`(12) Patent Application Publication (10) Pub. No.: US 2008/0166005 A1
`Terlizzi et al.
`(43) Pub. Date: Jul. 10, 2008
`
`
`US 20080166005A1
`
`(54) HEADSET ELECTRONICS
`
`(75)
`
`Inventors:
`
`Jeffrey J. Terlizzi, San Francisco,
`CA (US); Emery A. Sanford, San
`Francisco, CA (US); M. Evans
`Hankey, San Francisco, CA (US);
`Terry Tikalsky, Sunnyvale, CA
`(US); John Tang, San Carlos, CA
`(US); Daniele De Iuliis, San
`Francisco, CA (US); Peter
`Russell-Clark, San Francisco, CA
`(US)
`
`Correspondence Address:
`ROPES & GRAY LLP
`PATENT DOCKETING 39/361, 1211 AVENUE OF
`THE AMERICAS
`NEW YORK, NY 10036-8704
`
`(73) Assignee:
`
`Apple Inc, Cupertino, CA (US)
`
`(21) Appl. No.:
`
`11/824,443
`
`(22)
`
`Filed:
`
`Jun. 28, 2007
`
`Related US. Application Data
`
`(60) Provisional application No. 60/878,852, filed on Jan.
`5, 2007, provisional application No. 60/879,177, filed
`
`on Jan. 6, 2007, provisional application No. 60/879,
`193, filed on Jan. 6, 2007, provisional application No.
`60/879,195, filed on Jan. 6, 2007, provisional applica-
`tion No. 60/936,965, filed on Jun. 22, 2007.
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`H04R 25/00
`
`(2006.01)
`
`(52) U.S.Cl. ......................................... 381/375;381/380
`
`(57)
`
`ABSTRACT
`
`A wireless headset device that includes an earbud assembly
`and a primary housing assembly, fixed to the earbud assem-
`bly, is provided. The earbud assembly can include an earbud
`flexible circuit board having mounted thereon a receiver and
`processing circuitry. The primary housing assembly can
`include a microphone and a primary housing flexible circuit
`board electrically coupled to the earbud circuit board and the
`microphone. In some embodiments, the headset device can
`include at least one flexible circuit board and the primary
`housing can include a connector assembly. The at least one
`flexible circuit board can be electrically coupled to the con-
`nector assembly and can include Universal Serial Bus (USB)
`circuitry operative to process USB protocol communications
`and serial circuitry operative to process serial protocol com-
`munications.
`
`1021
`
`
`
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 1 0f 60
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`US 2008/0166005 A1
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`Patent Application Publication
`
`Jul. 10, 2008 Sheet 2 0f 60
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`US 2008/0166005 A1
`
`CIRCUITRY
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`SWITCHING
`
`3
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 3 0f 60
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`Jul. 10, 2008 Sheet 4 0f 60
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`Patent Application Publication
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 6 0f 60
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`US 2008/0166005 A1
`
`CIRCUITRY
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 7 0f 60
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`Jul. 10, 2008 Sheet 18 0f 60
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`US 2008/0166005 A1
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 19 0f 60
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`US 2008/0166005 A1
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 20 0f 60
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`US 2008/0166005 A1
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`Patent Application Publication
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`Jul. 10, 2008 Sheet 21 0f 60
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`US 2008/0166005 A1
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`US 2008/0166005 A1
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`Jul. 10, 2008 Sheet 23 0f 60
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`Jul. 10, 2008 Sheet 25 0f 60
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`US 2008/0166005 A1
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`US 2008/0166005 A1
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`Jul. 10, 2008
`
`HEADSET ELECTRONICS
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] This application claims the benefit of certain
`copending, commonly assigned US. Provisional Patent
`Applications, namely, Ser. No. 60/878,852 filed on Jan. 5,
`2007; Ser. No. 60/879,177 filed on Jan. 6, 2007; Ser. No.
`60/879,193 filed on Jan. 6, 2007; Ser. No. 60/879,195 filed on
`Jan. 6, 2007; and Ser. No.
`filed on Jun. 22, 2007
`(Attorney Docket No. 104677-0102-001 (P5389USP1)),
`entitled “Single User Input Mechanism for Controlling Elec-
`tronic Device Operations”; all of which are incorporated
`herein by reference.
`[0002] Commonly assigned DiFonzo et al. US. patent
`application Ser. No. 11/235,873, filed Sep. 26, 2005 (Attor-
`ney Docket No. P3794USl/119-0060US.1), entitled “Elec-
`tromagnetic Connector for Electronic Device” is hereby
`incorporated by reference in its entirety.
`[0003] Commonly assigned Rohrbach et al. US. patent
`application Ser. No. 11/235,875, filed Sep. 26, 2005 (Attor-
`ney Docket No. P3593USl/119-0060US), entitled “Mag-
`netic Connector for Electronic Device” is hereby incorpo-
`rated by reference in its entirety.
`[0004] Commonly assigned Andre et al. US. patent appli-
`cation Ser. No. 11/456,833, filed Jul. 11, 2006 (Attorney
`Docket No. P3981USl), entitled “Invisible, Light-Transmis-
`sive Display System” is hereby incorporated by reference in
`its entirety.
`[0005] Commonly assigned Andre et al. US. patent appli-
`cation Ser. No. 11/551,988, filed Oct. 23, 2006 (Attorney
`Docket No. P4246USX1), entitled “Invisible, Light-Trans-
`missive Display System” is hereby incorporated by reference
`in its entirety.
`[0006] Commonly assigned Sanford et al. US. patent
`application Ser. No. 11/651,094, filed Jan. 6, 2007 (Attorney
`Docket No. P4983US2), entitled “Antenna and Button
`Assembly for Wireless Devices” is hereby incorporated by
`reference in its entirety.
`[0007] Commonly assigned Terlizzi et al. US. patent appli-
`cation Ser. No. 11/650,130, filed Jan. 5, 2007 (Attorney
`Docket No. 104677-0015-101 (P4630USl)), entitled “Sys-
`tems and Methods for Determining the Configuration ofElec-
`tronic Connections” is hereby incorporated by reference in its
`entirety.
`[0008] Commonly assigned Rabu et al. US. patent appli-
`cation Ser. No. 11/620,669, filed Jan. 6, 2007 (Attorney
`Docket No. 104677-0011-102 (P4628US2)), entitled “Appa-
`ratuses and Methods that Facilitate the Transfer of Power and
`
`Information Among Electrical Devices” is hereby incorpo-
`rated by reference in its entirety.
`
`FIELD OF INVENTION
`
`[0009] The present invention can relate to headsets. More
`particularly, the present invention can relate to headsets for
`communicating with an electronic device.
`
`BACKGROUND OF THE INVENTION
`
`[0010] Headsets for providing hands-free communications
`are known in the art. Such headsets typically can be used in
`conjunction with a cellular telephone or a computer (e.g.,
`Voice over IP). Some existing headsets include a microphone,
`a speaker (also referred to as a receiver), electronics for con-
`
`trolling the headset and communicating with another device
`(e.g., a cellular telephone), a battery and a connector for
`re-charging the battery.
`[0011] There are many aspects involved in the design of
`headsets. For example, the size and weight ofheadsets can be
`key issues because ofhow they typically mount to a user’s ear.
`A heavy or large headset can pull on a user’s ear, creating an
`uncomfortable fit. The shape of headset earpieces (e.g., ear-
`buds) may also be an important design consideration to take
`into account as it is desirable for earpieces to fit comfortably
`in, on, or over a wide range of different sizes and shapes of
`ears.
`
`[0012] Additionally, the acoustic performance of headsets,
`such as receiver sound generation quality and microphone
`sound reception quality (e. g., ability to pick up a user’s voice
`without undue background noise), can be important design
`considerations. Achieving desired receiver and microphone
`acoustic performance can become increasingly difficult as the
`size of a headset decreases.
`
`[0013] Another example of an important design consider-
`ation can be the user interface ofa headset. It may be desirable
`for a user interface to be intuitive for a first-time user, yet
`convenient for an experienced user.
`[0014] Aesthetics may be yet another important design
`consideration for headsets.
`
`Further still, ease of manufacturing headsets can be
`[0015]
`another design consideration. For example, it can be desirable
`to design a headset that can be mass produced in an affordable
`fashion.
`
`In view of the foregoing, there is a need for an
`[0016]
`improved headset that addresses one or more of the above-
`identified considerations.
`
`SUMMARY OF THE INVENTION
`
`In accordance with one embodiment of the present
`[0017]
`invention, a wireless headset device that includes an earbud
`assembly and a primary housing assembly, fixed to the earbud
`assembly, is provided. The earbud assembly can include an
`earbud flexible circuit board having mounted thereon a
`receiver and processing circuitry. The primary housing
`assembly can include a microphone and a primary housing
`flexible circuit board electrically coupled to the earbud circuit
`board and the microphone.
`[0018]
`In accordance with another embodiment of the
`present invention, a wireless headset device that includes an
`earbud assembly and a primary housing assembly, fixed to the
`earbud assembly,
`is provided. The earbud assembly can
`include an earbud flexible circuit board. The primary housing
`assembly can include a battery retaining region and a primary
`housing flexible circuit board. The circuit board components
`and circuitry can be selectively mounted on the earbud flex-
`ible circuit board and the primary housing flexible circuit
`board to maximize a size of the battery retaining region.
`[0019]
`In accordance with yet another embodiment of the
`present invention, a wireless device that includes an earbud
`assembly and a primary housing assembly, fixed to the earbud
`assembly, is provided. The primary housing assembly can
`have predetermined dimensions. The earbud assembly and
`the primary housing assembly can each have mounted therein
`a flexible circuit board comprising circuitry.
`[0020]
`In accordance with yet another embodiment of the
`present invention, a headset device that includes an earbud
`assembly, a primary housing assembly, and at least one flex-
`ible circuit board is provided. The primary housing assembly
`
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`can be fixed to the earbud assembly and can include a con-
`nector assembly. The at least one flexible circuit board can be
`electrically coupled to the connector assembly and can
`include Universal Serial Bus (USB) circuitry operative to
`process USB protocol communications and serial circuitry
`operative to process serial protocol communications.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0021] The present invention will be apparent upon consid-
`eration of the following detailed description, taken in con-
`junction with accompanying drawings, in which:
`[0022]
`FIG. 1 is a simplified block diagram ofa headset in
`accordance with an embodiment of the present invention;
`[0023]
`FIG. 2 is a simplified block diagram of a headset
`connector system in accordance with an embodiment of the
`present invention;
`[0024]
`FIG. 3 is a simplified cross-sectional illustration of a
`connector assembly in accordance with an embodiment ofthe
`present invention;
`[0025]
`FIG. 4 is a simplified cross-sectional illustration of
`another connector assembly in accordance with an embodi-
`ment of the present invention;
`[0026]
`FIG. 5 is a simplified block diagram ofa headset in
`accordance with an embodiment of the present invention;
`[0027]
`FIG. 6A is a simplified cross-sectional illustration
`ofa portion of a headset in accordance with an embodiment of
`the present invention;
`[0028]
`FIG. 6B is a simplified cross-sectional illustration of
`a screw in accordance with an embodiment of the present
`invention;
`[0029]
`FIG. 7 is a simplified block diagram of a display
`system in accordance with an embodiment of the present
`invention;
`[0030]
`FIG. 8 is a simplified block diagram of a power
`distribution system in accordance with an embodiment of the
`present invention;
`[0031]
`FIG. 9 is a simplified block diagram of another
`power distribution system in accordance with an embodiment
`of the present invention;
`[0032]
`FIGS. 10A and 10B are illustrations of a headset in
`accordance with an embodiment of the present invention;
`[0033]
`FIG. 11 is an exploded view of a headset in accor-
`dance with an embodiment of the present invention;
`[0034]
`FIG. 12 is an exploded view of a headset in accor-
`dance with another embodiment of the present invention;
`[0035]
`FIG. 13 is a simplified diagram showing how soft-
`ware in a Bluetooth device is organized in accordance with an
`embodiment of the present invention;
`[0036]
`FIG. 14 is a simplified block diagram of the electri-
`cal system of a headset in accordance with an embodiment of
`the present invention;
`[0037]
`FIG. 15 is a simplified block diagram of the core
`processor of a headset in accordance with an embodiment of
`the present invention;
`[0038]
`FIG. 16 is a simplified schematic diagram of a
`power distribution system in accordance with an embodiment
`of the present invention;
`[0039]
`FIGS. 17A-17C are illustrations of a traditional cir-
`cuit board and distribution ofelectrical components in a head-
`set;
`FIG. 18 is a simplified block diagram of a circuit
`[0040]
`board with an improved distribution of electrical components
`in a headset in accordance with an embodiment of the present
`invention;
`
`FIGS. 19A and 19B are illustrations comparing the
`[0041]
`traditional circuit board of FIGS. 7A-7C to a circuit board
`
`with an improved distribution of electrical components in a
`headset in accordance with an embodiment of the present
`invention;
`[0042]
`FIG. 20A-20C are illustrations of an improved dis-
`tribution of electrical components in a headset in accordance
`with an embodiment of the present invention;
`[0043]
`FIG. 21A is an illustration of a headset earbud in
`accordance with an embodiment of the present invention;
`[0044]
`FIG. 21B is a simplified exploded view of a headset
`earbud in accordance with an embodiment of the present
`invention;
`[0045]
`FIGS. 22-25 and FIG. 26A are simplified illustra-
`tions of a headset earbud in various states of assembly in
`accordance with some embodiments ofthe present invention;
`[0046]
`FIG. 26B is a simplified cross-sectional view ofan
`audio receiver in accordance with an embodiment of the
`
`present invention;
`[0047]
`FIG. 27A is a simplified cross-sectional view of a
`partially assembled headset earbud in accordance with an
`embodiment of the present invention;
`[0048]
`FIG. 27B is a simplified cross-sectional view of a
`fully assembled headset earbud in accordance with an
`embodiment of the present invention;
`[0049]
`FIG. 28 is an exploded view ofan attachment system
`in accordance with an embodiment of the present invention;
`[0050]
`FIG. 29 is a flowchart of an illustrative process for
`assembling a portion of a headset in accordance with an
`embodiment of the present invention.
`[0051]
`FIGS. 30A and 30B are illustrations of a tool that
`can be used to assist in assembly of a portion of a headset in
`accordance with an embodiment of the present invention;
`[0052]
`FIG. 30C is an illustration ofthe tool of FIGS. 30A
`and 30B being used in accordance with an embodiment ofthe
`present invention;
`[0053]
`FIG. 31 is a cross-sectional view ofa “finished” tube
`in accordance with an embodiment of the present invention;
`[0054]
`FIG. 32 is a cross-sectional view of an initially
`manufactured tube in accordance with an embodiment of the
`
`present invention;
`[0055]
`FIG. 33 is a perspective view ofa cross section ofthe
`tube of FIG. 31 in accordance with an embodiment of the
`
`present invention;
`[0056]
`FIG. 34 is an illustrative die and stamper for modi-
`fying the initially manufactured tube ofFIG. 32 in accordance
`with an embodiment of the present invention;
`[0057]
`FIG. 35 is a cross-sectional view ofthe tube ofFIG.
`34 once the stamper and die are removed from the tube in
`accordance with an embodiment of the present invention;
`[0058]
`FIG. 36 is a perspective view ofthe tube of FIG. 35
`once the tube is machined to create an internal wall in accor-
`
`dance with an embodiment of the present invention;
`[0059]
`FIG. 37 is a cross-sectional view of an illustrative
`tube formed using a single impact extrusion in accordance
`with an embodiment of the present invention;
`[0060]
`FIG. 38 is a perspective view ofthe tube of FIG. 37
`once the tube is machined to create an internal wall in accor-
`
`dance with an embodiment of the present invention;
`[0061]
`FIG. 39 is a cross-sectional view of an illustrative
`tube formed using a double impact extrusion in accordance
`with an embodiment of the present invention;
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`FIG. 40 is a perspective view ofthe tube of FIG. 39
`[0062]
`once the tube is machined to create an internal wall in accor-
`
`dance with an embodiment of the present invention;
`[0063]
`FIG. 41 is a cross-sectional view of an illustrative
`tube formed using a progressive deep draw process in accor-
`dance with an embodiment of the present invention;
`[0064]
`FIG. 42 is a perspective view of a cross section ofthe
`tube of FIG. 41 in accordance with an embodiment of the
`
`present invention;
`[0065]
`FIG. 43 is a perspective view ofthe tube ofFIGS. 41
`and 42 once the tube is machined to create an internal wall in
`
`accordance with an embodiment of the present invention;
`[0066]
`FIG. 44 is a flow chart of an illustrative process for
`forming an extruded tube with a feature on the internal sur-
`face of the tube with using a die and stamper in accordance
`with an embodiment of the present invention;
`[0067]
`FIG. 45 is a flow chart of an illustrative process for
`forming a tube with a feature on the internal surface of the
`tube using a single impact extrusion in accordance with an
`embodiment of the present invention;
`[0068]
`FIG. 46 is a flow chart of an illustrative process for
`forming a tube with a feature on the internal surface of the
`tube using a impact extrusion on both ends of the tube in
`accordance with an embodiment of the present invention;
`[0069]
`FIG. 47 is a flow chart of an illustrative process for
`forming a tube with a feature on the internal surface of the
`tube using a progressive deep draw process in accordance
`with an embodiment of the present invention;
`[0070]
`FIG. 48 is a cross-sectional view of a visual indica-
`tor system in accordance with an embodiment of the present
`invention;
`[0071]
`FIG. 49 is an illustration of a visual indicator system
`of a headset in accordance with an embodiment ofthe present
`invention;
`[0072]
`FIGS. 50A and 50B are illustrations of a headset in
`accordance with an embodiment of the present invention;
`[0073]
`FIG. 51 is an illustration of a connector in accor-
`dance with an embodiment of the present invention;
`[0074]
`FIG. 52 is an exploded view of a connector in accor-
`dance with an embodiment of the present invention;
`[0075]
`FIG. 53 is an illustration of a microphone boot in
`accordance with an embodiment of the present invention;
`[0076]
`FIG. 54 is a cross-sectional view of a connector in
`accordance with an embodiment of the present invention;
`[0077]
`FIGS. 55A-55D are illustrations of a headset in
`accordance with an embodiment of the present invention;
`[0078]
`FIG. 56 is a cross-sectional view of an electrical
`contact assembly coupled to a circuit board in accordance
`with an embodiment of the present invention;
`[0079]
`FIGS. 57A and 57B are illustrations of an electrical
`contact assembly in accordance with an embodiment of the
`present invention;
`[0080]
`FIGS. 58A-58C are illustrations of an electrical
`contact assembly in accordance with an embodiment of the
`present invention;
`[0081]
`FIGS. 59A and 59B are illustrations of electrical
`contacts in accordance with an embodiment of the present
`invention;
`[0082]
`FIGS. 60A and 60B are illustrations of a connector
`plate in accordance with an embodiment of the present inven-
`tion;
`FIGS. 61A and 61B are illustrations of magnetic
`[0083]
`components of a connector in accordance with an embodi-
`ment of the present invention;
`
`FIGS. 62A and 62B are illustrations of a connector
`[0084]
`in accordance with an embodiment of the present invention;
`[0085]
`FIGS. 63A and 63B are illustrations of a connector
`in accordance with an embodiment of the present invention;
`[0086]
`FIG. 64 is an illustration of a headset coupling with
`a complementary connector in accordance with an embodi-
`ment of the present invention;
`[0087]
`FIG. 65 is a simplified graph of magnetic and spring
`forces involved in the coupling of a headset with a comple-
`mentary connector in accordance with an embodiment of the
`present invention;
`[0088]
`FIG. 66 is an illustration of a docking device that can
`receive a headset in accordance with an embodiment of the
`
`present invention;
`[0089]
`FIG. 67A is an illustration of a connector in accor-
`dance with an embodiment of the present invention;
`[0090]
`FIG. 67B is an illustration of a headset coupling
`with a complementary connector in accordance with an
`embodiment of the present invention; and
`[0091]
`FIG. 68 is a chart listing exemplary modes and func-
`tions of a communications system in accordance with an
`embodiment of the present invention.
`
`DETAILED DESCRIPTION OF THE INVENTION
`
`[0092] The present invention relates to headsets and meth-
`ods for manufacturing the same. Headsets are communication
`devices that are worn on a user’s head in order to allow hands
`free data and/or voice communication with a ho st device such
`
`as a computer, phone handset, cellular phone, an automobile
`and/or the like. Headsets can include one or more speakers (in
`proximity to one or both ears) for audio output and/or one or
`more microphones for audio input.
`[0093] Headsets can come in a variety of form factors or
`shapes. In some cases, headsets can be embodied as an ear-
`piece that serves as the primary support mechanism for wear-
`ing the headset. For example the headset may be supported on
`the head by an earpiece worn over or in the ear. Alternatively,
`the headset may be supported by a frame or band that fits on
`or over the user’s head. The headset may include a fixed or
`movable boom that places the microphone closer to the user’s
`mouth (wraps around the face). Alternatively, the headset
`may be boomless such that the microphone is integrated with
`the earpiece thereby forming a more compact device (e.g.,
`smaller, lighter, more aesthetically pleasing, etc.).
`[0094] According to one aspect of the invention, the head-
`set can be embodied as a small compact unit including a
`primary housing and an earbud member extending therefrom.
`The earbud member may be attached to or integrally formed
`with the primary housing. Various components can be placed
`at the surface of or within the confines of the earbud member
`
`and the primary housing. In fact, both ofthem can include one
`or more components depending on the needs of the device.
`The components contained within each ofthese can be widely
`varied. Examples of operational components can include
`speakers, microphones, antennas, connectors, buttons, dis-
`plays, indicators, battery, and associated processors, control-
`lers and circuitry. Generally, the earbud member includes at
`least a speaker while the primary housing includes at least a
`microphone (although this is not a requirement). Depending
`on their size, each of these members can include additional
`components of the headset. In one embodiment, the primary
`housing includes an antenna, user interface button, indicator
`or display (e.g., LEDs), battery, microphone, and/or a con-
`nector along with any accompanying circuitry while a
`
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`speaker, a processor, and its accompanying circuitry can be
`located in the earbud. The button can be located on one end of
`
`the main housing. A user can interface with this button to
`perform various functions (e.g., terminating calls).
`[0095] The shape and size and orientation of the earbud
`member and primary housing can be widely varied. In one
`embodiment, the earbud member is configured for insertion
`into the ear such that it supports the remaining portions of the
`headset (e. g., primary housing) proximate the user’s head. In
`one embodiment, the primary housing can be configured as a
`longitudinal member (e.g., a tube). In one example, an earbud
`member, which contains a speaker, perpendicularly protrudes
`away from one end of a longitudinally extending primary
`housing, which includes a microphone at an opposite end of
`the longitudinally extending primary housing. Furthermore,
`the earbud member can expand outwardly and then inwardly
`from a neck portion that couples to the primary housing in
`order to form a bud that fits into an ear.
`
`[0096] The primary hou