JBL Flip 3
A textile mesh structure is used in quite some modern products, like the JBL speakers and the Google Home. I was wondering how they design with such flexible materials in a rigid product. Furthermore, the charging port of the speaker needs to be repaired, so that are two good reasons to take this product apart.
The textile is wrapped around a hard shell and glued at the edges. The red logo is mechanicaly fixed in the shell by bending two metal pins.
The most intriguing button I have seen so far. It uses the flexibility of the body, which makes it water proof and gives a modern feel. Light shines through the plastic at the thin areas. Another plastic parts acts as a spring and adds resistance to the button.
The next part in the button setup is this flexible material. It is produced of two materials to selectively guide the light.
The same flexible part as seen above has some raised edges which press the switch on the pcb.
The actual switch is just ofset from the center, corresponding with the raised edges of the flexible part. In the center, where pressed, there are multiple leds.
This must have been a complicated part to injection mould. There are snap-fits, integrated springs and a complicated almost-closed cilinder.
A sin in sustainable design is the use of glues. It makes this product very hard to repair. But off course you don't want any vibrations in the product to distort the sound.
A much used socket for flat flexible cables is these FFC connector which work with "zero insertion force", also called ZIF.