TWI786037B - Integrated loudspeaker device having an acoustic chamber containing sound adsorber material - Google Patents

Abstract

An acoustic device having a housing and an acoustic transducer is disclosed. The housing has a transducer space for the acoustic transducer, and a back volume space. The back volume is filled with a sound adsorber material. The sound adsorber material in the back volume space is configured to virtually increase the size of the back volume space, and shift the resonant frequency of the back volume space. The acoustic chamber for the acoustic transducer and the sound adsorber material is integral to the split-shell housing of the acoustic device. The sound adsorber material is retained in a portion of the acoustic chamber by an acoustically permeable material that facilitates gas exchange within the back volume space, and between the sound adsorber material and the transducer space. The acoustically permeable material is configured in different arrangements to facilitate the gas exchange.

Description

Integrated loudspeaker device having an acoustic chamber comprising sound-absorbing material

The present invention relates to the field of acoustic devices and in particular the invention relates to a small loudspeaker device with sound-absorbing material integrated in the rear volume of the housing of the speaker device.

In acoustic technology, it is known to place a sound-absorbing material in a rear volume of a loudspeaker device to acoustically enlarge the rear volume in practical terms. In a speaker device with a physically smaller rear volume, a sound absorbing material lowers the resonant frequency of the speaker device to a value similar to that of a speaker device with a physically larger rear volume.

More specifically, sound-absorbing materials placed in the rear volume of a speaker device improve its sound characteristics, such as broadband performance and the apparent acoustic volume of the speaker. Examples of sound-absorbing materials include zeolite materials, zeolite-based materials, silicon dioxide (SiO ₂ ), aluminum oxide (Al ₂ O ₃ ), zirconia (ZrO ₃ ), magnesium oxide (MgO), ferric oxide (Fe ₃ O ₄ ), molecular sieves, fullerenes, carbon nanotubes and activated carbon or charcoal. Unlike activated carbon, zeolite materials and zeolite-based materials are electrically insulating. Since zeolite materials and zeolite-based materials are not electrically conductive, zeolite materials and zeolite-based materials will not affect electrical components (e.g., antennas, batteries, internal electronics, etc.) incorporated into a device such as a speaker device having such a sound-absorbing material . Furthermore, the non-conductive zeolite material or zeolite-based material will not cause a short circuit if the non-conductive zeolite material or zeolite-based material becomes relaxed within the device. In addition, encapsulation of zeolite materials and zeolite-based materials is much easier than in the case of activated carbon weaves.

A problem arises when inserting or placing sound-absorbing materials consisting of or at least comprising powders, loose granules, loose granules in the rear volume of the loudspeaker device. In addition, the rear volume of a small speaker (such as a speaker device placed in a mobile phone, earphone, etc.) is usually constrained by other circuit components in the immediate physical area surrounding the speaker, and sometimes the shape of the rear volume is complex and Does not meet acoustic requirements. A known technique uses tubes that pack a sound-absorbing material, but these tubes usually do not fit well in a rear volume having a complex shape. Inserting sound absorbing material directly into the rear volume can be difficult in practice. In addition, if the sound absorbing material is not securely encapsulated, it can get into different components of the speaker device and the handheld device using the speaker device, and thus, damage the speaker device or the handheld device including the speaker device as a component.

U.S. Application No. 13/818,374 (the entire contents of which are incorporated herein by reference) discloses an audio system comprising an electroacoustic transducer or one of the resonance volumes having a resonance volume formed to improve the quality of the emitted sound The speaker of the shell. The audio system disclosed in application Ser. No. 13/818,374 includes a zeolite particulate material or a substantially spherical zeolite particulate material filling a portion of a resonant volume of a loudspeaker. The zeolite material is a sound-absorbing material which, depending on the formulation of the material, causes an actual acoustic expansion of the volume of the resonant space by a factor of 1.5 or more. Therefore, the volume of the enclosure of a speaker comprising zeolite material can be made smaller compared to the enclosure of an air-filled speaker.

Used as a small speaker such as is commonly found in today's hand-held consumer electronic devices The encapsulation of a zeolite-based material for a sound absorber inside the rear volume has been challenging. Although not electrically destructive, the zeolite materials disclosed in Application Serial No. 13/818,374 can interfere with the proper operation of a small speaker and other components within a handheld consumer electronic device if not properly contained within the device. Furthermore, due to the generally confined space within the volume behind a small speaker, gas exchange can be resisted and the efficiency of zeolite-based absorbers can be reduced by design constraints. Although the small loudspeaker rear volume can completely fill a zeolite-based absorber, as long as a limited amount of absorbing surface area is exposed to pressure changes caused by movement of the acoustic transducer, the resonant frequency shift disclosed in Application No. will be limited.

The disclosed invention relates to housing elements of a mobile device, such as a speaker, that when joined form an integrated acoustic chamber for an acoustic sensor. The acoustic chamber has a rear volume, a front volume and a volume occupied by the acoustic sensor. In the rear volume of the acoustic chamber, a mass of sound-absorbing material is arranged in a cavity created by the walls of the acoustic chamber. The chamber containing the sound absorbing material is sealed from the rest of the acoustic chamber using a breathable material with low acoustic resistance. The breathable material retains the sound absorbing material in its designated chamber while allowing gas exchange between the sound absorbing material and the remainder of the acoustic chamber.

An embodiment of a housing for a mobile device according to the present invention may include: a printed circuit substrate; and a shield configured to cooperate with the printed circuit substrate to create a housing for an acoustic sensor in the mobile device. In this embodiment, the shield may include: a chamber wall that, when engaged with an inner surface of the printed circuit substrate, defines a substantially sealed acoustic chamber; an acoustic sensor (such as a speaker or receiver) , which is disposed within the acoustic chamber; an acoustic port, which is acoustically coupled to the acoustic sensor; an inner chamber wall, which is disposed within the acoustic chamber and defines a rear volume; and a mass of sound-absorbing material, which is disposed within within the rear volume. In this example, a A breathable member is mechanically coupled to a top portion of the chamber wall and a top portion of the inner chamber wall, wherein the breathable member retains the sound absorbing material within a defined volume within the acoustic chamber. The breathable member of this embodiment has low acoustic resistance and may include one or more of a cashmere material or a mesh material, and the pore size of the material of the breathable member is adjusted to be smaller than the size of the sound-absorbing particles. The gas permeable member is mechanically attached to the top portion of the chamber wall to the top portion of the inner chamber wall by gluing, crimping, stamping, embossing, heat sealing or ultrasonic welding. This embodiment may further comprise a chamber liner interposed between the printed circuit substrate and the top portion of the chamber wall, wherein a thickness of the chamber liner is determined by a restriction by which it facilitates gas exchange. size. Additionally, this embodiment may further include an acoustic port gasket interposed between the acoustic sensor and the acoustic port disposed in the shroud, wherein the acoustic port gasket seals the front volume from the rearward volume . In this embodiment, in the acoustic chamber, the rear volume is partially filled with a zeolite-based material having substantially spherical sound-absorbing particles having a minimum diameter of at least 300 microns.

Another embodiment of a housing for a mobile device may include: a first housing element comprising a printed circuit board having an acoustic sensor electrically and mechanically coupled to the printed circuit board; and A second housing element is mechanically coupled to the first housing element to form the housing of the mobile device. In this embodiment, the second housing element may include: a continuous vertical element defining a substantially sealed acoustic chamber when engaged with the printed circuit board of the first housing element; In a sensor space acoustically coupled to the acoustic sensor (e.g., a speaker or a receiver); an internal vertical element disposed in the acoustic chamber and intersecting the continuous vertical element to define a rear volume a plurality of sound-absorbing particles disposed within the rear volume; and a sound-transmitting material mechanically coupled to a top portion of the continuous vertical element and a top portion of the inner vertical element, wherein the sound-transmitting material Sound-absorbing particles are held in a defined space within the acoustic chamber. In this embodiment, the acoustic A sensor occupies the sensor space when the first housing element and the second housing element are coupled together. In this embodiment, the rear volume of the acoustic chamber is partially filled with substantially spherical particles having a minimum diameter of at least 200 microns (or in another embodiment, a minimum diameter of at least 350 microns) One of the zeolite-based sound-absorbing particles. This embodiment may include a chamber liner interposed between the printed circuit board and the top portion of the continuous vertical element, wherein a thickness of the chamber liner determines the size of a restriction by which gas exchange is facilitated . In this embodiment, the acoustically transparent material may be mechanically attached to the top portion of the continuous vertical element and the top portion of the inner vertical element by gluing or ultrasonic welding.

In a variation of this embodiment, the inner vertical element may include an opening configured to facilitate gas exchange of the sound-absorbing particles, wherein the opening may include a material having substantially the same mechanical coupling to the continuous vertical element. A material of the sound resistance of the sound-transmitting material of the top portion and the top portion of the inner vertical element, and the material disposed in the opening of the inner vertical element may include a cashmere material or a mesh material one or more. In a further variation, the inner vertical element may include an opening configured to facilitate gas exchange of the sound-absorbing particles, wherein the opening may include a top portion having a different mechanical coupling to the continuous vertical element and A material of acoustic resistance of the sound-transmissive material of the top portion of the inner vertical element. In some embodiments, the material disposed in the opening of the inner vertical element may include a breathable material that may include particles sized to retain the sound absorbing particles in a defined area in the rear volume. Multiple apertures. In some embodiments, the housing can include an acoustic port liner interposed between the acoustic sensor and the acoustic port disposed in the second housing element, wherein the acoustic port liner is configured to The first housing element seals the sound port from the rear volume when engaged with the second housing element.

Another embodiment of a casing of a mobile device may include: a first casing element, the first A housing element includes a printed circuit board having an acoustic sensor (e.g., a speaker or receiver) electrically and mechanically coupled to the printed circuit board; and a second housing element mechanically coupled to the first housing components to form the casing of the mobile device. The second housing may include: a continuous vertical element defining a substantially sealed acoustic chamber when engaged with the printed circuit board of the first housing element; A sensor space for the sensor; an internal vertical element disposed in the acoustic chamber and intersecting the continuous vertical element to define a rear volume. In this embodiment, the inner vertical element may include: an opening configured for gas exchange; a low acoustic resistance insert completely covering the opening; a mass of sound-absorbing particles disposed within the rear volume an acoustically transparent material mechanically coupled to a top portion of the continuous vertical element and a top portion of the inner vertical element, wherein the acoustically transparent material retains the sound absorbing particles in a defined space within the acoustic chamber. This embodiment may also include a cavity liner interposed between the printed circuit board and the top portion of the continuous vertical element and the top portion of the inner vertical element. In this embodiment, the acoustic sensor occupies the sensor space when the first housing element and the second housing element are coupled together. In some embodiments, the low acoustic resistance insert and the acoustically transparent material in the inner vertical member each comprise one or more of a cashmere material or a mesh material. Furthermore, in some embodiments, the rear volume of the acoustic chamber is partially filled with zeolite-based sound absorbing particles having substantially spherical particles having a minimum diameter of at least 300 microns and a maximum diameter of 900 microns.

An embodiment of a housing for a mobile device can be manufactured in the following manner. After the shroud has been substantially completed, it is easy to receive the material in the rear volume of the acoustic chamber designated for the sound absorbing material. A quantity of sound-absorbing material is measured and loaded into a dispensing hopper. The shroud is positioned below the dosing funnel and vibrates when the sound absorbing material is poured into the designated portion or portions of the rear volume of the acoustic chamber. If the rear volume has multiple chambers, the sound-absorbing material measurement step The steps and dispensing steps will be repeated as many times as necessary. After filling, the shroud is vibrated several times to ensure that the sound absorbing material settles to the designated portion or portions of the acoustic chamber. A gas permeable member is then placed over the acoustic chamber and mechanically attached to the acoustic chamber by gluing, ultrasonic welding, or other techniques. A chamber liner is aligned with the wall of the acoustic chamber, and then, the printed circuit board is bonded to the shroud, thereby completing the housing of the acoustic sensor of the mobile device.

Other embodiments of a housing for a mobile device can be fabricated in the following manner. After the shroud has been substantially completed, it is easy to receive the material in the rear volume of the acoustic chamber designated for the sound absorbing material. A breathable member is placed over the acoustic chamber that will receive the sound absorbing material and is mechanically attached to the acoustic chamber by gluing, ultrasonic welding, or other techniques. A quantity of sound-absorbing material is measured and loaded into a dispensing hopper. The shroud is positioned below the dosing funnel, and the sound-absorbing material is poured into a designated portion of the rear volume of the acoustic chamber through a dosing funnel aligned with a fill port disposed in the shroud or several specified sections. If the rear volume has multiple chambers, the sound-absorbing material measuring step and the compounding step will be repeated as many times as necessary. After filling, the shroud is vibrated several times to ensure that the sound absorbing material settles to the designated portion or portions of the acoustic chamber. A chamber liner is aligned with the wall of the acoustic chamber, and then, the printed circuit board is bonded to the shroud, thereby completing the housing of the acoustic sensor of the mobile device.

Other features and advantages of the disclosed invention will become apparent from the following description combined with the following drawings.

10:Speaker device

12: Acoustic sensor

13: Upper speaker housing

14: Lower speaker housing

15: dotted line

16: Sound-absorbing bag

17: rear volume

18: breathable wall

19: Sound-absorbing material

30: Enclosure/Acoustic Device

31: Printed circuit board (PCB) housing

32: Printed circuit board

33: shield

34: Acoustic sensor

35: rear volume

36: Sensor contact

37: Chamber liner

38: Sound port liner

39: sound port

40: Front volume

41: chamber wall

42: Breathable member attachment point

43: breathable components

44: Internal chamber wall

45: side tabs

46: Upper tab

47: Lower tab

48: breathable insert

49: ventilation hole

50: Wall opening

51: limit

52: Loading port

53: Fill port seal

A-A: section line

B-B: section line

S100: step

S110: step

S120: step

S130: step

S140: step

S150: step

S160: Steps

S170: step

S180: Steps

S190: step

S200: Steps

S210: step

S300: Steps

S310: step

S320: step

S330: step

S340: step

S350: Steps

S360: Steps

S370: Steps

S380: Steps

S390: Steps

S400: Steps

S410: step

S420: step

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention, and are used together with "implementation mode" to explain the purpose, advantages and principles of the present invention. In the schema, Fig. 1 is a three-quarter view of a loudspeaker device for installation in an acoustic device; Fig. 2 is a longitudinal cross-sectional view of the loudspeaker device of Fig. 1 having a first embodiment comprising a sound-absorbing material; Fig. 3 is a longitudinal cross-sectional view of the loudspeaker device of FIG. 1 having a second embodiment comprising a sound-absorbing material; FIG. 4 is a longitudinal cross-sectional view of an acoustic device with a shield and a printed circuit Board provides the acoustic cavity that encloses acoustic sensor; Figure 5 is a longitudinal cross-sectional view of an acoustic device, wherein a shield of the acoustic device and a printed circuit board provide an acoustic cavity that encloses the acoustic sensor and according to the present invention The sound-absorbing material of a first embodiment; Fig. 6 is a longitudinal cross-sectional view of an acoustic device, wherein a shield of the acoustic device and a printed circuit board provide an acoustic chamber enclosing the acoustic sensor and the acoustic chamber according to the present invention A sound-absorbing material of a second embodiment; Fig. 7 is a cross-sectional view of a first embodiment of an inner chamber wall according to the present invention; Fig. 8 is a second embodiment of an inner chamber wall according to the present invention A cross-sectional view of an example; Fig. 9 is a longitudinal cross-sectional view of an acoustic device, wherein a shield of the acoustic device and a printed circuit board provide an acoustic chamber enclosing an acoustic sensor and a third according to the present invention The sound-absorbing material of the embodiment; Fig. 10A and Fig. 10B are a flow chart of a process for manufacturing an acoustic device, wherein a shield of the acoustic device and a printed circuit board provide an acoustic chamber enclosing an acoustic sensor and according to the present invention One embodiment of the sound-absorbing material; and Figures 11A and 11B are flow charts of a process for manufacturing an acoustic device in which a shield and a printed circuit board of the acoustic device provide an acoustic chamber enclosing an acoustic sensor and According to this The sound-absorbing material of an embodiment of the invention.

Those skilled in the art should understand that the components in the figure are only shown for simplicity and clarity. It should further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence, while those skilled in the art will understand that specificity with respect to order is not actually necessary. It should also be understood that the terms and expressions used herein have their ordinary meanings according to such terms and expressions relative to their respective scope of investigation and research, except where the specific meanings are otherwise set forth herein.

A detailed description of the disclosed embodiments will be provided with reference to the accompanying drawings.

While the invention is susceptible to embodiments in many different forms, the drawings show (and as will be described in detail) preferred embodiments of the invention, it being understood that this disclosure is considered an example of the principles of the invention, and It is not intended that the broad aspects of the invention be limited to the illustrated embodiments.

Referring to FIG. 1 and FIG. 2 , a speaker device 10 is shown in the figures. The speaker device 10 includes an upper speaker housing 13 , a lower speaker housing 14 , and an acoustic sensor 12 . The upper speaker housing 13 is joined to the lower speaker housing 14 using fasteners, locking tabs or a suitable adhesive. The adhesive used to join the upper speaker housing 13 and the lower speaker housing 14 should preferably not have any venting properties that could affect the sound absorbing material in the rear volume and affect its efficiency. When the sound absorbing material 19 is disposed internally in the speaker device 10, the dotted line 15 indicates the inner position of the sound absorbing material 19 in the speaker device. The upper speaker housing 13 includes a sensor opening 11 which allows sound transmission/airflow from the acoustic sensor 12 to the space outside the device. Other elements of the loudspeaker device, such as electrical contacts, pads, and internal wiring, are not shown in FIG. 1 .

Referring to FIG. 2 , one method of encapsulating the sound-absorbing material 19 is shown in the figure. "Sound-absorbing material" (as used herein) refers to the zeolite material disclosed in Application Serial No. 13/818,374, although other sound-absorbing materials may be used if desired. As shown along section line A-A in Fig. 2, the loudspeaker device 10 is placed behind The volume 17 extends around the acoustic sensor 12 and into the inner portion of the volume in which the sound absorbing bag 16 is placed. Application No. 14/003,217 (the entire content of which is incorporated herein by reference) discloses a technique for enclosing the sound absorbing material 19 with a bag. As disclosed in Application No. 14/003,217, the sound-absorbing bag 16 is manufactured to fit the interior contour of the rear volume, and one side of the sound-absorbing bag 16 includes a Gas exchange one low acoustic resistance one permeable material. The breathable material must also retain the sound absorbing material 19 within the inner chamber of the bag. The remaining sides of the sound-absorbing bag 16 are made of a material that is relatively air-permeable or has a high acoustic resistance. The sound absorbing bag 16 is positioned such that gas exchange occurs between the sound absorbing material 19 and the rear volume 17 through the breathable material.

Referring to FIG. 3 , another method of retaining the sound-absorbing material 19 within the rear volume of the loudspeaker device 10 is illustrated. As shown along section line A-A in FIG. 3 , instead of a sound-absorbing bag 16 , a gas-permeable wall 18 is arranged in the rear volume 17 . The gas permeable wall 18 is held in its position within the rear volume 17 by tabs, flanges or suitable adhesive. If an adhesive is used, it should preferably not have any venting properties that could affect the sound-absorbing material in the rear volume and affect its absorption capacity. The gas permeable wall 18 may comprise a perforated or etched polypropylene material, a mesh material with low acoustic resistance, a filter material, or other gas permeable material with a low acoustic resistance. As shown in FIG. 3 , the sound absorbing material 19 is held in a portion of the rear volume 17 opposite the location of the acoustic sensor 12 .

As shown in FIGS. 2 and 3 , gas exchange between the sound-absorbing material 19 and the rear volume 17 is facilitated by a breathable material placed between the sound-absorbing material 19 and the rear volume 17 . However, as shown in Figures 2 and 3, the sound absorbing material 19 located at the interface with the rear volume (ie, immediately adjacent to the breathable material) will absorb or desorb gas before the sound absorbing material 19 moves away from the rear volume interface. Even though the sound absorbing material 19 is a particle (rather than a much smaller particle), the sound absorbing material 19 presents acoustic resistance to gas passing through the breathable material. This acoustic resistance causes the sound-absorbing material 19 closest to the rear volume interface More interaction with gas exchange, and the absorber further away from the breathable material may have less interaction. This non-uniform interaction in gas exchange can cause the efficiency of the sound absorbing material 19 to decrease (if the path through the sound absorbing material is too long/narrow).

Referring to FIG. 4, one embodiment of an acoustic sensor 34 disposed in a substantially sealed acoustic chamber defined by a shield 33 and a printed circuit board 32 of an audio device is depicted. In the context of this application, an audio device includes any type of electronic device having an audio function, such as playback of voice messages, music or other sound files, such as a music player, mobile phone, and the like. Audio devices having a microphone are also included since the sound absorbing material can enhance the frequency response of the microphone element. In FIG. 4, the substantially sealed acoustic chamber consists of a printed circuit board 32, a shroud 33 having a continuous vertical member (i.e. chamber wall 41) and a top portion interposed between the chamber wall 41 and the printed circuit board. The chamber liner 37 between the top portions of 32 is defined. In some embodiments, chamber wall 41 is a continuous wall formed from injection molded plastic or machined from metal. Instead of a complete loudspeaker unit having its own upper and lower loudspeaker housing shells, the embodiment shown in Figure 4 relies on providing a printed circuit board 32 and shroud 33 of the loudspeaker housing. Typically, with this type of speaker configuration, the speaker is not completed until the printed circuit board 32 and shroud 33 of the audio device are engaged.

Sound port 39 allows sound to propagate to the environment outside the chamber formed by printed circuit board 32 and shroud 33 and chamber liner 37 . Acoustic sensor 34 is electrically and mechanically coupled to printed circuit board 32 via sensor contacts 36 disposed between printed circuit board 32 and acoustic sensor 34 . Solder or other conductive material may be used to electrically and mechanically couple acoustic sensor 34 to printed circuit board 32 . Alternatively, the acoustic sensor 34 may have spring contacts that are pushed against the printed circuit board 32 to provide electrical continuity. Acoustic sensor 34 receives electrical signals from printed circuit board 32 via sensor contacts 36 .

Acoustic sensor 34 is spaced from sound port 39 and the inner surface of shroud 33 by sound port liner 38 . sound port The gasket 38 divides the substantially sealed acoustic chamber into a pre-volume 40 and a post-volume 35 . The front volume 40 is the volume accessible through the sound port 39 and bounded by the sound port liner 38, the portion of the inner surface of the shield 33 within the sound port liner 38, and the portion of the acoustic sensor 34 facing the sound port 39 . The substantially sealed acoustic chamber rear volume 35 consists of a portion of the inner surface of the shroud 33 outside the acoustic port liner 38, the inner surface of the chamber wall 41, the chamber liner 37, and the printing inside the chamber liner 37. A portion of the inner surface of circuit board 32 is delimited. The rest of the printed circuit board 32 is mechanically coupled to the shroud 33 to compress the chamber liner 37 against the top portion of the chamber wall 41 , and against the acoustic sensor 34 in the area of the sound port 39 and within the shroud 33 The surface compresses the sound port liner 38 . Compression of chamber liner 37 and port liner 38 substantially seals the acoustic chamber of acoustic sensor 34 . As is well known, the rear volume 35 improves the operation of the acoustic sensor, in this example a speaker. The air flow from the rear side of the acoustic sensor 34 into the rear volume 35 during the movement of the acoustic sensor 34 due to the electrical signal received through the sensor contact 36 is shown in FIG. 4 .

FIG. 4 also depicts a housing 30 and a PCB housing 31 , wherein the housing 30 is mounted on the shroud 33 and the PCB housing 31 is mounted on the printed circuit board 32 . Cover 30 and PCB housing 31 are optional components of audio devices and are often included to cover shield 33 and printed circuit board 32 for aesthetic reasons. More specifically, shroud 33 may have parting lines, fastener ports, or aesthetically unpleasing finish lines, and shroud 30 is attached to shroud 33 to mask such manufacturing artifacts. Similarly, PCB housing 31 is mounted on printed circuit board 32 to cover patch wires, electrical traces, and other manufacturing artifacts.

Referring to FIG. 5, there is depicted an embodiment of an acoustic sensor 34 disposed in a substantially sealed acoustic chamber having a sound absorbing material 19 formed from a printed circuit board of an audio device. 32 and shield 33 limit. Most of the structural features of the embodiment of FIG. 5 are the same as those shown in FIG. 4 . In the embodiment shown in FIG. 5, the rear volume 35 is now composed of a mass of sound-absorbing material 19, an inner vertical element (i.e. the inner chamber wall 44) and in turn composed of the inner chamber wall 44, the chamber wall 41 and the permeable The volume delimited by the air member 43 is occupied by the air permeable member 43 containing the sound absorbing material 19 . The gas permeable member 43 is mechanically coupled or attached to the gas permeable member attachment point 42 on the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 . The breathable member 43 covers only those parts of the substantially sealed acoustic chamber (ie the rear volume 35 ) that will receive the sound absorbing material 19 . Other portions of the substantially sealed acoustic chamber, such as the portion in which the acoustic sensor is located, will not be covered with the gas permeable member 43 . This allows the acoustic sensor 34 to be repaired and replaced without removing the gas permeable member 43 or disturbing the sound absorbing material 19 . The chamber liner 37 covers the portion of the gas permeable member 43 that is mechanically coupled or attached to the top portion of the chamber wall 41 .

Although FIG. 5 only discloses a single rear volume 35 that will contain the sound absorbing material 19, it is contemplated that the rear volume 35 may include the entire substantially sealed acoustic chamber defined by the chamber wall 41, shroud 33, and printed circuit board 32. Multiple chamber type areas in the room. It is further contemplated that each of these multiple chamber-type regions within the substantially sealed acoustic chamber will be covered by a gas-permeable member 43, preferably a single piece that is configured to cover all chamber-type regions. The ventilation member 43 covers. One can also expect that depending on the overall design of the substantially sealed acoustic chamber defined by the chamber walls 41 , shroud 33 and printed circuit board 32 , multiple gas permeable members 43 may also be obtained. Additionally, one of the breathable members 43 covering the chambers containing the sound absorbing material 19 will not cover the volume in the acoustic chamber designated to be occupied by the acoustic sensor to facilitate repair or replacement of the acoustic sensor 34 .

As shown in Figure 2, a sound absorbing bag 16 comprising a sound absorbing material 19 can be used in this type of speaker configuration where the speaker housing is molded as or an integral part of the housing of an audio device. One limitation of the sound absorbing bag 16 is that the corners of the rear volume 35 (as shown in Figures 4 and 5) will not have any sound material disposed therein. This is due to manufacturing constraints inherent in the sound absorbing bag 16 . More specifically, a ninety degree angle cannot be molded into the sound-absorbing bag 16 and also requires some tolerance for proper bag placement in the rear volume 35 , and thus a small amount of the rear volume 35 does not receive the sound-absorbing material 19 . because Fill ports for sound absorbing material 19 would be visible on the housing of an audio device and would not be aesthetically pleasing to potential device buyers, so the other methods shown in FIG. Manufactured as or an integral part of the housing of the audio device. Furthermore, there is a danger that regular day-to-day use of the audio device will cause the seal over the fill port to dislodge or rupture, thereby allowing the sound absorbing material to escape.

The air flow from the rear side of the acoustic sensor 34 to the rear volume 35 during movement of the acoustic sensor 34 due to receiving an electrical signal through the sensor contact 36 is shown in FIG. 5 . During operation, the acoustic sensor 34 generates a pressure in the rear volume 35 and this pressure causes a gas exchange with the sound-absorbing material 19 . The gas permeable member 43 facilitates this gas exchange between the rear volume 35 and the sound absorbing material 19 . Preferably, the sound absorbing material 19 is a loose zeolite particulate material as disclosed in US Application Serial No. 14/818,374 (the entire contents of which are incorporated by reference). More preferably, the loose zeolite particulate material (used as sound absorbing material 19) is substantially spherical and has a diameter in the range of 100 microns or greater. The loose zeolite particulate material is preferred for its ease of use in the manufacture of acoustic devices of the type disclosed herein. Other types of sound absorbing materials (such as zeolite powder or activated carbon) can also be used, but may not be as easy to use in the manufacturing process.

As is known in the art, the energy of sound or gas passing through a material can be described together with the acoustic resistance (ie, measured in MKS rayl). For the embodiment shown in FIG. 5, the air permeable member 43 should have an acoustic resistance (typically 260 MKS Rui). If the opening is small, the choice of material to be used as the breathable member 43 can cause the acoustic resistance at the opening to exceed the threshold of 260 MKS ray, thereby resulting in poor acoustic performance. More specifically, if the threshold of 260 MKS is exceeded, the gas in the rear volume is prevented from reaching the sound-absorbing material 19 . Therefore, if a cashmere material is chosen for the breathable member 43, care must be taken not to exceed the threshold of 260 MKS Ray, especially if the limit 51 is small. For some embodiments, the cashmere material is a heterogeneous material, and more specifically, a flat layer material made of nylon fibers with an undefined pattern. The purpose of the cashmere material is to hold the sound absorbing material 19 and to allow gas to interact with the sound absorbing material 19 . The structure of the cashmere material and any pore size in the material is such that the sound absorbing material 19 (in powder form, particulate form or granular form) cannot pass through the cashmere material.

Alternatively, a mesh material may be used for the breathable member 43 . In some embodiments, unlike the cashmere material, the surface structure and material structure of the mesh material are well defined. For example, a layer of mesh material suitable for use as the breathable member 43 may have a nominal thickness of 115 microns, a pore size of 130 microns, and an acoustic resistance of 8.5 MKS Rai per square centimeter. Like the cashmere material, the purpose of the mesh material is to hold the sound absorbing material 19 and to allow gas to interact with the sound absorbing material 19 . The structure of the mesh material and any pore sizes in the material are such that the sound absorbing material 19 (in powder, particulate or granular form) cannot pass through the mesh material. An acoustic engineer has a wider design latitude than mesh materials because the acoustic resistance of mesh materials is lower and is a known quantity.

The gas permeable member 43 may be coupled to the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 by gluing, crimping, stamping, embossing, heat sealing or, preferably, ultrasonic welding. Breathable member attachment points 42 . One advantage of ultrasonic welding is that a consistent and reliable adhesive is formed between the air permeable member 43 and the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44, wherein the air permeable member 43 is a cashmere or mesh shape material. Ultrasonic welding causes the materials to fuse, thereby forming a strong mechanical bond when the materials are fused together. Generally, ultrasonic welding softens the fibers in the mesh material, but does not melt the fibers. The ultrasonic welding technique ensures that the material comprising the gas permeable member 43 is securely fastened to the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44, thereby preventing any leakage of the sound absorbing material 19 while still allowing gas and sound absorbing material 19 interactions.

Another feature of using the breathable member 43 to hold the sound absorbing material 19 is that the acoustic sensor 34 can be repaired or replaced without disturbing or losing the sound absorbing material 19 . Securely attaching the breathable member 43 to the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 prevents the sound absorbing material 19 from escaping from its designated volume.

As shown in FIG. 5 , restriction 51 is the passage between the top portion of interior chamber wall 44 and the interior surface of printed circuit board 32 . The size of the restriction 51 is based on the thickness of the chamber liner 37 . Preferably, the thickness of the chamber liner 37 is 0.3 mm, but other thicknesses can be used to adjust the height of the restriction 51 .

In the embodiment shown in FIG. 5, the inner chamber wall 44 is formed from a solid material, preferably injection molded plastic or machined metal. In the loudspeaker embodiments shown in FIGS. 2 and 3 , the limited amount of surface area exposure of the sound absorbing material 19 can affect the performance of the sound absorbing material 19 . More specifically, since the airflow near the acoustic sensor is higher and the airflow at the wall at the far end of the rear volume is lower, the sound absorption is further away from the breathable material that facilitates gas exchange between the sound absorption material 19 and the rear volume. The material 19 does not experience the same air flow/gas velocity as the amount of sound absorbing material 19 close to the breathable member. This is due to the acoustic spring formed by the proximity of the rear volume and the sound absorbing material 19 which itself presents a certain amount of acoustic resistance to the gas pushed into the volume occupied by the sound absorbing material 19 . Furthermore, the gas exchange must flow through the restriction 51 between the top surface of the inner chamber wall 44 and the printed circuit board 32 . Restriction 51 may also present additional acoustic resistance if the acoustic resistance becomes too small.

The embodiment shown in FIG. 5 has only a PCB housing 31 instead of a case 30 . In this embodiment, the outer surface of the shroud 33 has been polished to present an aesthetically pleasing surface to the device purchaser, and thus the case 30 is exotic. The PCB housing 31 is present due to the electrical traces of the printed circuit board 32 .

Referring to FIG. 6, another embodiment of an acoustic sensor 34 disposed in a substantially sealed acoustic chamber having a sound-absorbing material 19 is depicted by A printed circuit board 32 and a shield 33 define an audio device. Most of the structural features of the embodiment of FIG. 6 are the same as those shown in FIG. 5 . In the embodiment shown in FIG. 6, the rear volume 35 is now composed of a mass of sound-absorbing material 19, an inner chamber wall 44 and within the volume bounded by the inner chamber wall 44, the chamber wall 41 and the gas permeable member 43. The air permeable member 43 comprising the sound absorbing material 19 occupies. The gas permeable member 43 is mechanically coupled or attached to the gas permeable member attachment point 42 on the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 . The breathable member 43 covers only those parts of the substantially sealed acoustic chamber (ie the rear volume 35 ) that will receive the sound absorbing material 19 . Other portions of the substantially sealed acoustic chamber, such as the portion in which the acoustic sensor 34 is located, will not be covered with the gas permeable member 43 . This allows the acoustic sensor 34 to be repaired and replaced without removing the gas permeable member 43 or disturbing the sound absorbing material 19 . Chamber liner 37 covers the portion of gas permeable member 43 that is mechanically coupled or attached to the top portion of chamber wall 41 .

In the shroud 33, a filling port 52 is shown. The filling port 52 is located in the bottom surface of the shroud 33 and provides a port between the portion of the volume 35 after filling with the sound absorbing material 19 and the outside of the shroud 33 . The loading port 52 is used to facilitate a particular technique for loading a specific type of sound absorbing material 19 into the rear volume. The filling port 52 is covered with a filling port seal 53 . The fill port seal 53 can be made from a foil or film material and can be self-adhesive. Any adhesive used in the vicinity of the sound absorbing material 19 should not adversely affect the performance of the sound absorbing material. The portion of the fill port 52 on the exterior of the shroud 33 preferably has a countersunk cavity or ring around its diameter that accommodates the fill port seal 53 and so the fill port seal 53 is flush with the outer surface of the shroud 33 . The size of the filling port is preferably at least 1.5 mm in diameter. Figure 6 shows two fill ports 52, one in the bottom surface of the shroud 33 and one in the chamber wall 41, in actual practice only one fill port 52 will be used. The location of the fill port 52 will depend on several factors such as the design of the shroud 33, the physical complexity of the volume area designated to contain the sound absorbing material 19, and the use of other components to fill the shroud 33 and insert the sound absorbing material 19. Manufacturing sequence of material 19. Unlike the embodiment shown in FIG. 5 , the embodiment in FIG. 6 includes a shroud 30 because shroud 33 may have parting lines, fastener ports, or aesthetically unpleasing finishing lines, and Shroud 33 may have a fill port 52 with a fill port seal 53 that needs to be covered.

Although FIGS. 5 and 6 only disclose a single rear volume 35 that will contain the sound absorbing material 19, it is contemplated that the rear volume 35 may include the entire substantially sealed enclosure defined by the chamber wall 41, shroud 33, and printed circuit board 32. Multiple chamber type regions within an acoustic chamber. It is further contemplated that each of these multiple chamber-type regions within the substantially sealed acoustic chamber will be provided by a gas-permeable member 43, preferably a one-piece ventilator configured to cover all chamber-type regions. The ventilation member 43 covers. One can also expect that depending on the overall design of the substantially sealed acoustic chamber defined by the chamber walls 41 , shroud 33 and printed circuit board 32 , multiple gas permeable members 43 may also be obtained. Additionally, the breathable member 43 covering one of the chambers containing the sound absorbing material 19 will not cover the volume in the acoustic chamber designated to be occupied by the acoustic sensor to facilitate repair or replacement of the acoustic sensor 34 .

The embodiment shown in FIG. 6 has a PCB housing 31 and a cover 30 . In this embodiment, even though the outer surface of the shroud 33 may be polished to present an aesthetically pleasing surface to the device purchaser, if the fill port 52 is positioned such that it penetrates the outer surface of the shroud 33, then There is a danger that the fill port seal 53 could be damaged or shifted out of place, the sound absorbing material 19 could be contaminated or could leak out of the rear volume. Thus, the housing 30 protects the fill port seal 53 and presents an aesthetically pleasing surface to the device purchaser. The PCB housing 31 is present due to the electrical traces of the printed circuit board 32 .

7 and 8 are views of the acoustic device 30 along the section line B-B. Referring to FIG. 7 , a wall opening 50 is provided in the interior chamber wall 44 . In the wall opening 50, an upper tab 46, side tabs 45 and lower tab 47 are provided. These tabs can be a long piece of solid material (as shown in Figure 7) or can be solid A series of tabs occupying essentially the same space as the elongate piece of solid material shown in FIG. 7 . Tabs 45, 46, 47 may be injection molded plastic, machined metal or other suitable material. A breathable insert 48 is seated in the wall opening 50 and held in position by the upper tab 46 , side tab 45 and lower tab 47 . The breathable insert 48 holds the sound absorbing material 19 in the chamber delimited by the chamber wall 41 , the inner chamber wall 44 and the breathable member 43 . The breathable insert 48 also expands the amount of exposed surface area of the sound absorbing material 19 . Thus, gas exchange takes place through the gas-permeable member 43 and the gas-permeable insert 48 , thereby improving the efficiency of the sound-absorbing material 19 . The breathable insert 48 can be made of the same materials as discussed above for the breathable member 43 and should have an acoustic resistance in MKS ray below the established threshold of the breathable member 43 .

Referring to Figure 8, another embodiment of a breathable insert 48 is shown. In this embodiment, a gas impermeable material is etched, stamped or otherwise machined to have a plurality of ventilation holes 49 . The vent holes 49 are sized to prevent the sound absorbing material 19 from passing through the vent holes while allowing gas exchange between the rear volume 35 and the sound absorbing material 19 to occur. Preferably, a polypropylene foil is used to create the breathable insert 48 . There are several reasons why polypropylene foil is an ideal material for the breathable insert 48 . Polypropylene foil does not become brittle as it ages, it is highly resistant to damaging ultraviolet light, and it resists damage from several types of chemicals. In general, polypropylene foils have a very low density of less than 1 gram/cm ³ and most foils are resistant to heat up to 140 degrees Celsius. Similar materials such as Kapton ^® may also be used. The vents 49 can be formed in various geometries and sizes as long as the vents 49 do not exceed a predetermined acoustic resistance threshold (preferably 260 MKS Rui).

Referring to FIG. 9 , the embodiment depicted herein is based on the inner chamber wall 44 embodiment shown in FIGS. 7 and 8 . The chamber liner 37 has been expanded to include a portion disposed between the top portion of the inner chamber wall 44 and the printed circuit board 32 . The additional partial closure of the chamber liner 37 along the The acoustic path of the printed circuit board 32 and routes the gas to the wall opening 50 . Although it appears that the gas permeable member 43 is now redundant, the sound absorbing material 19 is still required to be maintained in its bounded volume if the acoustic sensor 34 needs to be repaired or replaced.

Referring to FIGS. 10A-10B , there is disclosed a method for manufacturing an audio device having a speaker housing as an integral part of its housing. Preferably, the manufacturing method is carried out using computer-controlled manufacturing equipment with maximum efficiency, although manual assembly of the audio device is also envisaged. More specifically, the description of the manufacturing process assumes that an audio device undergoing assembly has been placed in an assembly carrier that moves the audio device along an assembly trajectory through various computer-controlled assembly stations. There may be other steps not described in this manufacturing method, such as interposing pads or making electrical connections. However, these types of steps are common to the manufacturing process and are not part of the present invention.

Referring to FIGS. 10A and 10B , one embodiment of a method of manufacturing an audio device having a speaker housing as an integral part of its housing will be described. In step S100 , the shield 33 is placed in an assembly carrier, and the dosing funnel is aligned with the rear volume 35 of the shield 33 . At this stage of the manufacturing process, the assembled audio device is positioned in an assembly carrier, and preferably the assembly carrier facilitates the alignment of the dosing funnel with the rear volume 35 in the shroud 33 . Alternatively, the dosing funnel can be manually aligned with the rear volume 35 in the shroud 33 . The purpose of the dosing funnel is to ensure that all measured doses of sound absorbing material enter the rear volume 35 in the shroud 33 . Preferably, a zeolitic material having a substantially spherical shape is used as sound absorbing material, and this form of zeolitic material is preferably used to fill a closed shroud 33 rear volume. At this stage of the manufacturing process of the acoustic device, it is assumed that no other components need to be installed in the housing 33 , except the acoustic sensor 34 . Although additional components can be added after placing the sound absorbing material 19 in the rear volume 35 , there is a risk of disturbing or contaminating one of the sound absorbing materials 19 .

In step S110, a predetermined amount of sound-absorbing material is loaded into the dispensing hopper. Based on The amount of sound-absorbing material to be loaded into the rear volume 35 of the shroud 33 is determined by the planner wishing to achieve the desired acoustic effect. For example, the amount of sound-absorbing material deposited into the rear volume 35 of the shroud 33 depends on the amount of resonance shift that the acoustic design engineer wishes to achieve. The measurement of the amount of sound-absorbing material 19 for insertion into the rear volume 35 of the shroud 33 is performed volumetrically or gravimetrically.

In step S120 , the carrier holding the acoustic device undergoing dosing is vibrated while the sound-absorbing material 19 from the dosing hopper is poured into the dosing funnel and subsequently into the rear volume 35 in the shroud 33 . If the sound absorbing material 19 is in powder, particulate or granular form, the shroud 33 is vibrated as the sound absorbing material 19 is poured into the rear volume 35 via the dispensing funnel to allow relatively quick and even dispersion of the material.

In step S130, the vibration of the carrier holding the shield 33 is stopped for a predetermined time. The cessation of vibration allows the sound absorbing material 19 now located inside the rear volume 35 in the shroud 33 to settle. The settlement of the sound-absorbing material 19 is important for measuring whether the rear volume has been properly filled.

In step S140, the vibration of the carrier holding the shield 33 is restarted for a predetermined time. Repeated vibrations of the shield 33 both during and after the dosing step are necessary to ensure that the sound-absorbing material 19 inside the rear volume 35 of the shield 33 has reached all cavities in the rear volume 35 . As previously indicated, the settling of the sound absorbing material 19 is important for measuring whether the rear volume 35 has been properly filled. When the second vibration of the shield 33 is over, the dosing funnel is removed.

In step S150 , the level of the sound-absorbing material 19 inside the volume 35 behind the shield 33 is measured. The measurement can be done visually. Preferably, one of the lasers that illuminate the sound-absorbing material 19 is used to measure the level.

In step S160 , the measurement level of the sound-absorbing material 19 in the rear volume 35 is compared with the design requirements of the manufactured special shield 33 . If the level of the sound-absorbing material 19 is lower than the design specification, then in step S170, the shield 33 is rejected. If the level of the sound-absorbing material 19 is within the design specifications, then The manufacturing procedure moves to step S180.

In step S180, the gas permeable member 43 is aligned with the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 and the gas permeable member 43 is attached to the top portion of the chamber wall 41 and the inner chamber wall 44 top part. The breathable member 43 holds the sound absorbing material 19 in a designated volume within the rear volume 35 . As shown, the gas permeable member 43 can be coupled to the top portion of the chamber wall 41 and the inner chamber wall 44 by gluing, crimping, stamping, embossing, heat sealing, or preferably by ultrasonic welding Air permeable member attachment points 42 on the top portion. If an adhesive is used, the adhesive preferably does not have any venting properties that could affect the performance of the sound-absorbing material 19 in the rear volume 35 .

In step S190 , the chamber liner 37 is aligned with the chamber wall 41 in the shroud 33 . The chamber liner 37 is aligned with the chamber wall 41 in the shroud 33 . As shown in FIGS. 5 , 6 and 9 , the chamber liner is supported on the top portion of the chamber wall 41 and is positioned at a distance from the chamber wall 41 now attached to the gas permeable member attachment point 42. Above the ventilation member 43 . At this point in the assembly process, the acoustic sensor 34 can be placed in place in the shroud 33 . Alternatively, the acoustic sensor 34 may be mechanically attached to the printed circuit board 32 and then manipulated into position when the printed circuit board 32 is bonded to the shroud 33 .

In step S200, the printed circuit board 32 is aligned with the shroud 33, and the two components are fitted together to create a finished acoustic device. Mechanical attachment of the printed circuit board 32 and shroud 33 is achieved using fasteners, suitable adhesives, and/or interlocking tabs molded into the respective components. If an adhesive is used, the adhesive preferably does not have any venting properties that could affect the sound-absorbing material 19 in the rear volume 35 . The attachment of the printed circuit board 32 and the shroud 33 creates a sealed acoustic chamber within the housing housing of the acoustic sensor 34 .

In step S210, the complete acoustic device is removed from the assembly carrier, and the complete acoustic device is subjected to Test to determine whether it meets the design requirements of the acoustic device.

Referring to FIGS. 11A-11B , another method for manufacturing an audio device having a speaker housing as an integral part of its housing is disclosed. Preferably, the manufacturing method is carried out using computer-controlled manufacturing equipment with maximum efficiency, although manual assembly of the audio device is also envisaged. More specifically, the description of the manufacturing process assumes that an audio device undergoing assembly has been placed in an assembly carrier that moves the audio device along an assembly trajectory through various computer-controlled assembly stations. There may be other steps not described in this manufacturing method, such as inserting pads or making electrical connections. However, these types of steps are common to the manufacturing process and are not part of the present invention.

Referring to FIGS. 11A and 11B , another embodiment of a method of manufacturing an audio device having a speaker housing as an integral part of its housing will be described. In step S300, the shield 33 is placed in an assembly carrier. During this stage of the manufacturing process, the assembled audio device is positioned in a mounting carrier, and in some embodiments of the manufacturing process, it will be necessary to align audio devices assembled at different angles during the manufacturing process.

In step S310, the gas permeable member 43 is aligned with the top portion of the chamber wall 41 and the top portion of the inner chamber wall 44 and the gas permeable member 43 is attached to the top portion of the chamber wall 41 and the inner chamber wall 44 top part. The breathable member 43 holds the sound absorbing material 19 in a designated volume within the rear volume 35 . As shown, the gas permeable member 43 can be coupled to the top portion of the chamber wall 41 and the inner chamber wall 44 by gluing, crimping, stamping, embossing, heat sealing, or preferably by ultrasonic welding Air permeable member attachment points 42 on the top portion. If an adhesive is used, the adhesive preferably does not have any venting properties that could affect the performance of the sound-absorbing material 19 in the rear volume 35 .

In step S320 , the shield in the assembly carrier is realigned to expose the filling port 52 so that the dosing funnel can be aligned with the filling port 52 . Preferably, the assembly carrier facilitates the dispensing funnel and filling port 52 which will allow the sound absorbing material 19 to enter the rear volume 35 in the shroud 33 . Alternatively, the dosing funnel can be manually aligned with the filling port 52 in the shroud 33 . The purpose of the dosing funnel is to ensure that all measured doses of the sound absorbing material 19 enter the rear volume 35 in the shroud 33 . Preferably, a zeolitic material having a substantially spherical shape is used as sound absorbing material 19 and this form of zeolitic material is preferably used to fill a closed shroud 33 rear volume. At this stage of the manufacturing process of the acoustic device, it is assumed that no other components need to be installed in the housing 33 , except the acoustic sensor 34 . Although additional components can be added after placing the sound absorbing material 19 in the rear volume 35 , there is a risk of disturbing or contaminating one of the sound absorbing materials 19 .

In step S330, a predetermined amount of sound-absorbing material is loaded into the dispensing hopper. The amount of sound absorbing material to be loaded into the rear volume 35 of the shroud 33 is determined based on the desired acoustic effect that the designer wishes to achieve. For example, the amount of sound-absorbing material deposited into the rear volume 35 of the shroud 33 depends on the amount of resonance shift that the acoustic design engineer wishes to achieve. The measurement of the amount of sound-absorbing material 19 for insertion into the rear volume 35 of the shroud 33 is performed volumetrically or gravimetrically.

In step S340 , the carrier holding the acoustic device undergoing dosing is vibrated while the sound-absorbing material 19 from the dosing tank is poured into the dosing funnel and then into the rear volume 35 in the shield 33 through the filling port 52 . If the sound absorbing material 19 is in powder, particulate or granular form, vibrating the shroud 33 and the filling port 52 allows the material to be dispersed relatively quickly and evenly as the sound absorbing material 19 is poured into the rear volume 35 via the dosing funnel.

In step S350, the vibration of the carrier holding the shield 33 is stopped for a predetermined time. The cessation of vibration allows the sound absorbing material 19 now located inside the rear volume 35 in the shroud 33 to settle. The settlement of the sound-absorbing material 19 is important for measuring whether the rear volume has been properly filled.

In step S360, the vibration of the carrier holding the shield 33 is resumed for a predetermined time. Repeated vibrations of the shield 33 both during the dosing step and after the dosing step ensure that the shield 33 is The sound-absorbing material 19 inside the volume 35 has reached all the cavities in the rear volume 35 . As previously indicated, the settling of the sound absorbing material 19 is important for measuring whether the rear volume 35 has been properly filled. When the second vibration of the shield 33 is over, the dosing funnel is removed.

In step S370, the level of the sound-absorbing material 19 inside the volume 35 behind the shield 33 is measured. The measurement can be done visually. Preferably, one of the lasers that illuminate the sound-absorbing material 19 is used to measure the level.

In step S380, the measured level of the sound-absorbing material 19 in the rear volume 35 is compared with the design requirements of the manufactured special shield 33. If the level of the sound-absorbing material 19 is lower than the design specification, then in step S390, the shield 33 is rejected. If the level of the sound-absorbing material 19 is within the design specifications, the manufacturing process moves to step S400.

In step S400 , a filling port seal 53 is used to seal the filling port 52 . The fill port seal 53 may be an insert seal that fits to the fill port 52 or a foil or film that is glued or attached to the fill port 52 . The foil or film may be self-adhesive.

In step S410 , the chamber liner 37 is aligned with the chamber wall 41 in the shroud 33 . As shown in FIGS. 5 , 6 and 9 , the chamber liner is supported on the top portion of the chamber wall 41 and is positioned at a distance from the chamber wall 41 now attached to the gas permeable member attachment point 42. Above the ventilation member 43 . At this point in the assembly process, the acoustic sensor 34 can be placed in place in the shroud 33 . Alternatively, the acoustic sensor 34 may be mechanically attached to the printed circuit board 32 and then manipulated into position when the printed circuit board 32 is bonded to the shroud 33 . Next, the printed circuit board 32 is aligned with the shroud 33 and the two housings are mated together to create the finished acoustic device. Mechanical attachment of the printed circuit board 32 and shroud 33 is achieved using fasteners, suitable adhesives, and/or interlocking tabs molded into the components. If an adhesive is used, the adhesive preferably does not have any venting properties that could affect the sound-absorbing material 19 in the rear volume 35 . Of the printed circuit board 32 and the shield 33 Attachment within the housing shell of the acoustic sensor 34 creates a sealed acoustic chamber.

In step S420, the complete acoustic device is removed from the assembly carrier, and the complete acoustic device is tested to determine whether it meets the design requirements of the acoustic device.

The foregoing description of the preferred embodiment of the invention has been presented for purposes of illustration and description. The foregoing description is not intended to be exhaustive or to limit the invention to the precise forms disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiment was chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments with various modifications as are suited to the particular use contemplated.

It should be noted that any entity disclosed herein (eg, speaker device, etc.) is not limited to one dedicated entity as described in some embodiments. Rather, the disclosed invention can be implemented in various ways and with arbitrary granularity at the device level while still providing the desired functionality. It should be noted that the term "comprising" does not exclude other elements or steps and "a" does not exclude a plurality. Furthermore, elements described in association with different embodiments may be combined. It should also be noted that the element symbols in the patent application should not be regarded as limiting the scope of the patent application. While particular embodiments have been shown and described, several modifications can be made without departing significantly from the spirit of the invention and the scope of protection is limited only to that of the appended claims. Additionally, abbreviations are used only to enhance the readability of the specification and claims. It should be noted that these abbreviations are not intended to reduce the generality of the terms used and that the abbreviations should not be construed to limit the scope of the patent application to the embodiments described therein.

30‧‧‧Case/acoustic device

31‧‧‧Printed circuit board (PCB) housing

32‧‧‧Printed circuit board

33‧‧‧Shield

34‧‧‧Acoustic sensor

35‧‧‧Rear volume

36‧‧‧Sensor contacts

37‧‧‧Chamber liner

38‧‧‧Sound Port Liner

39‧‧‧sound port

40‧‧‧Anterior chamber volume

41‧‧‧chamber wall

Claims (16)

A housing for a mobile device comprising: a printed circuit substrate; a shield configured to cooperate with the printed circuit substrate to create the housing for the mobile device, wherein the shield comprises: a cavity a chamber wall defining a substantially sealed acoustic chamber when engaged with an inner surface of the printed circuit substrate; an acoustic sensor disposed within the acoustic chamber; an acoustic port acoustically coupled to the acoustic chamber a sensor; an inner chamber wall disposed within the acoustic chamber and defining a rear volume; a mass of sound-absorbing material disposed within the rear volume; and an air permeable member mechanically coupled to the a top portion of the chamber wall and a top portion of the inner chamber wall, wherein the breathable member retains the sound absorbing material within a defined volume within the acoustic chamber; and a chamber liner inserted into Between the printed circuit substrate and the top portion of the chamber wall, wherein a thickness of the chamber liner determines the size of a restriction through which gas exchange is facilitated; the inner chamber wall includes an opening organized state to promote gas exchange of the sound-absorbing material, wherein the opening includes the gas-permeable portion having substantially the same as or different from the top portion mechanically coupled to the chamber wall and the top portion of the inner chamber wall One of the materials of sound resistance of components. The casing of a mobile device according to claim 1, wherein the breathable member has low acoustic resistance and includes one or more of a cashmere material or a mesh material. The casing of the mobile device according to claim 2, wherein the pore size of the material of the breathable member is adjusted to be smaller than the size of granules of the sound-absorbing material. The housing of a mobile device according to claim 1, wherein the breathable member is mechanically attached to the top portion of the chamber wall by gluing, crimping, stamping, embossing, heat sealing or ultrasonic welding and the top portion of the inner chamber wall. The housing of the mobile device according to claim 1, further comprising an acoustic port liner interposed between the acoustic sensor and the sound port disposed in the shield, wherein the sound port liner extends from the rear The placement volume seals a preposition volume. The mobile device housing of claim 1, wherein the rear volume portion of the acoustic chamber is partially filled with substantially spherical zeolite-based sound absorbing particles having a minimum diameter of at least 300 microns. A housing for a mobile device comprising: a first housing element including a printed circuit board having an acoustic sensor electrically and mechanically coupled to the printed circuit board; a second A housing element mechanically coupled to the first housing element to form the housing of the mobile device, wherein the second housing element comprises: A continuous vertical element defining a substantially sealed acoustic chamber when engaged with the printed circuit board of the first housing element; an acoustic port disposed in a sensor space acoustically coupled to the acoustic sensor ; an internal vertical element disposed in the acoustic chamber and delimiting a rear volume with the continuous vertical element; a plurality of sound-absorbing particles disposed within the rear volume; a sound-transmitting material mechanically coupled to a top portion of the continuous vertical element and a top portion of the inner vertical element, wherein the sound-transmissive material retains the sound-absorbing particles in a defined space within the acoustic chamber; and a chamber liner, via interposed between the plate and the top portion of the continuous vertical element, wherein a thickness of the chamber liner determines the size of a restriction through which gas exchange is facilitated; wherein the acoustic sensor is between the first housing element and the The second housing element occupies the sensor space when coupled together; the inner vertical element includes an opening configured to facilitate gas exchange of the sound-absorbing particles, wherein the opening includes a material having substantially the same or different mechanical properties. A material that is coupled to the acoustic resistance of the sound-transmissive material of the top portion of the continuous vertical element and the top portion of the inner vertical element. The mobile device housing of claim 7, wherein the rear volume portion of the acoustic chamber is partially filled with zeolite-based sound absorbing particles having substantially spherical particles having a minimum diameter of at least 200 microns. The mobile device housing of claim 7, wherein the rear volume portion of the acoustic chamber is partially filled with zeolite-based sound absorbing particles having substantially spherical particles having a minimum diameter of at least 350 microns. The housing of a mobile device as claimed in claim 7, wherein the sound-transmitting material is mechanically attached to the top portion of the continuous vertical element and the top portion of the inner vertical element by gluing or ultrasonic welding. The housing of a mobile device according to claim 7, wherein when the opening comprises a material having substantially the same acoustic resistance as the sound-transmitting material, the material disposed in the opening of the inner vertical element comprises a One or more of cashmere material or a mesh material. The housing of a mobile device as claimed in claim 7, wherein when the opening comprises a material having an acoustic resistance different from that of the sound-transmitting material, the material disposed in the opening of the inner vertical member comprises a gas permeable A material comprising a plurality of apertures sized to retain the sound absorbing particles in a defined area in the rear volume. The housing of the mobile device as claimed in claim 7, further comprising an acoustic port liner interposed between the acoustic sensor and the sound port disposed in the second housing element, wherein the sound port liner is passed through configured to seal the sound port from the rear volume when the first housing element is engaged with the second housing element. A housing for a mobile device comprising: a first housing element including a printed circuit board having an acoustic sensor electrically and mechanically coupled to the printed circuit board; a second A casing element mechanically coupled to the first casing element to form the casing of the mobile device, wherein the second casing element includes: a continuous vertical element in contact with the printed circuit board of the first casing element when engaged, defines a substantially sealed acoustic chamber; an acoustic port disposed in a sensor space acoustically coupled to the acoustic sensor; an internal vertical element disposed in the acoustic chamber, and A rear volume is defined with the continuous vertical element, wherein the inner vertical element further comprises: an opening configured for gas exchange; and a low acoustic resistance insert completely covering the opening; a mass of sound-absorbing particles which disposed within the rear volume; and an acoustically transparent material mechanically coupled to a top portion of the continuous vertical element and a top portion of the inner vertical element, wherein the acoustically transparent material retains the sound absorbing particles in in a defined space within the acoustic chamber; and a chamber liner interposed between the printed circuit board and the top portion of the continuous vertical member; wherein the acoustic sensor is between the first housing member and the The second housing element occupies the sensor volume when coupled together; the low acoustic resistance insert has an acoustic resistance substantially the same as or different from the acoustically transparent material. The casing of a mobile device according to claim 14, wherein the low-sound-resistance insert and the sound-transmitting material in the inner vertical element each comprise one or more of a cashmere material or a mesh material. The housing of a mobile device as claimed in claim 14, wherein the rear volume portion of the acoustic chamber is partially filled with a zeolite having substantially spherical particles having a minimum diameter of at least 300 microns and a maximum diameter of 900 microns Basic sound-absorbing particles.

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