reduces, or eliminates, resonance between the sensor housing 300 and the sensor cover 490 by reducing the amount of force required from the securing member 450 to secure the sensor housing 400 in place. Figure 7 shows an elevation view of the headgear 200 of Figure 2, illustrating the relative positioning of the sensor covers 490, 495 protruding through the housing walls 410, 415 of the earcups 101, 105 of the headgear 200. The elevation view shown in Figure 7 shows the rear side of the headgear 200, which faces generally backwards (i.e., facing away from the wearer’s front) when worn. Figure 8 shows a schematic representation of a housing 600 comprising a non-metal material, which may be equivalent to housing 100 shown in Figure 2 or housing 400 shown in Figure 4, that houses a radio frequency antenna 500. The housing 600 may be formed entirely of a non-metal material, such as plastic. Alternatively, the housing 600 may be formed partially of a non-metal material and partially of a metal material. Tn the case where the housing 600 is formed partially of a non-metal material and partially of a metal material, the projection portion 612 in particular may be formed from the non-metal material in order to minimize interference with radio frequency signals 650 being sent to and from the radio frequency antenna 500 housed in the projection portion 612. The housing 600 is partially covered by a cover 620 comprising a metal material that is releasably attached to the housing, for example by way of a magnet coupling or a bayonet fitting. The cover 620 may be formed entirely of a metal material, such as stainless steel. Alternatively, the cover 620 may be formed partially of a non-metal material, such as plastic, and partially of a metal material. In the example shown in Figure 8, the cover if formed entirely of a metal material and so includes a gap portion 625 that uncovers the part of the housing, which in the example shown in Figure 8 is the projection portion 612, that houses the radio frequency antenna 500. The gap portion 625 shown in Figure 8 is a notch in the cover 620. As shown in Figure 8, the projection portion 612 is arcuate along its length and defines at least part of a perimeter of the circular housing 600. The projection portion 612 substantially fills the gap portion 625. For example, when the cover is attached to the housing, the protrusion portion may occupy at least 90% of an area or volume of the gap portion, the area or volume being the area or volume required to complete rotational symmetry of the cover. The radio frequency antenna 500 occupies more than half of the interior length of the projection portion 612. 5 Figure 9 shows a schematic cross-section of the housing 600 of Figure 8. The radio frequency antenna 500 being provided in the projection portion 612 of the housing 600, which protrudes through the gap portion 625 of the cover 620, prevents the cover from interfering with the radio frequency signals 650 being sent to and from the radio frequency antenna 500. 10 As shown in Figure 9, the projection portion 612 projects away from a base of the hosing 600 in a direction away from the ear of the wearer. The projection portion 612 defines a channel having walls, and the radio frequency antenna is provided on one of the walls of the channel, for example on the base 480 of the channel as shown in Figure 4.

Claims

1. An earcup for headgear, the headgear for wearing on a wearer’s head, the earcup comprising:a housing assembly to be supported over an ear of the wearer, the housing assembly comprising:a housing;a radio frequency antenna housed by the housing; anda cover coupled to the housing, the cover comprising a gap portion;wherein the cover is coupled to the housing to partially cover the housing such that the radio frequency antenna is uncovered by the cover due to the presence of the gap portion.

2. The earcup as claimed in claim 1, wherein the housing comprises one or more external surfaces of the headgear, and wherein the cover covers a majority of the one or more external surfaces of the housing.

3. The earcup as claimed in any preceding claim, wherein the gap portion comprises a notch for exposing the housing through the gap portion of the cover.

4. The earcup as claimed in any preceding claim, wherein the housing comprises a projection portion projecting through the gap portion of the cover, and wherein the radio frequency antenna is housed within the projection portion.

5. The earcup claimed in claim 4, wherein the projection portion projects away from a base of the hosing in a direction away from the ear of the wearer.

6. The earcup claimed in claim 4 or claim 5, wherein the projection portion is arcuate along a length of the projection portion.

7. The earcup claimed in any of claims 4 to 6, wherein the projection portion defines at least part of a perimeter of the housing.

8. The earcup as claimed in any of claims 4 to 7, wherein the projection portion defines a channel having walls, and wherein the radio frequency antenna is provided on one of the walls of the channel.

9. The earcup as claimed in any preceding claim, wherein the radio frequency antenna is housed by a portion of the housing that is formed of or comprises a non-metal material.

10. The earcup as claimed in any of claims 4 to 9, wherein the projection portion substantially fills the gap portion.

11. The earcup as claimed in any of claims 4 to 10, wherein, in use, the proj ection portion sits towards a rear portion of the ear of the wearer.

12. The earcup as claimed in any of claims 4 to 11, wherein the radio frequency antenna occupies over half of an interior length of the projection portion.

13. The earcup as claimed in any preceding claim, wherein the cover is removably coupled to the housing.

14. The earcup as claimed in any preceding claim, wherein the cover is formed of or comprises a metal material.

15. A housing of an earcup for a headgear, the headgear for wearing on a wearer’s head, the housing comprising a projection portion for housing a radio frequency antenna, wherein the housing is releasably couplable with a cover for covering the housing except at the projection portion.

16. A cover releasably couplable to a housing of an earcup for headgear, the headgear for wearing on a wearer’s head, the cover for covering the housing, the cover comprising a gap portion for uncovering a portion of the housing for housing a radio frequency antenna.21

Citation Information

Patent Citations

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    US11184696B1