Wearable devices, e.g., smartwatches, earbuds, etc., trend towards miniaturization for the purposes of aesthetics and ergonomics. However, certain components are better made of larger volume, e.g., larger batteries enable longer times between recharges. There is thus a dichotomy of requirements: miniaturization for user comfort versus larger volume for longer battery life. The shell of an earbud is typically constructed of two distinct sections, such that electronics can be inserted inside the shell before the sections are hermetically sealed together.

This disclosure describes a shell, a hermetic sealing interface, and an assembly technique for wearable devices such as earbuds. The techniques enable watertight sealing of the device while using thinner walls. The thin-wall feature enables the insertion of larger components into the wearable device or the shrinking of the volume of the wearable device, leading to better performance and/or ergonomics.

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Creative Commons License
This work is licensed under a Creative Commons Attribution 4.0 License.