Open-ear headphone

1. A flexible arm that is configured to be located between and physically and electrically connect an acoustic module of an open-ear headphone to a battery housing of the open-ear headphone, wherein the flexible arm defines an original resting length and position between the acoustic module and the battery housing, the flexible arm comprising:

a flexible printed circuit that extends through the entire original resting length of the flexible arm and comprises a conductor that is configured to carry electrical energy between the acoustic module and the battery housing; and

a flexible material that encases at least some of the flexible printed circuit;

wherein a length of the flexible printed circuit within the flexible arm is greater than the original resting length of the flexible arm, such that the flexible printed circuit can better accommodate tension or compression on the flexible arm as the flexible arm is bent from its original resting position.

2. The flexible arm of claim 1 wherein the flexible printed circuit defines one or more open curves along its length within the flexible arm.

3. The flexible arm of claim 2 wherein the one or more open curves are simple open curves.

4. The flexible arm of claim 1 wherein the original resting position of the flexible arm lies along a curved axis.

5. The flexible arm of claim 4 wherein the flexible printed circuit defines at least one simple open curve along its length within the flexible arm.

6. The flexible arm of claim 5 wherein the flexible printed circuit defines a plurality of both simple open upward curves and simple open downward curves along its length within the flexible arm.

7. The flexible arm of claim 6 wherein each simple open downward curve of the flexible printed circuit is adjacent to one more of the simple open upward curves.

8. The flexible arm of claim 4 wherein the curved axis defines a simple open curve.

9. The flexible arm of claim 8 wherein the curved axis is generally “C”-shaped.

10. The flexible arm of claim 4 wherein the curved axis bisects the flexible arm, and wherein different parts of a first surface of the flexible printed circuit lie on different sides of the curved axis.

11. The flexible arm of claim 1 wherein the flexible material comprises two mating members that each define a series of simple open curves along the original resting length of the flexible arm.

12. The flexible arm of claim 11 wherein the simple open curves of the two mating members are complimentary.

13. The flexible arm of claim 12 wherein the two mating members each define a wave-shaped mating surface wherein convex portions of one member are aligned with and fit into concave portions of the other member, and wherein the flexible printed circuit is located between the mating surfaces of the two mating members.

14. The flexible arm of claim 1 further comprising an over-mold that encircles the flexible material along at least most of the original resting length of the flexible arm.

15. The flexible arm of claim 14 wherein the over-mold further covers at least some of the battery housing.

16. The flexible arm of claim 1 further comprising a flexible printed circuit stress relief member proximate the flexible material, wherein the stress relief member defines an opening through which the flexible printed circuit is threaded.

17. The flexible arm of claim 1 wherein the flexible printed circuit defines an open slot along a portion of its length in the flexible arm, to accommodate twisting of the flexible printed circuit about its length.

18. A flexible arm that is configured to be located between and physically and electrically connect an acoustic module of an open-ear headphone to a battery housing of the open-ear headphone, wherein the flexible arm defines an original resting length and position between the acoustic module and the battery housing, wherein the original resting position of the flexible arm lies along a generally “C”-shaped curved axis, the flexible arm comprising:

a flexible printed circuit that extends through the entire original resting length of the flexible arm and comprises a conductor that is configured to carry electrical energy between the acoustic module and the battery housing; and

a flexible material that encases at least some of the flexible printed circuit;

wherein the flexible printed circuit defines at least one simple open curve along a length of the flexible printed circuit within the flexible arm, such that its length within the flexible arm is greater than the original resting length of the flexible arm, such that the flexible printed circuit can better accommodate tension or compression on the flexible arm as the flexible arm is bent from its original resting position.

19. The flexible arm of claim 18 wherein the flexible printed circuit defines a plurality of both simple open upward curves and simple open downward curves along its length within the flexible arm, wherein each simple open downward curve of the flexible printed circuit is adjacent to a simple open upward curve.

20. The flexible arm of claim 19 further comprising a flexible printed circuit stress relief member proximate the flexible material, wherein the stress relief member defines an opening through which the flexible printed circuit is threaded.