HK1171601B - Accessory controller for electronic devices - Google Patents

Description

Accessory controller for an electronic device

This application claims priority to U.S. patent application No.12/203,866 filed on 3/9/2008, which is incorporated herein by reference in its entirety.

Technical Field

The present invention relates to electronic devices, and more particularly, to accessories for electronic devices, such as accessories with button controls.

Background

Electronic devices, such as computers, media players, and cellular telephones, often contain audio jacks. An accessory (such as a headset) has a mating plug. A user wishing to use a headset with an electronic device may connect the headset to the electronic device by plugging the headset plug into a matching audio jack on the electronic device. Electronic devices, such as notebook computers and media players, typically use miniature-sized (3.5mm) microphone jacks and plugs because audio connectors such as these are relatively compact.

Stereo audio connectors typically have three contacts. The outermost end of the audio plug is commonly referred to as the tip. The innermost portion of the plug is commonly referred to as the sleeve. There is annular contact between the tip and the sleeve. When such terms are used, stereo audio connectors such as these are sometimes referred to as tip-ring-sleeve (TRS) connectors. The sleeve may act as a ground. Tip contacts may be combined with the sleeve for processing the left vocal tract and ring contacts may be combined with the sleeve for processing the right vocal tract.

In devices such as cellular telephones, it is often necessary to communicate a microphone signal from a headset to the cellular telephone. In arrangements where it is desired to process both stereo audio signals and microphone signals, the audio connector typically contains additional ring terminals. Audio connectors such as these have a tip, two rings, and a sleeve, and are therefore sometimes referred to as four-contact connectors or tip-ring-sleeve (TRRS) connectors. When a four-contact connector is used, the sleeve may act as a ground. The tip contact and the outermost ring contact may be used in conjunction with ground to convey audio for the left earphone speaker channel and the right earphone speaker channel. The innermost ring contact may be used in conjunction with ground to transmit the microphone signal.

Some users may wish to operate their cellular phones or other electronic devices remotely. To accommodate this need, some modern headsets that may use a microphone feature a button. When the user presses the button, the microphone line is shorted to ground. Monitoring circuitry within the cellular telephone to which the headset is connected may detect the momentary grounding of the microphone line and may take appropriate action. Button presses are typically used to answer an incoming call or to skip tracks during playback of a media file.

Conventional button arrangements such as these provide limited functionality.

Accordingly, it would be desirable to provide headsets and other accessories with improved button placement.

Disclosure of Invention

An accessory, such as a headset, is provided that includes a button controller assembly. The earphones may each include a speaker, a button controller assembly, an audio plug, and a cord connecting the speaker, the button controller assembly, and the audio plug. The button controller assemblies may each be formed from a housing having a first housing portion and a second housing portion.

The first housing portion and the second housing portion of each button controller may have an associated plastic engagement feature. For example, the first housing part may have a snap. The plastic frame may be ultrasonically welded to the second housing portion. When assembled to form a completed unit, the catch on the first housing may engage a rail on the frame. Sufficient clearance may be provided between the engagement structures to allow the first and second housing portions to float relative to one another. The first housing portion and the second housing portion may move unimpeded by the engagement structure up to a given amount of travel. When a given amount of travel is reached, the first housing structure may still be curved. This allows the first housing structure to flex inwardly toward the second housing structure and its associated frame when the user squeezes the first and second housing structures together in order to actuate a desired button within the button controller assembly.

The push button function may be provided by a dome switch mounted within the push button controller assembly. The housing portions may be formed using a two-shot molding process so that each housing portion may include two different types of plastic. The plastic may have different colors, different textures, different rigidity, or other suitable properties. By using different colors for different portions of the housing, certain portions of the housing may be hidden from view and the button area may be made conspicuous.

Resilient members within the button controller assembly may be used to help bias the housing portions apart. The resilient members may be mounted on opposite ends of the plastic frame. The wires for the headset may be engaged through holes in the plastic frame and the crimp metal plate.

Integrated circuits, microphones and other circuitry may be mounted in the button controller assembly. The circuit may be used to detect a button activation event when a user squeezes the various portions of the housing together. When a button selection is detected, the circuitry may transmit a corresponding signal to the electronic device through the wires of the headset.

An air gap may be formed at the interface between the plastic portions in the button controller assembly. For example, a narrow gap may be formed where the first housing portion and the second housing portion meet. It is also possible to form a slit-like air gap at the intersection between the housing part and the plastic frame. Due to the presence of these air gaps, sound can reach the microphone within the interior of the button controller assembly without using a dedicated microphone port.

To assist the user in determining whether the button controller assembly contains a microphone, the exterior surface of the button controller assembly housing may be provided with a visual indicator that the button controller assembly contains a microphone. As an example, the visual indicator may be provided in the form of a non-operative microphone port. The non-operative microphone port may have a structure similar to a conventional microphone port such as a metal element with a hole. A non-operative port may be formed by omitting a hole through the housing to block sound from entering the interior of the housing through the port.

Other features of the present invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments.

Drawings

FIG. 1 is a schematic diagram of an illustrative accessory in communication with an electronic device in a system in accordance with an embodiment of the present invention;

FIG. 2 is a perspective view of an illustrative accessory (such as a headset) that may be provided with user-selectable buttons in accordance with an embodiment of the present invention;

FIG. 3 is a perspective view of an illustrative accessory (such as a headset) connected to an adapter accessory having user-selectable buttons in accordance with an embodiment of the present invention;

FIG. 4 is a perspective view showing the upper surface of an illustrative button controller assembly for controlling the operation of an electronic device in accordance with an embodiment of the present invention;

FIG. 5 is a perspective view showing the lower surface of an illustrative button controller assembly for controlling the operation of an electronic device in accordance with an embodiment of the present invention;

FIG. 6 is an exploded perspective view of an illustrative button controller assembly for controlling the operation of an electronic device in accordance with an embodiment of the present invention; and

FIG. 7 is a cross-sectional side view of an illustrative button controller assembly for controlling the operation of an electronic device in accordance with an embodiment of the present invention.

Detailed Description

The present invention relates generally to electronic devices and accessories for electronic devices.

A typical accessory may be, for example, a headset that includes a button controller assembly. The button controller assembly may include buttons for controlling operation of the electronic device.

FIG. 1 shows an illustrative system by which an accessory can be used with an electronic device. As shown in FIG. 1, electronic device 12 may be coupled to accessory 14 through a communication path 16.

Electronic device 12 may be a device such as a desktop computer or a portable electronic device such as a laptop computer or what is sometimes referred to as an ultra-portable small portable computer. Electronic device 12 may also be a somewhat smaller portable electronic device such as a wristwatch device, pendant device, or other wearable or miniature device. If desired, the electronic device 12 may include wireless capabilities.

The electronic device 12 may be a handheld electronic device such as a cellular telephone, a media player with wireless communication capability, a handheld computer (i.e., personal digital assistant), a remote controller, a Global Positioning System (GPS) device, a handheld gaming device, or the like. The electronic device 12 may also be a hybrid device combining the functionality of a variety of conventional devices. Examples of hybrid electronic devices include cellular telephones that include media player functionality, gaming machines that include wireless communication capabilities, cellular telephones that include gaming and email functionality, and portable devices that receive email, support mobile telephone calls, have media player functionality, and support Web browsing. The electronic device 12 may also be a device such as a television or audio receiver, or other suitable electronic device. The electronic device 12 may be provided in the form of a stand-alone device (e.g., a handheld device carried in a user's pocket), or the electronic device 12 may be provided as an embedded system. Examples of systems in which electronic device 12 may be embedded include automobiles, boats, airplanes, houses, security systems, media distribution systems for commercial and home applications, display devices (e.g., computer monitors and televisions), and so forth. These are merely illustrative examples.

Path 16 may include wires for connecting accessory 14 to electronic device 12. For example, 4 wires, or more wires or less wires may be used in path 16.

Headphones typically include a pair of speakers that a user can use to play audio from an electronic device. The accessory 14 may be a headset having a button controller assembly with one or more buttons. When a user actuates a button on the button controller assembly, circuitry within the button controller assembly may collect button actuation data and may transmit the button actuation data to the electronic device 12 via path 16.

As an example, when a user presses a button on a button controller assembly within the accessory, a corresponding signal is provided to the electronic device to instruct the electronic device to take an appropriate action. Because the buttons are located on the headset rather than the electronic device, the user can place the electronic device in a remote location, such as on a table or in a pocket, while using the conveniently located headset button control device.

If the electronic device is a media player and is in the process of playing a song or other media file for the user, the electronic device may be instructed to pause the currently playing media file when the user presses a button. As another example, if the electronic device is a cellular telephone with media player capabilities and the user is listening to a song when an incoming telephone call is received, actuation of the button by the user may instruct the electronic device to answer the incoming telephone call. For example, actions such as these may be taken when a media player or cellular telephone is placed within a pocket of a user.

The accessory with the button controller assembly may be provided in the form of an adapter, if desired. As shown in FIG. 1, for example, accessory 14 may be an adapter that provides a user with button control functionality. Conventional stereo headphones or other suitable accessories 130 (e.g., accessories without button functionality, or accessories with reduced button functionality relative to accessory 14) may then be inserted into accessory 14 using communication path 17. The path 17 may be, for example, a three-wire or four-wire path (as examples).

For clarity, aspects of the present invention are sometimes described in the context of an accessory, such as a headset. However, this is merely illustrative. The accessories within system 10 may take the form of any suitable device that connects to electronic equipment 12. Examples of accessories include audio devices, such as audio devices that contain or operate with one or more speakers. The speakers within accessory 14 may be provided as earpieces or earphones, or the speakers within accessory 14 may be provided as a set of independently powered or unpowered speakers (e.g., a desk speaker). If desired, the accessory may include an audio visual device such as a receiver, amplifier, television or other display, or the like. A device such as this may receive audio signals from device 12 using a path such as path 16. For example, the audio signal may be provided in the form of an analog audio signal that need only be amplified and passed to a speaker for listening by a user of the device 12. An optional microphone in the accessory may communicate the microphone signal to the device 12. User input may be collected from device 12 using buttons or other user interface devices. The use of these and other suitable accessories in system 10 is merely illustrative. In general, any suitable accessory may be used in the system 10, if desired.

Accessories, such as headphones, are typically connected to an electronic device using an audio plug (plug audio connector) and a mating audio jack (jack audio connector). Such audio connectors may be provided in various forms. Most commonly, audio connectors take the form of 3.5mm (1/8 ") miniature plugs and jacks. Other sizes, such as 2.5mm subminiature connectors and 1/4 inch connectors, are also sometimes used. In the context of accessories such as headphones, these audio connectors and their associated cables are typically used to convey analog signals, such as audio signals for speakers and microphone signals. The audio connector may include an optical communication structure to support optical signal transmission, if desired.

As shown in FIG. 1, path 16 may be used to connect electronic device 12 and accessory 14 at connection points 16A and 16B. In a typical arrangement, path 16 includes one or more audio connectors, such as a 3.5mm plug and socket, or other suitably sized audio connector, at connection points such as points 16A and 16B. The conductors in path 16 may be used to pass signals on path 16. In general, any suitable number of wires may be present in path 16. For example, there may be two, three, four, five or more than five individual wires. These conductors may be part of one or more cables. The cable may include a solid core, stranded wire, shielded wire, single ground, multiple ground, twisted pair, or any other suitable cable configuration.

In the usual case, the device 12 may be, for example, a handheld device having media player and cellular telephone capabilities. Accessory 14 may be a headset having a microphone and a user input interface, such as a button-based interface for gathering user input. Path 16 may be a four conductor audio cable connected to devices 12 and 14 using, for example, a 3.5mm audio jack and plug.

Audio connectors for interconnecting device 12 and accessories (such as accessory 14) may include audio plugs that mate with corresponding audio jacks. These connectors may be used at any suitable location or locations within pathway 16, such as locations 16A or 16B. For example, an audio jack may be formed in the housing of device 12 at location 16A, and a mating plug on the end of cable 16 may be inserted into the jack at location 16A.

An example of a suitable audio plug is a four-contact plug. The four-contact plug may have four conductive regions arranged along the cylindrical post that mate with four corresponding conductive regions within the four-contact receptacle. The area at the tip of the plug is sometimes referred to as the tip contact. The region at the opposite end of the plug is sometimes referred to as the sleeve contact. The two intervening regions are sometimes referred to as first and second ring contacts. Using this terminology, a four-contact plug is sometimes referred to as a tip-ring-sleeve (TRRS) plug, and its mating socket is sometimes referred to as a TRRS socket. Sockets and plugs having different numbers of contacts (e.g., less than four or more than four) may also be used. In general, the audio connector in path 16 may be formed by any suitable plug (plug connector) and any suitable jack (receptacle connector) or any other suitable mating connector. Additionally, the connectors may be placed at any suitable location along path 16. In a typical arrangement, a jack is mounted within device 12 and connects a mating plug to accessory 14 via a cable attached at location 16B. This is however merely illustrative. The socket may be mounted within accessory 14 at location 16B and the plug may be connected to device 12 at location 16A via a cable. As another example, a socket may be used in both device 12 and accessory 14, and a two-headed cable (i.e., a cable having a plug connector at either end) may be used to connect device 12 and accessory 14. Adapters may also be used. For example, an adapter may be plugged into device 12 (e.g., using a digital port). An adapter, which may be considered a type of accessory 14, may be provided with a socket into which a plug of a headset or other device may be inserted to complete the path 16. In this type of scenario, the adapter may contain circuitry to perform functions that would otherwise be performed by the buttons and circuitry on the headset.

Fig. 2 shows an illustrative attachment. The accessory 14 of fig. 2 is an earphone with a microphone. The speaker 92 may be provided in the form of, for example, over-the-ear speakers, ear plugs, or ear buds. A two-conductor wire, such as wire 94, may be connected to speaker 92. The button controller assembly 100 may include a microphone. In some applications, a microphone may not be needed, and may be omitted from accessory 14 to reduce costs. In other applications, such as cellular phone applications, recording applications, etc., a microphone may be used to collect audio signals (e.g., sounds from a user's voice).

In the example of FIG. 2, the button controller assembly 100 includes three buttons. More buttons, fewer buttons, or no button user input devices may be included in accessory 14, if desired. In addition, these devices do not have to be mounted to the same unit as the microphone. The arrangement of fig. 2 is merely illustrative.

In the illustrative three-button arrangement, when it is desired to advance through a track being played back by a music application, the user may press a first of the three buttons, such as button 102, or the button may be used to increase the volume setting. A second of the three buttons, such as button 104, may be pressed when it is desired to stop music playback, answer an incoming cellular telephone call made to device 12 from a remote caller, or when it is desired to make a menu selection. A third of the three buttons, such as button 106, may be selected when it is desired to move to the previous track or when it is desired to lower the volume setting. Multi-click, click and hold operations, and other user input modes may also be used. The examples of high/low volume, forward/reverse trajectory, and "answer call" described in connection with fig. 2 are merely illustrative. In general, the actions taken in response to a given command may be adjusted by the system designer by modifying the software within device 12.

As shown in fig. 2, a cable, such as cable 108, may be integrated within accessory 14. At its distal end, a connector such as an audio connector 110 may be provided to the cable 108. In the example of fig. 2, accessory 14 has two speakers 92 and a microphone. The connector 110 may thus be a four-contact type connector (i.e., a TRRS plug). In accessories that omit one of the microphone and speaker, signals may be transmitted on fewer wires (e.g., using a three-contact connector). Connectors with additional contacts (e.g., to transfer auxiliary power, to transfer control signals, etc.) may also be used if desired. Audio connectors with optical cores may be used to pass optical signals other than electrical signals.

The attachment 14 may be provided with circuitry that assists in the transfer of signals from the button controller unit 100 to the device 12 via path 16. In general, signals may be communicated using any suitable communication format (e.g., analog, digital, hybrid arrangements based on both analog and digital formats, optical, electrical, etc.). These signals may be conveyed on any suitable conductors in path 16. To avoid having to provide additional wires in path 16 and to ensure that accessory 14 is as compatible as possible with standard audio jacks, it may be advantageous to pass signals over existing wiring (e.g., speaker, microphone, and ground). In particular, it may be advantageous to use microphone lines and ground lines (e.g., lines connected to contacts such as ring contact 52 and sleeve S within audio plug 110) to communicate signals such as user input signals and control signals between accessory 14 and electronic device 12.

With one suitable communication arrangement, buttons (such as buttons 102, 104, and 106) may be encoded with different impedances. When a user presses a given button, device 12 may measure the impedance of user input interface 100 via the microphone line and ground, and may thus determine which button was pressed. With another suitable arrangement, a button may be provided that when pressed shorts the microphone and ground in the cable 108. The electronic device 12 may detect this type of transient short circuit. With another suitable arrangement, a button press in the interface 100 may be converted into an ultrasonic tone that is transmitted through the microphone line and ground. The electronic device 12 can detect and process the ultrasonic tone. These are merely illustrative examples. Any suitable communication circuitry may be provided in the button controller assembly 100 to support communication between the accessory 14 and the device 12, if desired.

Additionally, electronic device 12 may support communication using two or more communication arrangements. For example, different approaches may be used to support legacy hardware and new hardware, to support different types of software applications, to support reduced power operation in certain device operating modes, and so forth.

In the example of FIG. 2, the button controller assembly 100 is located between the path portion 124 and the path portion 120. In this type of arrangement, path 108 may contain four wires (for left audio, right audio, microphone, and ground), while path portion 120 may contain two wires (for ground and right audio). Path portion 122 may contain two wires (for ground and left audio). This is merely an illustrative example. The button controller assembly 100 may be located on any suitable portion of the wires within the accessory 14, if desired. For example, the button controller assembly 100 may be located at an intermediate position along the path segment 108, rather than between the path segments 120 and 124 as shown in the example of FIG. 2.

Fig. 3 shows how accessory 14 may be provided in the form of an adapter that allows button functionality to be added to accessory 130, which does not necessarily include button functionality. As shown in fig. 3, the headset 130 may have an audio plug 116 that plugs into a mating audio jack 114 on the adapter accessory 14. The plug 116 and jack 114 may be audio connectors, such as tip-ring-sleeve (TRS) or TRRS connectors. The headset 130 may include a speaker 92, a conductive path 94, and an optional component 132 (e.g., for an older button or microphone).

The adapter accessory 14 may include an electrical path that passes audio signals from the device 12 to a speaker in the headset 130 and microphone signals from a microphone to the device 12 (e.g., the adapter 14 or a microphone in the component 132). The adapter 14 may also include circuitry to handle communications with the device 12 via path 16 that would otherwise be included within the button controller component of the headset accessory. Thus, the headset 130 in the arrangement of fig. 3 need not include such circuitry. In the example of fig. 3, headset 130 includes speaker 92 and may include microphone 132, but need not include any buttons, as buttons 102, 104, and 106 are included on accessory 14. Accessory 14 may have a cable, such as cable 108, with an audio connector 118 for insertion into a mating audio jack on device 12. An adapter type arrangement such as that of fig. 3 allows a user to add button functionality to an accessory, such as a headset that does not include buttons. This would be particularly advantageous if the user had several different types of button-less headsets, but wanted to use buttons such as buttons 102, 104 and 106 to remotely control electronic device 12. The adapter accessory of fig. 3, such as accessory 14, may be provided with a microphone if desired.

Any suitable form factor may be used for the button controller assembly 100. Fig. 4 shows an illustrative example. As shown in FIG. 4, the button controller assembly 100 may be formed using an elongated housing structure. The housing may have multiple portions. For example, a housing for the button controller assembly 100 may have an upper portion such as portion 200 and a lower portion such as portion 202. The cable 204 may extend from either end of the button controller assembly 100.

In FIG. 4, the button controller assembly 100 contains three button zones. The button area 102 is marked with a "+" to indicate to the user that the area forms a button that can be pressed when it is desired to increase playback volume or take other such appropriate action. The button region 104 may be used to form a button to perform a function such as pausing playback or other suitable action. The button area 106 is marked with "-" in order to instruct the user that the button area 106 forms a button that can be pressed when it is desired to reduce the playback volume or take other appropriate action.

The upper housing portion 200 and the lower housing portion 202 may be attached to an internal structure. For example, the upper housing portion 200 and the lower housing portion 202 may be rigidly or movably connected to a frame, such as the frame 206. The frame 206 may have a structure that engages the cable 204 and helps support the housing portions 200 and 202.

Housing portions 200 and 202 and frame 206 may be formed of any suitable material. By way of example, some or all of housing portions 200 and 202 and frame 206 may be formed from a plastic, such as a hybrid plastic formed from polycarbonate and acrylonitrile butadiene styrene (i.e., a PC/ABS plastic). With one suitable arrangement, the housing portions 200 and 202 may be formed from multiple shots of plastic. For example, housing portions 200 and 202 may be formed using a two shot molding process. With this type of arrangement, different portions of each housing may be formed from different plastics. This allows to provide individually tailored material properties to different parts of the respective housing. These attributes may include, for example, different textures, different colors, different rigidities (i.e., different flexibilities), different durability levels, and the like.

By way of example, it may be desirable to form portions of housing 200, such as portions in region 104, from a plastic having more texture than the plastic in regions 102 and 106. This may help the user of the button controller interface 100 to recognize when the user's finger is over the area 104. As shown in fig. 4, the surface of housing 200 in region 104 may also be recessed relative to the surface of housing 200 in regions 102 and 106 to facilitate user identification of each button region.

As another example, snaps and other features on the interior portions of the housings 200 and 202 may be formed from a plastic that is more rigid than the other housing portions. With this type of approach, certain structures may be formed from plastic that is flexible enough to deform under the pressure of a user's fingers, while other structures (e.g., snaps and other internal engagement structures) may be rigid enough to exhibit the desired level of durability and strength.

The housing, frame and other structures of the button controller assembly 100 may be configured to allow the housing portions 200 and 202 to float relative to each other when a user actuates a desired button. One or both housing portions may also be curved along their length. When floating, structures within the housing catch each other, which limits the maximum amount of travel that can be allowed. As an example, the snap feature may protrude into a hole or be captured by a rail. The housings may float (move freely) relative to each other as long as the catch does not abut against the edge of the hole or rail. Once (in this example) the catch bears against the edge of the hole or rail, the maximum amount of allowable travel is reached and further travel will be impeded. The curved housing portions enable additional bending movement beyond that permitted only by "floating" between the housing portions.

With one illustrative configuration, the upper housing 200 and the frame 206 may be rigidly attached to one another, while the lower housing 202 may be allowed to move (i.e., float) relative to the upper housing 200 when a user squeezes a desired one of the buttons formed by the regions 102, 104, and 106. The lower housing 200 may also flex slightly when the user squeezes the assembly 100 by pressing a desired one of the buttons. This flexibility may help provide for selection of a single button without inadvertently actuating other buttons.

As shown in the perspective view of FIG. 5, the button controller assembly 100 may have a length L that is greater than its width W and thickness T. In one illustrative configuration, the length L may be about 28mm, the width W may be about 5.19mm, and the thickness T may be about 3.34 mm. The thickness of the housing 200 may be about 0.4mm, and the thickness of the housing 202 may be about 0.4 mm. The cable 204 may have a diameter of about 1.6 mm.

The button controller assembly 100 may include a microphone. Because there is typically an air gap between the housing members and other structures in the assembly 100, sound can typically reach the interior of the button controller assembly 100 without providing a separate microphone port. As a result, the button controller assembly 100 may not be provided with a dedicated microphone port, if desired. Sound from outside the assembly 100 may reach the interior of the assembly 100 through air gaps, such as air gap 208 between the housing 202 and the housing 200, air gap 210 between the housing 202 and the frame 206, and air gap 212 between the housing 200 and the frame 206. These gaps may exist on both ends of the assembly 100 as well as on either side of the assembly 100. When a gap such as this exists, the microphone in the assembly 100 may be mounted inside the assembly 100 without providing additional holes in the housings 200 and 202.

While it is possible to install a microphone within the assembly 100 without providing a dedicated microphone port, a user of the button controller assembly 100 may be confused as to whether the button controller assembly 100 contains a microphone. To avoid this confusion, it may therefore be desirable for the button controller assembly 100 to be provided with a visual indicator that informs the user of the presence of the microphone.

In the example of FIG. 5, the lower housing 202 is provided with a non-operative microphone port 214 that serves as a visual indicator of the presence of a microphone in the button controller assembly 100. The port 214 may be provided with a porous metal disc, such as disc 218. The housing 202 may be provided with a circular recess within which the disc 218 is mounted. Each of the circular recess 216 and the disc 218 may have a diameter of about 1.57mm, for example. The disk 218 may be formed from a metal disk (e.g., stainless steel) that is approximately 0.1mm thick and has a hole with a diameter of approximately 0.209 mm. The holes may be formed in the disk 218 by chemical etching or other suitable fabrication technique. The disc 218 may be formed from a wire mesh or fabric, if desired.

A double-sided adhesive film (tape) may be used to mount the disc 218 within the circular recess 216. The circular recess 216 may have a closed bottom without holes so sound does not pass through the port 214. In this type of configuration, the port 214 does not function as a microphone port, but rather acts as a user visual indication of the presence of a microphone in the button controller assembly 100. If desired, a functional microphone port comprising a wire mesh may be provided in the assembly 100 in addition to or in place of the non-operative port 214. Additionally, other types of visual indicators may be used to indicate to the user that a microphone is present in the button controller assembly 100. For example, printed shapes in the form of markings, microphone symbols, or microphone ports may be provided on the exterior of the housing of the assembly 100. Suitable visual indicators may also be provided by using appropriately colored plastic portions within the housing of the assembly 100, or other visual indicators may be used.

FIG. 6 shows an exploded perspective view of the button controller assembly 100. As shown in fig. 6, the lower housing 202 may be formed from two different types of plastic using a two-shot molding process. A first plastic may be used to form housing portion 202A. A second plastic may be used to form housing portion 202B. Portion 202B may be formed, for example, from a plastic that is more durable and less flexible than portion 202A. This may help to allow portion 202A to bend along its length when pressed by a user, while ensuring that portion 202B is sufficiently stiff to act as an engagement structure. If desired, portions 202A and 202B may be formed from plastics having similar or identical rigidity.

Plastic portions 202A and 202B may have different textures or colors. The darker color is more preferred for the portions 202B because these portions of the housing 202 can be seen through the air gaps in the housing (e.g., air gaps 210 and 212 of FIG. 5) when the button controller assembly 100 is fully assembled. The portion 202B may be configured to form a snap or other engagement structure that helps attach the housing 202 to the button assembly 100.

The central snap member 220 may be formed of a material such as metal. An example of a suitable metal for component 220 is stainless steel. Stainless steel or other such material may be used for the member 220 so that the member 220 may serve as a durable surface against which the push button switch may rest during operation of the push button controller assembly 100.

The holes 222 in the member 220 may mate with corresponding heat stake portions on the inside of the housing 202. The component 220 may be attached to the housing 202 by melting the uppermost portion of the heat stake after the hole 222 is placed over the heat stake. The tabs 224 have holes that engage with snaps or other engagement structures that are part of the housing 200 or that are attached to the housing 200. For example, the housing 200 and the frame 206 may be rigidly connected to one another such that the frame 206 becomes part of the housing portion 200 and the apertures (such as the apertures 248) in the tabs 224 of the section 220 may mate with corresponding snaps or other engagement features (such as the snaps 250) on the frame 206.

The dome switch assembly 228 may be used to provide a user-controllable push button switch to the button controller assembly 100. As shown in fig. 6, dome switches 226, such as dome switches 226A, 226B and 226C, may be mounted on a printed circuit board 230. Integrated and other circuitry 232, such as a microphone, may be mounted on opposite sides of the printed circuit board 230. The circuit 232 may be electrically connected to the dome switch 226. When the button controller assembly 100 is assembled, the switch 226A is longitudinally and laterally aligned with the region 102, and the switches 226B and 226C are aligned with the regions 104 and 106, respectively. When the user squeezes a given area, the corresponding portion of the housing 202 is pressed inward. As this portion of housing 202 moves inward, the corresponding portion of member 220 is pressed against a protrusion on the appropriate one of dome switches 226. Since (in a suitable arrangement) the member 220 is formed of metal, the projections do not dig into the member 220 over time, as may occur with the projections resting on soft plastic.

If desired, the protrusion 242 is covered with a durable material (such as epoxy) to help ensure a crisp switch activation event. Each dome switch 226 may have a circular metal dome portion with a protrusion formed thereon. Transparent adhesive tape may be used to hold the metal dome in place on dome switch assembly 226. On its inner surface, the dome switch may have traces that connect to corresponding traces within the printed circuit board 230. The dome switch may be attached to the printed circuit board 230 using an adhesive film.

To ensure that the dome switch is actuated when the user squeezes the assembly 100, sufficient clearance may be provided for snaps and other engagement structures that attach the various parts of the assembly 100 together to allow the housing 202 to float (travel) unimpeded. The maximum allowable travel between the two float members of the assembly 100 may be, for example, 0.15mm to 0.2mm in the vertical direction.

If the user presses, for example, region 104, the central region of housing 202 will press inward against switch 226B to actuate switch 226B. During actuation, the housing 202 travels inward toward the frame 206 and the housing 200. The housing 202 is also preferably curved so that the ends of the housing 202 (or the associated ends of the components 220) are not pressed significantly inward as the central region of the housing 202 travels inward. This is accomplished by ensuring that dome switches 226A and 226C and structure 256 of housing portion 200B are pressed outwardly with sufficient force to resist inward movement of housing 202 that would result if the central portion of housing 202 were pressed inwardly against switch 226B. As this example demonstrates, the button housing 220 preferably has a free travel range resulting from the use of snaps and other engagement features that non-rigidly attach the housing 202 to the frame 206, yet flexibility to accommodate selection of a single button without inadvertently activating more than one dome switch 226 at a time.

A resilient member, such as resilient member 236, may be provided to help bias housing 202 outwardly away from frame 206 and housing 200. The resilient member 236 may be formed of any suitable material. By way of example, the resilient element 236 may be formed from a resilient material (such as silicone) and may therefore sometimes be referred to as a rubber grommet. The resilient member 236 may be mounted within a recess in the frame 206 and looped around the cable 204. The outermost portions of the resilient members 236 may be bent so that they press evenly against the inner surface of the housing portion 202A. The resilient member 236 may be located at an end of the assembly 100 or at any other suitable location along the length of the assembly 100. Particularly when located at the ends of the assembly 100, the elastic element 236 may serve as a decorative screen to help mask the interior portions of the assembly 100 from view. Any suitable number of resilient elements 236 may be used within the assembly 100 (e.g., one, two, three, more than three, etc.).

Circuitry 232 may detect which dome switch is actuated by the user and may transmit a corresponding signal to device 12 via wires within cable 204. As shown in FIG. 6, some wires within the cable 204, such as wire 234, pass through the button controller assembly 100 (i.e., pass speaker signals to the speaker), while other wires may be soldered to pads on the printed circuit board 230. A metal crimp structure, such as a crimp (crimp) band 205, may be crimped to the end of the cable 204 to prevent the cable 204 from being pulled out of the frame 206.

When assembled, the portion 202B of the housing 202 may engage portions of the frame 206. For example, catch 238 may engage rail portion 240 of frame 206, and catch 246 may engage rail portion 244 of frame 206. The section 220 may be heat staked to the housing 202 and may have tabs 224 with apertures that engage mating features in the frame 206. The apertures (such as aperture 248) in the tabs 224, the mating engagement features (e.g., snaps 250) on the frame 206, and the respective mating engagement features on the housing portion 202B and the frame 206 are preferably configured to allow vertical travel (e.g., 0.15mm to 0.2mm floating travel) between the housing 202 and the frame 206 (and thus the housing 200) when the button is actuated. At least some of the engagement features in the button controller assembly 100 may be formed entirely of plastic parts. For example, the plastic engagement structure formed by the snap 238 can mate with the plastic rail portion 240 without the use of any metal parts. The structure (such as the snap 238) may be sufficiently flexible to flex laterally inward (e.g., approximately 0.3mm to rest on a rail (such as rail 240 within the frame 206)) during assembly.

The frame 206 may be rigidly attached to the housing portion 200. The alignment structure 252 may help longitudinally align the frame 206 with the housing 200. When properly aligned, the ridge 254 on the frame 206 extends along the inner surface of the housing 200 adjacent to the alignment structure 252. The ridge 254 and the housing 200 may be welded together using ultrasonic welding, forming a unitary structure in which the frame 206 is rigidly attached to the housing 200 and does not significantly travel relative to the housing 200. Although the button indicia (i.e., "+", recesses, and "-") are provided on the upper housing 200 rather than the lower housing 202 in the examples of fig. 4, 5, and 6, during button actuation, the housing 202, rather than the housing 200, travels and flexes inwardly against the dome switch 226. Dome switch 226 preferably rigidly supports housing 200 so that a desired dome switch boss can be depressed by a user.

The housing 200 may be formed by a two-shot molding process if desired. This allows portion 200B to be formed of a different plastic than portion 200A. Portion 200B may be formed, for example, of a darker colored plastic than portion 200A. This helps reduce visibility of portion 200B through air gaps, such as gaps 208 and 210 (fig. 5), and helps improve visibility of portion 200B within region 104 on the outermost surface of component 100 (as shown in fig. 4). The features 256 form a structure for supporting the integrated circuit 232 and the subassembly 228, as well as a structure that bears against an interior portion of the housing 202 when squeezed, to facilitate independent definition of the button zones 102, 104, and 106. The end portion 258 of the frame 206 acts as an environmental seal and a cosmetic cover that helps block the user from viewing the interior of the button controller assembly 100.

FIG. 7 shows a cross-sectional side view of the button controller assembly 100 of FIG. 5 when assembled for use in the system 10.

According to one embodiment, a button controller assembly is provided that includes first and second housing portions, each aligned with a respective portion of the first housing portion, and a plurality of switches mounted within the housing, the first and second housing portions having engagement structures that attach the first and second housing portions to one another while allowing the first and second housing portions to float relative to one another such that movement between the first and second housing portions is unimpeded by the engagement structures for a given maximum amount of travel.

In accordance with another embodiment, a button controller assembly is provided wherein the first housing portion and the second housing portion comprise plastic, and wherein the engagement structure comprises plastic.

In accordance with another embodiment, a button controller assembly is provided that includes a microphone in an interior portion of the button controller assembly, and a visual indicator on at least one housing portion that visually indicates the presence of the microphone in the interior portion of the button controller assembly.

In accordance with another embodiment, a button controller assembly is provided wherein the visual indicator includes a non-operative microphone port.

In accordance with another embodiment, a button controller assembly is provided wherein the non-operative microphone port includes structure that appears to be a microphone port but blocks sound from entering an interior portion of the button controller assembly.

According to another embodiment, a button controller assembly is provided wherein the non-operative microphone port comprises a metal disk with holes mounted on top of a plastic without holes.

According to another embodiment, a button controller assembly is provided wherein the first housing has a circular recess without holes in which a metal disk is mounted.

In accordance with another embodiment, a button controller assembly is provided wherein a plastic frame is connected to the second housing portion.

In accordance with another embodiment, a button controller assembly is provided wherein the engagement structure includes a plastic catch on the first housing portion that engages a portion of the plastic frame while allowing the first and second housing portions to float relative to each other.

In accordance with another embodiment, a button controller assembly is provided wherein at least one of the first and second housing portions comprises a two-shot plastic having different first and second plastic portions.

In accordance with another embodiment, a button controller assembly is provided wherein the first plastic portion and the second plastic portion comprise different colored plastics, and wherein the first plastic portion is aligned with a button actuation area in which a user button press causes actuation of a first one of the switches, and wherein the second plastic portion is aligned with at least one button actuation area in which a user button press causes actuation of a second one of the switches.

According to another embodiment, a button controller assembly is provided wherein the second plastic portion has a recessed surface.

In accordance with another embodiment, a button controller assembly is provided wherein the first housing portion flexes in addition to floating relative to the second housing portion when a user squeezes the button controller assembly to actuate a given one of the switches.

According to another embodiment, a button controller assembly is provided that further includes a resilient member biasing the first and second housing portions apart.

In accordance with another embodiment, a button controller assembly is provided wherein the first and second housing portions comprise mating plastic portions defining an elongated button controller assembly housing, and wherein the resilient members are positioned at opposite ends of the button controller assembly housing.

According to another embodiment, a button controller assembly is provided that further includes at least one integrated circuit mounted on a printed circuit board, wherein the switch is mounted on the printed circuit board.

According to another embodiment, a button controller assembly for controlling an electronic device in a headset is provided, comprising a housing having an air gap between housing portions that move relative to each other, the housing having an outer surface, and an inner portion in which a microphone is mounted, and a visual indicator on the outer surface of the housing indicating that the housing contains the microphone, wherein the microphone receives sound from outside the housing through the air gap.

In accordance with another embodiment, a button controller assembly is provided that further includes a plurality of dome switches in the interior portion that are selectively actuated by a user by squeezing different areas on the exterior surface.

In accordance with another embodiment, a button controller assembly is provided wherein the housing is elongated and has a central recessed portion aligned with a given one of the different regions on the outer surface.

According to another embodiment, a button controller assembly is provided wherein the recessed portion is formed from a first plastic and the other portions of the housing are formed from a second plastic, and wherein the first plastic and the second plastic have different colors and are part of a two-shot plastic construction.

According to another embodiment, a button controller assembly is provided that further includes a resilient member that biases the respective housing portions apart.

In accordance with another embodiment, a button controller assembly is provided that further includes an integrated circuit and a dome switch mounted on the printed circuit board, wherein the visual indicator includes a non-operative microphone port.

In accordance with another embodiment, there is provided a headset for an electronic device having an audio jack, the headset comprising two speakers, a button controller assembly, a four-contact audio plug that plugs into the audio jack of the electronic device, and wires that connect the speakers, the button controller assembly, and the four-contact audio plug, wherein the button controller assembly comprises a switch and first and second housing portions, wherein the first and second housing portions move relative to each other when a user squeezes the first and second housing portions together to actuate a given one of the switches, and wherein the first and second housing portions have plastic engagement features that engage each other such that the first and second housing portions travel unimpeded with respect to each other, up to a given maximum amount of travel.

In accordance with another embodiment, a headset is provided wherein the first housing portion comprises a two-shot plastic having first and second shots of different colors.

According to another embodiment, a headset is provided, further comprising a silicon element biasing the first housing portion and the second housing portion apart.

According to another embodiment, there is provided a headset wherein there are three of the switches, wherein the switches comprise dome switches, and wherein when a user squeezes the first and second housing portions together, the first housing portion bends and the second housing is rigid and non-bending.

In accordance with another embodiment, a headset is provided wherein the button controller assembly contains a microphone and at least one of the housing portions includes a non-operative microphone port that serves as a visual indicator that the button controller assembly contains a microphone.

In accordance with another embodiment, an earphone is provided wherein the non-operative microphone port comprises a metal disc with holes mounted in a housing recess without holes.

In accordance with another embodiment, a headset is provided, further comprising a frame rigidly attached to at least one of the housing portions, wherein the frame engages the wires.

The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Claims (15)

1. A headset for an electronic device having an audio jack, comprising:

two loudspeakers;

a button controller assembly; and

a wire connecting the speaker and a button controller assembly, wherein the button controller assembly comprises:

a first housing portion and a second housing portion, the first housing portion having a first button actuation area and a second button actuation area; and

a first switch and a second switch mounted between the first housing portion and the second housing portion, wherein each respective switch is aligned with a respective button activation region of the first housing portion,

wherein the first and second housing portions float relative to each other when a user squeezes the first and second housing portions together to actuate a given one of the first and second switches, and wherein the first and second housing portions have plastic engagement features that engage each other such that the first and second housing portions travel relative to each other unimpeded up to a given maximum amount of travel;

wherein a press on the first button actuation area causes actuation of the first switch and bending of the first housing portion such that the second switch is not actuated, and a press on the second button actuation area causes actuation of the second switch and bending of the first housing portion such that the first switch is not actuated.

2. The headset of claim 1, further comprising a silicon element biasing the first housing portion and the second housing portion apart.

3. The headset of claim 1, further comprising a third switch, wherein the first switch, the second switch, and the third switch are dome switches, and wherein when a user squeezes the first housing portion and the second housing portion together, the first housing portion flexes and the second housing portion is rigid and does not flex.

4. The headphones defined in claim 1 wherein the button controller assembly contains a microphone and wherein at least one of the first and second housing portions comprises a non-operative microphone port that serves as a visual indicator that the button controller assembly contains a microphone, wherein the non-operative microphone port comprises a perforated metal disk that fits within a non-perforated housing recess.

5. The headset of claim 4, further comprising a frame rigidly attached to at least one of the first and second housing portions, wherein the frame engages the wires, wherein at least one air gap exists between the at least one of the first and second housing portions and the frame, and wherein the microphone receives sound from outside the first and second housing portions through the at least one air gap.

6. The headset of claim 1, further comprising a four-contact audio plug that plugs into the audio jack of an electronic device and is connected to the cord.

7. A button controller assembly comprising:

first and second housing portions having engagement structures that attach the first and second housing portions to one another while allowing the first and second housing portions to float relative to one another such that movement between the first and second housing portions is not impeded by the engagement structures for a given maximum amount of travel, the first housing portion having a first button actuation area and a second button actuation area;

a first switch and a second switch mounted between the first housing portion and the second housing portion, wherein each respective switch is aligned with a respective button activation region of the first housing portion, wherein a press on the first button activation region causes activation of the first switch and bending of the first housing portion such that the second switch is not activated, and a press on the second button activation region causes activation of the second switch and bending of the first housing portion such that the first switch is not activated; and

a microphone positioned between the first and second housing portions, the microphone receiving audio from an air gap between the first and second housing portions.

8. The button controller assembly defined in claim 7 wherein the first housing portion and the second housing portion are formed from plastic and wherein the engagement structures are formed from plastic.

9. The button controller assembly defined in claim 7 further comprising a visual indicator on at least one of the first and second housing portions that includes a non-operative microphone port that visually indicates the presence of a microphone within the button controller assembly, wherein the non-operative microphone port comprises a structure that appears to be a microphone port but blocks sound from entering an interior portion of the button controller assembly.

10. The button controller assembly defined in claim 7 wherein a plastic frame is connected to the second housing portion.

11. The button controller assembly defined in claim 10 wherein the engagement structures comprise plastic snaps on the first housing portion that engage portions of the plastic frame while allowing the first and second housing portions to float relative to one another.

12. The button controller assembly defined in claim 7 wherein at least one of the first and second housing portions comprises a two-shot plastic having different first and second plastic portions.

13. The button controller assembly defined in claim 12 wherein the first plastic portion and the second plastic portion comprise different colored plastics and wherein the first plastic portion is aligned with the first button actuation area and wherein the second plastic portion is aligned with the second button actuation area.

14. The button controller assembly defined in claim 7 further comprising a resilient member that biases the first and second housing portions apart, wherein the first and second housing portions comprise mating plastic portions, and wherein the resilient member is positioned at opposite ends of the housing of the button controller assembly.

15. The button controller assembly defined in claim 7 further comprising at least one integrated circuit mounted on a printed circuit board, wherein the first and second switches are mounted on the printed circuit board.