System and method of assembling a compression triggered headset power saving system for an audio headset

A method of manufacturing a compression triggered headset power saving system in a first earcup assembly of an audio headset comprising:

• operatively coupling a first compression sensor cap to a first spring switch housed within a first compression sensor sleeve to form a first compression sensor trigger, wherein movement of the first compression sensor cap toward the first compression sensor sleeve causes the first compression sensor cap to electrically contact a first pogo electrical contact to urge the first pogo electrical contact outside an edge of the first compression sensor sleeve and into contact with a first electrical contact plate and contacts a second electrical pogo contact to urge the second electrical pogo contact into contact with a second electrical contact plate;
• biasing the first spring switch to push the first compression sensor cap away from a first plurality of pogo electrical contacts that includes the first electrical pogo contact and the second electrical pogo contact inside of the first compression sensor sleeve and decouple electrically conductive contact with the first electrical contact plate and the second electrical contact plate when the ear cup cushion is decompressed as the audio headset is removed from a user's head;
• mounting the first electrical contact plate and the second electrical contact plate to an outer surface of an ear cup plate;
• operatively coupling the first electrical contact plate and the second electrical contact plate to a printed circuit board (PCB) and a speaker;
• and
• disposing the first compression sensor trigger within a first ear cup cushion mounted to an inner surface of the ear cup plate to form the first earcup assembly, wherein movement of the first compression sensor cap to engage a first plurality of pogo electrical contacts that includes the first electrical pogo contact and the second electrical pogo contact occurs under compression of the first ear cup cushion to close a first circuit of the first compression sensor trigger to the PCB to trigger providing power to the speaker.

A compression triggered headset power saving system for an audio headset comprising:

• a first compression sensor cap operatively coupled to a first spring switch housed within a first compression sensor sleeve to form a first compression sensor trigger, such that movement of the first compression sensor cap toward the first compression sensor sleeve causes the first compression sensor cap to electrically contact a first pogo electrical contact, to urge the first pogo electrical contact into contact with a first electrical contact plate, and contacts a second electrical pogo contact to urge the second electrical pogo contact into contact with a second electrical contact plate;
• a second compression sensor cap operatively coupled to a second spring switch housed within a second compression sensor sleeve to form a second compression sensor trigger, such that movement of the second compression sensor cap toward the second compression sensor sleeve causes the second compression sensor cap to electrically contact a third pogo electrical contact, to urge the third pogo electrical contact into contact with a third electrical contact plate, and contacts a fourth electrical pogo contact to urge the fourth electrical pogo contact into contact with a fourth electrical contact plate;
• the first electrical contact plate, the second electrical contact plate, the third electrical contact plate, and the fourth electrical contact plate mounted to an outer surface of an ear cup plate and operatively coupled to a printed circuit board (PCB) and a speaker;
• and
• the first compression sensor trigger and the second compression sensor trigger disposed within a first ear cup cushion mounted to an inner surface of the ear cup plate such that movement of the first compression sensor cap to engage the first electrical pogo contact and the second electrical pogo contact occurs under compression of the first ear cup cushion to close a first circuit of the first compression sensor trigger to the PCB, and movement of the second compression sensor cap to engage the third electrical pogo contact and the fourth electrical pogo contact occurs under compression of the first ear cup cushion to close a second circuit of the second compression sensor trigger to the PCB;
• and
• the PCB to trigger providing power to the speaker when either the first circuit to the PCB or the second circuit to the PCB is closed.