Wearable audio device with counter-bore port feature

1. A wearable audio device, comprising:

a frame comprising a first acoustic cavity and a second acoustic cavity;

an electro-acoustic transducer within the frame and configured to deliver acoustic energy into the first and second acoustic cavities;

a port integrated in the frame that acoustically couples one of the first or second acoustic cavities to a different volume;

a counter-bore feature in the frame adjacent to the port; and

a metal mesh covering the port and positioned proximate to the counter-bore feature,

wherein the counter-bore feature mitigates melting plastic from the frame entering into the port during a heat staking process.

2. The wearable audio device of claim 1 , wherein the counter-bore feature comprises a ledge in the frame extending at least partially annularly around the port, wherein the ledge is defined by a recess in adjacent walls of the frame, and wherein the ledge is located radially inboard of a stake location of the metal mesh relative to a primary axis of the port.

3. The wearable audio device of claim 2 , wherein the ledge extends around an entire annulus of the port.

4. The wearable audio device of claim 1 , wherein the frame comprises plastic, and wherein the metal mesh is directly bonded to the plastic proximate to the counter-bore feature by the heat staking process.

5. The wearable audio device of claim 4 , wherein the direct bond between the metal mesh and the plastic proximate the counter-bore feature mitigates occlusion of the port.

6. The wearable audio device of claim 1 , wherein the port acoustically couples the first and second cavities.

7. The wearable audio device of claim 1 , wherein the frame comprises an annular seat for the electro-acoustic transducer, and an integral extension that comprises the port.

8. The wearable audio device of claim 1 , wherein the port acoustically couples one of the first acoustic cavity or the second acoustic cavity to an environment external to the wearable audio device, wherein the port comprises a nozzle that is configured to deliver acoustic energy into an ear canal of a user of the wearable audio device.

9. The wearable audio device of claim 1 , wherein the first acoustic cavity is located proximate a front of the wearable audio device and the second acoustic cavity is located proximate a rear of the wearable audio device.

10. The wearable audio device of claim 1 , wherein the wearable audio device comprises an earbud, wherein the electro-acoustic transducer has an outer dimension equal to or less than approximately 20 mm.

11. A wearable audio device, comprising:

a frame comprising a first acoustic cavity and a second acoustic cavity;

an electro-acoustic transducer within the frame and configured to deliver acoustic energy into the first and second acoustic cavities;

a port integrated in the frame that acoustically couples one of the first or second acoustic cavities to a different volume;

a counter-bore feature in the frame adjacent to the port;

a rib adjacent to the counter-bore feature; and

a metal mesh covering the port and attached through the rib proximate to the counter-bore.

12. The wearable audio device of claim 11 , wherein the counter-bore feature comprises a ledge in the frame extending at least partially annularly around the port, wherein the ledge is defined by a recess in adjacent walls of the frame, wherein the ledge is located radially inboard of a stake location of the metal mesh relative to a primary axis of the port, and wherein the rib extends at least partially annularly around the port.

13. The wearable audio device of claim 12 , wherein the ledge and the rib each extend around an entire annulus of the port.

14. The wearable audio device of claim 11 , wherein the frame comprises plastic, wherein the metal mesh is directly bonded to the plastic at the rib proximate to the counter-bore feature by heat staking, wherein the counter-bore feature and the rib mitigate melting of the plastic into the port during the heat staking.

15. The wearable audio device of claim 14 , wherein the direct bond between the metal mesh and the plastic at the rib mitigates occlusion of the port.

16. The wearable audio device of claim 11 , wherein the port acoustically couples the first and second cavities.

17. The wearable audio device of claim 11 , wherein the port is located in an outer wall of the frame, and wherein the rib extends from the outer wall of the frame and is located radially outboard of the counter-bore feature relative to a primary axis of the port.

18. The wearable audio device of claim 11 , wherein the port acoustically couples one of the first acoustic cavity or the second acoustic cavity to an environment external to the wearable audio device, wherein the port comprises a nozzle that is configured to deliver acoustic energy into an ear canal of a user of the wearable audio device, and wherein the first acoustic cavity is located proximate a front of the wearable audio device and the second acoustic cavity is located proximate a rear of the wearable audio device.

19. A method comprising:

forming a frame for a wearable audio device comprising a port opening and a counter-bore feature at least partially surrounding the port opening;

placing a metal mesh over the port opening proximate to the counter-bore feature; and

heat staking the metal mesh into the frame around the port opening such that at least a portion of the frame melts during the heat staking and is collected in the counter-bore feature without entering the port opening.

20. The method of claim 19 , wherein the frame further comprises a rib extending from a wall proximate the port opening, wherein the heat staking comprises heat staking the metal mesh into the rib, and wherein at least a portion of the rib melts during the heat staking and is collected in the counter-bore feature without entering the port opening.