Electronic device with switch mechanism mounted to substrate

An electronic device includes a substrate having a top surface, a bottom surface and at least one opening therethrough. The substrate has a circuit. A switch mechanism is mounted to the substrate and is electrically connected to the circuit. The switch mechanism has an actuator configured to activate the switch mechanism. The switch mechanism has a housing holding the actuator and leads extending from the housing. The leads are electrically connected to the circuit. The switch mechanism is mounted to the substrate in the opening such that at least a portion of the housing is positioned below the top surface.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to electronic devices with switch mechanisms mounted to circuit boards.

Circuit boards have many applications, including use in electronic devices for controlling operations of the electronic device. Some electronic devices use switch mechanisms for the controls of the electronic device. The switch mechanisms are mounted to the circuit board and are presented at a user input of the electronic device, where the switch mechanisms may be actuated by a user. For example, some electronic devices use tactile switches associated with a keypad, where buttons or keys of the keypad are pressed to activate/deactivate the switch mechanisms. Some applications prefer electronic devices having low profiles. However, the switch mechanisms are typically mounted to the top surface of the circuit board and the thicknesses of the switch mechanisms add to the overall profile of the electronic device.

A need remains for electronic devices having low profiles for use in some applications.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a switch mechanism is provided that is configured to be mounted to a substrate having a top surface, a bottom surface and at least one opening therethrough and having a circuit. The switch mechanism includes an actuator configured to activate the switch mechanism and a housing holding the actuator. The housing has a top and a bottom and sides extending between the top and the bottom. The actuator being actuated from above the top of the housing. The switch mechanism includes leads extending from the housing having mounting pads being configured to be electrically connected to the circuit. The leads extend from the housing such that the mounting pads are elevated above the bottom of the housing to allow at least a portion of the housing to be positioned below the top surface of the substrate.

In a further embodiment, an electronic device is provided including a substrate having a top surface, a bottom surface and at least one opening therethrough. The substrate has a circuit. A switch mechanism is mounted to the substrate and is electrically connected to the circuit. The switch mechanism has an actuator configured to activate the switch mechanism. The switch mechanism has a housing holding the actuator and leads extending from the housing. The leads are electrically connected to the circuit. The switch mechanism is mounted to the substrate in the opening such that at least a portion of the housing is positioned below the top surface.

In another embodiment, an electronic device is provided including a substrate having a top surface, a bottom surface and at least one opening therethrough with a circuit. A switch mechanism is mounted to the substrate and is electrically connected to the circuit. The switch mechanism has an actuator configured to activate the switch mechanism. The switch mechanism has a housing holding the actuator and leads extending from the housing. The leads are electrically connected to the circuit. The switch mechanism is mounted to the substrate in the opening such that the actuator is positioned below the top surface of the substrate.

In a further embodiment, an electronic device is provided including a substrate having a top surface, a bottom surface and an edge extending between the top surface and the bottom surface to define a thickness profile of the substrate. The substrate has at least one opening therethrough at the edge. The substrate has a circuit. A switch mechanism is received in the opening at the edge and is electrically connected to the circuit. The switch mechanism has an actuator configured to activate the switch mechanism. The switch mechanism has a housing holding the actuator and leads extending from the housing. The leads are electrically connected to the circuit. The switch mechanism is mounted to the substrate in the opening such that the actuator is arranged within the thickness profile of the substrate and extends outward beyond the edge.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is an exploded perspective view of an electronic device100formed in accordance with one embodiment. The electronic device100includes a substrate102to which electrical components are connected (e.g., an assembly containing conductive elements), such as, but not limited to, a circuit board, which may be a 2D or 3D included circuit board, a rigid circuit board or a flexible circuit board. Other types of substrates include a molded interconnect device, or other types of devices. While the embodiments illustrated herein are in reference to a circuit board and referred to hereinafter as circuit board102, the subject matter herein is not intended to be limited to circuit boards. The electronic device100includes one or more switch mechanisms104, or simply switch(s)104, mechanically and electrically coupled to the circuit board102.

The electronic device100includes a user input106(shown poised for mounting to the circuit board102) having one or more user input actuators108used to actuate the one or more switches104. The user input106is positioned above the circuit board102and receives inputs from a user to control operation of the electronic device100. The user input106may be a plastic, silicone or other array of one or more mechanical actuator features. The user input106may be a keypad and the user input actuators108may be keys that may be pressed by a user to control the electronic device100. Other types of user inputs may be provided and the user inputs may have other types of user input actuators108. For example, rather than push buttons or keys, the user input106may have toggle buttons, rocker buttons, rotating buttons, slide buttons, molded domes, and the like used to adjust or actuate corresponding switches104.

The circuit board102includes a top surface112and a bottom surface114opposite the top surface112. The top surface112faces the user input106. Optionally, the top surface112may be upward facing and the bottom surface114may be downward facing; however other orientations are possible in alternative embodiments. The circuit board102includes one or more circuits116with switches104electrically connected to corresponding circuits116. The circuits116may be printed circuits printed on one or more layers of the circuit board102. The circuits116may include traces (such as on the top surface112, the bottom surface114or other layers of the circuit board102), pads (such as for mounting the switches104to the circuits116), vias (such as for routing between layers of the circuit board102), electrical components (such as resistors, transistors, capacitors, and the like), and the like.

The switch104is mechanically and electrically connected to the circuit board102, such as to a corresponding circuit116of the circuit board102. For example, the switch104may be soldered to the circuit board102. The switch104may have a low profile, which may reduce the overall height or thickness of the electronic device100. In an exemplary embodiment, the switch104is at least partially recessed relative to the top surface112of the circuit board102. For example, at least a portion of the switch104may be received in an opening118in the circuit board102. Optionally, substantially the entire switch104may be positioned below the top surface112. Optionally, substantially the entire switch104may be positioned below the bottom surface114.

FIG. 2is a perspective view of the switch mechanism104formed in accordance with an exemplary embodiment. The switch104includes a housing130having an actuator132that may be actuated, such as by the corresponding user input actuator108(shown inFIG. 1). The switch104includes a plurality of leads134extending from the housing130. The leads134are configured to be electrically connected to corresponding mounting pads and traces of the circuit116(shown inFIG. 1). In the illustrated embodiment, the leads134are conductive solder tails having corresponding mounting pads135for surface mounting and soldering to corresponding mounting pads of the circuit116. However other types of leads may be used in alternative embodiments, such as spring beams, compliant pins, and the like.

In an exemplary embodiment, the housing130includes and/or is formed from a dielectric material, such as a plastic material. The housing130extends between a top136and a bottom138. The actuator132is provided at the top136and is configured to face the user input actuator108. The top136may be oriented generally parallel to the top surface112(shown inFIG. 1) of the circuit board102(shown inFIG. 1). The leads134extend from sides140of the housing130. Optionally, the leads134may extend from the middle of the sides140, such as approximately centered between the top136and the bottom138; however the leads134may extend from the sides140near the top136or near the bottom138. Alternatively, the leads134may extend from the top136and/or the bottom138, as opposed to the sides140, and may be bent outward. Various leads134may be electrically connected by the actuator132when the switch104is activated and/or deactivated.

The actuator132is provided at the top136and is configured to face the user input actuator108. In the illustrated embodiment, the actuator132is a tactile button that is configured to be actuated by pressing in a pressing direction generally perpendicular to the top136. The user input actuator108may press the actuator132to actuate the switch104. Other types of actuators may be provided in alternative embodiments. For example, the actuator132may be a toggle actuator, a rocker actuator, a rotary actuator, a slide actuator, or another type of actuator. The actuator132may be toggled between an on state and an off state in various embodiments. In other embodiments, the actuator132controls an electrical state of the switch104. In other embodiments, the actuator132controls different circuit functions by rotating. Other types of movements of the actuator are possible in alternative embodiments.

FIG. 3is a top perspective view of a portion of the electronic device100showing one of the switch mechanisms104mounted to the circuit board102.FIG. 4is cross-sectional view of a portion of the electronic device100showing one of the switch mechanisms104mounted to the circuit board102. The openings118in the circuit board102are illustrated inFIGS. 3 and 4. In an exemplary embodiment, the openings118extend entirely through a thickness profile of the circuit board102between the top surface112and the bottom surface114. The openings118may have any size or shape, such as to receive the switch mechanism104and/or the user input actuator108(shown inFIG. 1). In the illustrated embodiment, the openings118are rectangular in shape; however the openings118may have other shapes in alternative embodiments.

In the illustrated embodiment, the switch104is recessed relative to the circuit board102to reduce the profile or height of the electronic device100. For example, the bottom138of the switch104is positioned below the top surface112. At least a portion of the switch104may be within the thickness profile of the circuit board102. In the illustrated embodiment, the entire housing130is positioned below the top surface112. Optionally, the top136of the housing130is positioned below the bottom surface114. The switch104is positioned below the opening118. A portion of the user input actuator108(shown inFIG. 1) may be configured to be received in the opening118to interface with the actuator132of the switch104.

The mounting pads135of the leads134are provided along upper surfaces of the leads134and face upward. The mounting pads135are electrically and mechanically connected to corresponding mounting pads150of the circuits116. The mounting pads135are soldered to the mounting pads150. The mounting pads135may be mechanically and electrically connected to the mounting pads150by other processes in alternative embodiments. The mounting pads150are provided on the bottom surface114. The mounting pads150may be electrically connected to conductors or traces of the circuit116on interior layers or on the top surface112using conductive vias (not shown) extending through the circuit board102. Optionally, the switches104may be supported from below such that the solder joints between the mounting pads135,150are not over stressed during actuation.

In the illustrated embodiment, the mounting pads135of the leads134are positioned at or above the top136of the housing130of the switch104. For example, the leads134may be bent upward to position the mounting pads135relative to the top136of the housing130. Other electrical components may be provided below the bottom surface114of the circuit board102. The switch104may have a lower profile than such electrical components such that the switches104do not increase the profile of height of the electronic device100. Recessing the switches104and providing the switches104below the circuit board102reduces the protruding height of the switches104above the circuit board102(in the illustrated embodiment, the switches104have zero protruding height above the top surface112) as compared to conventional electronic devices100that surface mount switches104to the top surface112, wherein the entire height or thickness of the switch104adds to the protruding height above the top surface of such circuit boards. As such, the electronic device100having the switches104mounted to the bottom surface114and provided below the bottom surface114reduces an overall profile or height of the electronic device100as compared to conventional electronic devices.

FIG. 5is a top perspective view of a portion of the electronic device100showing one of the switch mechanisms104mounted to the circuit board102.FIG. 6is a cross-sectional view of a portion of the electronic device100showing one of the switch mechanisms104mounted to the circuit board102. In an exemplary embodiment, the openings118extend entirely through a thickness profile of the circuit board102and the switches104are at least partially received in the openings118within the thickness profile. The openings118are sized and shaped to receive the switch mechanisms104.

In the illustrated embodiment, the switch104is recessed relative to the circuit board102to reduce the profile or height of the electronic device100. For example, the bottom138of the switch104is positioned below the top surface112. At least a portion of the switch104may be within the thickness profile of the circuit board102. In the illustrated embodiment, the entire housing130is positioned below the top surface112and the bottom138of the housing130is generally flush with the bottom surface114; however the bottom138may be above the bottom surface114or below the bottom surface114in alternative embodiments. A portion of the user input actuator108(shown inFIG. 1) may be configured to be received in the opening118to interface with the actuator132of the switch104.

The leads134extend upward from the housing130and are configured to be mounted to the mounting pads150on the top surface112. For example, the leads134extend through the opening118, such as along the side walls of the opening, to the top surface112. The mounting pads135of the leads134are provided along lower surfaces of the leads134and face downward. The mounting pads135are electrically and mechanically connected to corresponding mounting pads150of the circuits116. For example, the mounting pads135may be soldered to the mounting pads150. The mounting pads135may be mechanically and electrically connected to the mounting pads150by other processes in alternative embodiments. Optionally, the switches104may be supported from below such that the solder joints between the mounting pads135,150are not over stressed during actuation.

The switches104minimally increase the profile of height of the electronic device100. Recessing the switches104and providing the switches104within the openings118reduces the protruding height of the switches104above the circuit board102(in the illustrated embodiment, the switches104have near-zero protruding height above the top surface112as only the leads134extend above the top surface112) as compared to conventional electronic devices100that traditionally mount switches104to the top surface112, wherein the entire height or thickness of the switch104adds to the protruding height above the top surface of such circuit boards. As such, the electronic device100having the switches104mounted within the openings118and provided below the top surface112reduces an overall profile or height of the electronic device100as compared to conventional electronic devices.

FIG. 7is a top perspective view of a portion of the electronic device100.FIG. 8is an exploded view of a portion of the electronic device100.FIG. 9is a cross-sectional view of a portion of the electronic device100.FIGS. 7-9illustrate the switch104having the actuator132arranged as a right angle actuator.FIGS. 7-9illustrate the circuit board102having the opening118arranged at an edge160of the circuit board102. The opening118is open at the edge160. The actuator132is a side-actuated switch partially recessed into the opening118.

The edge160defines a thickness profile162of the circuit board102between the top surface112and the bottom surface114. The switch104is positioned within the thickness profile162. In an exemplary embodiment, the actuator132is positioned within the thickness profile162of the circuit board102. For example, a portion of the housing130may be arranged below the top surface112and a portion of the housing130may be positioned above the bottom surface114. In the illustrated embodiment, the top136of the housing130is provided above the top surface112and the bottom138of the housing130is provided below the bottom surface114. The housing130can also be entirely contained within the thickness profile162in other various embodiments. The switch104extends beyond the thickness profile162, such as above the thickness profile162and below the thickness profile162. The switch104may be positioned differently in alternative embodiments, such as with the top136flush with the top surface112and/or the bottom138flush with the bottom surface114. In other embodiments, the top136may be recessed below the top surface112and/or the bottom138may be provided above the bottom surface114. However, the switch104is recessed relative to the circuit board102such that the bottom138is positioned below the top surface112of the circuit board102to reduce the profile or height of the electronic device100.

In the illustrate embodiment, the leads134extend from the sides140such that the mounting pads135are mechanically and electrically connected to the mounting pads150on the top surface112of the circuit board102. The leads134are electrically connected to corresponding circuits116of the circuit board102. In alternative embodiments, the mounting pads150of the circuit board102may be provided on the bottom surface114. In other various embodiments, the mounting pads150may be recessed below the top surface112. For example, the circuit board102may have a notch out that exposes an interior layer of the circuit board102having the mounting pads150.

The switch104is provided at the edge160such that the actuator132is exposed beyond the edge160for actuation. The actuator132is positioned below the top surface112, such as within the thickness profile162. Having the switch104nested within the thickness profile162reduces the profile of the switch104above the top surface112thereby reducing the overall profile of the electronic device100.