Compact Bone Conduction Audio Transducer

A wearable computing system comprising:

• a support structure, wherein one or more portions of the support structure are configured to contact a wearer;
• an audio interface for receiving an audio signal;
• and
• a vibration transducer including:
• an electromagnet including a conductive coil surrounding a central core, wherein the conductive coil is configured to be driven by an electrical input signal to generate magnetic fields;
• a magnetic diaphragm that is configured to mechanically vibrate in response to the generated magnetic fields;
• and
• a pair of cantilevered flexible support arms that elastically couple the magnetic diaphragm to a frame, wherein the frame is connected to the electromagnet such that the magnetic diaphragm vibrates with respect to the frame when the electromagnet is driven by the input signal, wherein the pair of cantilevered flexible support arms are connected to opposing sides of the magnetic diaphragm and each of the pair of cantilevered flexible support arms extend adjacent respective opposing sides of the magnetic diaphragm free of connection to either of the pair of cantilevered support arms;
• and
• wherein the vibration transducer is embedded in the support structure and configured to vibrate based on the audio signal so as to provide information indicative of the audio signal to the wearer via a bone structure of the wearer.

A method of assembling a vibration transducer comprising:

• arranging a first flexible support arm with a first end and a second end such that:
• the first end is positioned over a first mounting surface of a magnetic diaphragm;
• and
• the second end is positioned over a first strut or sidewall of a frame of the vibration transducer, wherein overlapping regions of the first and second ends of the first flexible support arm overlap the first mounting surface of the magnetic diaphragm and the first strut or sidewall of the frame, respectively;
• arranging a second flexible support arm with a first end and a second end such that:
• the first end is positioned over a second mounting surface of the magnetic diaphragm, wherein the second mounting surface and the first mounting surface are on opposing sides of the magnetic diaphragm;
• and
• the second end is positioned over a second strut or sidewall of the frame, wherein overlapping regions of the first and second ends of the second flexible support arm overlap the second mounting surface of the magnetic diaphragm and the second strut or sidewall of the frame, respectively;
• and
• laser welding the first and second flexible support arms by directing a laser sufficient to generate heat for laser welding to the respective overlapping regions of the first and second flexible support arms such that one or more laser spot welds are formed to connect the magnetic diaphragm and the frame via the first and second flexible support arms and thereby elastically suspend the magnetic diaphragm with respect to the frame.