Abstract: Molded splitter structures and systems and methods for manufacturing molded splitter structures are disclosed.

Abstract: An accessory may be provided with a button controller having a microphone and switches. The switches may include dome switch members and metal switch terminals mounted in a switch module housing structure. The switch module housing structure may include one or more recesses in which electrical components are mounted. A conductive backplate may cover the recesses and may be coupled to the switch module housing structure. A conductive film may be attached to the switch module housing structure over the dome switch members. The conductive film and the conductive backplate may form an electromagnetic interference shield around the electrical components in the recesses. The switch module housing structure may include a non-conductive plastic overmolded onto a metal frame or may be formed from a first shot of non-conductive plastic and a second shot of conductive plastic to form an electromagnetic interference shield for the electrical components.

Abstract: A removable component for use with an earphone is disclosed. As an example, the removable component can be an ear tip. According to one aspect, an improved ear tip can be provided for use with a headphone. The ear tip is suitable for in-ear operation and can have a cosmetic deformable outer member. The deformable outer member can enable the ear tip to readily conform to a user's ear. The ear tip can also include an inner member to structurally support the outer member and to facilitate attachment to a headphone. Methods for forming such ear tips are also disclosed.

Abstract: A portable electronic device including an outer case having a wall in which a transducer-associated acoustic hole is formed. An inner case may be positioned inside the outer case. The inner case can include an acoustic port that opens to the transducer-associated acoustic hole and a relief port that opens to the outer case. A transducer having a diaphragm facing the acoustic port of the inner case is mounted within the inner case. A valve is further positioned over the relief port. The valve is configured to reduce an impact of an incoming air burst on the diaphragm.

Abstract: An ear piece for providing audio (e.g., from an electronic device) to the user is provided. The ear piece may include a compliant element operative to be inserted in the user's ear such that the compliant element deforms to retain the ear piece in the user's ear. The compliant element may include a connector portion coupling the compliant element to the ear piece housing, and an outer portion folded over the ear piece housing. To improve the user's comfort, the parting lines and other manufacturing defects may be hidden from view and from touch (e.g., the parting lines are then on the inner surface of the outer portion).

Abstract: Molded splitter structures and systems and methods for manufacturing molded splitter structures are disclosed.

Abstract: Embodiments of a method of injection molding with two molding steps and tools for this method are described. The transfer tool for high-volume manufacturing allows transfer of molded parts from one injection molding tool to another injection molding tool without separating the molded part from runners and without degating. The single step transfer, which can be performed without degating and without separating the molded parts from one another, can reduce cycle time as well as complexity.

Abstract: An accessory may be provided with a button controller having a microphone and switches. The switches may include dome switch members and metal switch terminals mounted in a switch module housing structure. The switch module housing structure may include one or more recesses in which electrical components are mounted. A conductive backplate may cover the recesses and may be coupled to the switch module housing structure. A conductive film may be attached to the switch module housing structure over the dome switch members. The conductive film and the conductive backplate may form an electromagnetic interference shield around the electrical components in the recesses. The switch module housing structure may include a non-conductive plastic overmolded onto a metal frame or may be formed from a first shot of non-conductive plastic and a second shot of conductive plastic to form an electromagnetic interference shield for the electrical components.

Abstract: A vented tip for in-the-ear headphones has a core portion to be mounted to a sound output tube of an in-the-ear earphone and a flange portion extending outward from and surrounding the core portion. The vented tip has a) an outer portion formed in the flange portion that is to be in contact with, and thereby form a seal with, a user's ear canal, and b) an inner portion spaced inwards from the outer portion to thereby not form the seal with the user's ear canal. The inner portion has a calibrated perforation or hole formed therein. Other embodiments that may help reduce bone conduction effects are also described and claimed.

Abstract: A portable electronic device including an outer case having a wall in which a transducer-associated acoustic hole is formed. An inner case may be positioned inside the outer case. The inner case can include an acoustic port that opens to the transducer-associated acoustic hole and a relief port that opens to the outer case. A transducer having a diaphragm facing the acoustic port of the inner case is mounted within the inner case. A valve is further positioned over the relief port. The valve is configured to reduce an impact of an incoming air burst on the diaphragm.

Abstract: A suction wand for use during a surgical operation involving cutting of bone which yields bone debris, the wand comprising a suction conduit, a suction tip, and a positive pressure conduit for directing gas toward the suction tip to expel debris.

Abstract: An outer cover for an electronic device, such as a portable electronic device, is disclosed. Since portable electronic devices are often portable, they can be damaged, such as scratched, dented, broken, and the like, when transported or used. The outer cover can serve to provide a protective member over part of the housing for the electronic device. The protective member, when placed on the portable electronic device can serve to reduce damage to sides of the portable electronic device. While the outer cover can provide side and/or edge protection, the outer cover need not also provide front or rear protection.

Abstract: An ear piece for providing audio (e.g., from an electronic device) to the user is provided. The ear piece may include a compliant element operative to be inserted in the user's ear such that the compliant element deforms to retain the ear piece in the user's ear. The compliant element may include a connector portion coupling the compliant element to the ear piece housing, and an outer portion folded over the ear piece housing. To improve the user's comfort, the parting lines and other manufacturing defects may be hidden from view and from touch (e.g., the parting lines are then on the inner surface of the outer portion).

Abstract: A system for reel-to-reel deposition of material onto flexible materials includes a reaction chamber, a feed reel arranged in the reaction chamber, the feed reel configured to support at least one continuous length of flexible material, a receiving reel arranged in the reaction chamber separate from the feed reel, the receiving reel configured to receive the flexible material, and at least one deposition target arranged in the reaction chamber, the deposition target configured to release vaporized target material for deposition onto surfaces of the flexible material.

Abstract: An accessory may be provided with a button controller having a microphone and switches. Plastic structures for the accessory may be formed by injection molding. Plastic structures may be molded around switch terminals. Switches may be formed using dome switch members and the switch terminals. A printed circuit with components may be mounted in the plastic structures. Recesses in the structures may be configured to receive the dome switch members, components on the printed circuit board, and wires in a cable. A backplate may be used to cover the printed circuit. A layer of plastic may be molded over the backplate to seal an interface created by the backplate. Cable strain relief structures may be molded into the layer of plastic. A lip on the strain relief structures may prevent particles from entering the controller.

Abstract: An accessory may be provided with a button controller having a microphone and switches. Plastic structures for the accessory may be formed by injection molding. Plastic structures may be molded around a printed circuit and wiring. The wiring may have a plastic jacket. The molded plastic structures may bond with the plastic jacket to retain the wiring. The molded plastic structures may be molded directly to the printed circuit board. Protrusions on the molded plastic structures may mate with openings in a metal clip. Housing structures may be mounted to the metal clip. The metal clip may be provided with a spring to short the metal clip to a trace on the printed circuit. The metal clip may also have a portion that receives electrostatic charge during electrostatic discharge events and that discharges the charge through the spring to the trace on the printed circuit.

Abstract: A suction wand for use during a surgical operation involving cutting of bone which yields bone debris, the wand comprising a suction conduit, a suction tip, and a positive pressure conduit for directing gas toward the suction tip to expel debris.

Abstract: A case can simultaneously enclose an object and restrain an associated cable, which can be attached to the object. The case has a base having an interior recess for storing the object and one or more peripheral recesses along the perimeter of the case that form winding areas for wrapping the associated cable. One or more doors are pivotably attached to the base so as to removably cover at least a portion of the winding areas to restrain the cable therein. One or more doors can be hinged on either side, bottom, or in the middle of the base. The one or more doors can also cover at least a portion of the interior recess to secure the object in the interior recess.

Abstract: A suction wand for use during a surgical operation involving cutting of bone which yields bone debris, the wand comprising a suction conduit, a suction tip, and a positive pressure conduit for directing gas toward the suction tip to expel debris.

Abstract: Embodiments of a method of injection molding with two molding steps and tools for this method are described. The transfer tool for high-volume manufacturing allows transfer of molded parts from one injection molding tool to another injection molding tool without separating the molded part from runners and without degating. The single step transfer, which can be performed without degating and without separating the molded parts from one another, can reduce cycle time as well as complexity.