Abstract: A method for determining a form for a headphone part using a representative model includes receiving data for at least one ear model. The ear model may be oriented within a coordinate system based on the data, where orienting is focused on the alignment with respect to one or more areas of the ear. A representative model is determined from a plurality of oriented ear models, where the representative model is a representation for a volume determined to be common to at least two oriented ear models. The size and/or shape for the headphone part is determined based upon the representative model.

Abstract: An earphone comprising an earphone housing having a wall comprising (1) a front side that joins (2) an end portion in which a primary sound output opening is formed, which joins (3) a face portion in which a secondary output opening is formed, which joins (4) a back side which joins the front side and encloses a driver, wherein the face portion and the front side form a tapered portion of the earphone housing that is dimensioned to be inserted into, and contact, an ear of a wearer, wherein the primary output opening is dimensioned to output sound generated by a diaphragm of the driver contained within the earphone housing into the ear, the secondary output opening is dimensioned to vent the ear to a surrounding environment, and wherein the primary output opening and the secondary output opening face different directions and are positioned over a sound output face of the driver.

Abstract: Seamless earbud structures and methods for making the same are disclosed. Seamless earbud structures can be constructed using an insert molding construction method, which overmolds a cosmetic material over two sub-enclosures that are mated together. The two sub-enclosures form a housing that can encompass a driver assembly (e.g., woofer and tweeter), a conductor bundle, and provide one or more acoustic volumes. The housing has a non-occluding member and a neck member, and has a seamless or nearly seamless construction. The cosmetic material is insert molded around the housing to provide a smooth and seamless surface disposed around the periphery of the housing.

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

Abstract: An earphone comprising an earphone housing having a body portion, the body portion having an acoustic output opening to output sound from a driver positioned therein into an ear of a user. An acoustic tuning member is positioned within the body portion. The acoustic tuning member defines a back volume chamber of the driver and includes an acoustic output port for outputting sound from the back volume chamber of the driver to improve an acoustic performance of the earphone.

Abstract: Intra-concha earphones are disclosed. In an embodiment, an intra-concha earphone includes a housing having a rear space divided into a back volume, a bass duct, and a vent chamber between a driver and a rear wall. The vent chamber may be acoustically coupled with the back volume through both an acoustic port and the bass duct. Furthermore, the vent chamber may be acoustically coupled with a surrounding environment through a vent port, which may be a sole acoustic opening in the rear wall. Thus, sound emitted by the driver may propagate through the acoustic port and the bass duct to meet in the vent chamber before being discharged through the vent port to the surrounding environment. Other embodiments are also described and claimed.

Abstract: An earphone comprising an earphone housing having a wall comprising (1) a front side that joins (2) an end portion in which a primary sound output opening is formed, which joins (3) a face portion in which a secondary output opening is formed, which joins (4) a back side which joins the front side and encloses a driver, wherein the face portion and the front side form a tapered portion of the earphone housing that is dimensioned to be inserted into, and contact, an ear of a wearer, wherein the primary output opening is dimensioned to output sound generated by a diaphragm of the driver contained within the earphone housing into the ear, the secondary output opening is dimensioned to vent the ear to a surrounding environment, and wherein the primary output opening and the secondary output opening face different directions and are positioned over a sound output face of the driver.

Abstract: An earphone comprising an earphone housing having a body portion, the body portion having an acoustic output opening to output sound from a driver positioned therein into an ear of a user. An acoustic tuning member is positioned within the body portion. The acoustic tuning member defines a back volume chamber of the driver and includes an acoustic output port for outputting sound from the back volume chamber of the driver to improve an acoustic performance of the earphone.

Abstract: Seamless earbud structures and methods for making the same are disclosed. Seamless earbud structures can be constructed using an insert molding construction method, which overmolds a cosmetic material over two sub-enclosures that are mated together. The two sub-enclosures form a housing that can encompass a driver assembly (e.g., woofer and tweeter), a conductor bundle, and provide one or more acoustic volumes. The housing has a non-occluding member and a neck member, and has a seamless or nearly seamless construction. The cosmetic material is insert molded around the housing to provide a smooth and seamless surface disposed around the periphery of the housing.

Abstract: An earphone comprising an earphone housing having a wall comprising (1) a front side that joins (2) an end portion in which a primary sound output opening is formed, which joins (3) a face portion in which a secondary output opening is formed, which joins (4) a back side which joins the front side and encloses a driver, wherein the face portion and the front side form a tapered portion of the earphone housing that is dimensioned to be inserted into, and contact, an ear of a wearer, wherein the primary output opening is dimensioned to output sound generated by a diaphragm of the driver contained within the earphone housing into the ear, the secondary output opening is dimensioned to vent the ear to a surrounding environment, and wherein the primary output opening and the secondary output opening face different directions and are positioned over a sound output face of the driver.

Abstract: An earphone comprising an earphone housing having a body portion, the body portion having an acoustic output opening to output sound from a driver positioned therein into an ear of a user. An acoustic tuning member is positioned within the body portion. The acoustic tuning member defines a back volume chamber of the driver and includes an acoustic output port for outputting sound from the back volume chamber of the driver to improve an acoustic performance of the earphone.

Abstract: An earphone comprising an earphone housing having a body portion acoustically coupled to a tube portion extending from the body portion, the body portion having an acoustic output opening to output sound from a driver positioned therein into an ear canal of a wearer. An acoustic tuning member is positioned within the body portion for acoustically coupling the driver to the tube portion. The acoustic tuning member defines a back volume chamber of the driver and includes an acoustic output port for outputting sound from the back volume chamber of the driver to the tube portion to improve an acoustic performance of the earphone.

Abstract: An earphone having an earphone housing including a tip portion dimensioned to be inserted into an ear canal of a wearer, a body portion extending outward from the tip portion, and a tube portion extending from the body portion. The body portion has a face portion that faces a pinna region of the ear when the tip portion is inserted into the ear canal. A primary output opening, that outputs sound from a driver in the housing to the ear canal, is formed in the tip portion. A secondary output opening, that outputs air from the ear canal to the surrounding environment, is formed in the face portion. The primary output opening and the secondary output opening are horizontally aligned when the tube portion is positioned vertically downward and an angle formed between the primary output opening, the tube portion and the secondary output opening is less than 90 degrees.

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

Abstract: An electrical device such as a headset may have a cable. Wires in the cable may be used to connect speakers in the headset to a connector such as an audio jack. The cable may have a tubular intertwined cable cover that covers the wires. Computer-controlled servo motors in fiber intertwining equipment may be adjusted in real time so that intertwined attributes such as intertwining density and intertwining tension are varied as a function of length along the intertwined cable cover. The fiber intertwining equipment may make these variations to locally increase the strength of the intertwined cable cover and the cable in the vicinity of a bifurcation in the cable and in the vicinity of the portion of the cable that terminates at the audio jack.

Abstract: This is directed to a cable structure for use with an electronic device. The cable structure can include one or more conductors around which a sheath is provided. To prevent the cable structure from tangling, the cable structure can include a core placed between the conductors and the sheath, where a stiffness of the core can be varied along different segments of the cable structure to facilitate or hinder bending of the cable structure in different areas. The size and distribution of the stiffer portions can be selected to prevent the cable from forming loops. The resistance of the core to bending can be varied using different approaches including, for example, by varying the materials used in the core, varying a cross-section of portions of the core, or combinations of these.

Abstract: A headset can include a cable structure connecting non-cable components such as jacks and headphones. The cable structure can be constructed using a molding process. Different approaches can be used to ensure that a conductor bundle extending through the cable structure remains centered within the cable structure during the molding process. A movable tube can be placed in the mold such that the conductor bundle is retained within the tube. As material is injected into the mold and reaches the tube, the tube can be displaced and progressively removed from the mold. Alternatively, the movable tube can be constructed such that the tube may combine with injected material to form a shell of the cable structure. Gates from which material is provided in the mold can be positioned and controlled to facilitate the injection of material in the mold while maintaining the centered position of the conductor bundle.

Abstract: A method for determining a form for a headphone part using a representative model includes receiving data for at least one ear model. The ear model may be oriented within a coordinate system based on the data, where orienting is focused on the alignment with respect to one or more areas of the ear. A representative model is determined from a plurality of oriented ear models, where the representative model is a representation for a volume determined to be common to at least two oriented ear models. The size and/or shape for the headphone part is determined based upon the representative model.

Abstract: An earphone comprising an earphone housing having a body portion acoustically coupled to a tube portion extending from the body portion, the body portion having an acoustic output opening to output sound from a driver positioned therein into an ear canal of a wearer. An acoustic tuning member is positioned within the body portion for acoustically coupling the driver to the tube portion. The acoustic tuning member defines a back volume chamber of the driver and includes an acoustic output port for outputting sound from the back volume chamber of the driver to the tube portion to improve an acoustic performance of the earphone.

Abstract: An earphone having an earphone housing including a tip portion dimensioned to be inserted into an ear canal of a wearer, a body portion extending outward from the tip portion, and a tube portion extending from the body portion. The body portion has a face portion that faces a pinna region of the ear when the tip portion is inserted into the ear canal. A primary output opening, that outputs sound from a driver in the housing to the ear canal, is formed in the tip portion. A secondary output opening, that outputs air from the ear canal to the surrounding environment, is formed in the face portion. The primary output opening and the secondary output opening are horizontally aligned when the tube portion is positioned vertically downward and an angle formed between the primary output opening, the tube portion and the secondary output opening is less than 90 degrees.