Patent Publication Number: US-10770242-B2

Title: Button assembly for a portable communication device

Description:
BACKGROUND OF THE INVENTION 
     Portable communication devices such as, for example, two-way radios, land mobile radios, hand-held telephones and the like often include push-to-talk assemblies. Push-to-talk is a means of communication commonly employed in wireless communication services that controls the switching between voice transmission and voice reception modes. These assemblies typically include buttons that when pressed allow a user to speak to another portable communication device. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, together with the detailed description below, are incorporated in and form part of the specification, and serve to further illustrate embodiments of concepts that include the claimed invention, and explain various principles and advantages of those embodiments. 
         FIG. 1  is a perspective view of a portable communication device in accordance with one embodiment. 
         FIG. 2  is rear view of the portable communication device of  FIG. 1 . 
         FIG. 3  is a side view of the portable communication device of  FIG. 1 . 
         FIG. 4  is a perspective, exploded view of a push-to-talk assembly of the portable communication device of  FIG. 1 . 
         FIG. 5  is a perspective, exploded view of a button and metal ring of the push-to-talk assembly. 
         FIG. 6  is a perspective, cross-sectional view of the portable communication device of  FIG. 1 , illustrating the push-to-talk assembly in an assembled state. 
         FIG. 7  is a cross-sectional view of the portable communication device of  FIG. 1 , taken along lines  7 - 7  in  FIG. 3 . 
         FIG. 8  is an enlarged portion of the cross-sectional view of  FIG. 7 , illustrating a catch element on the metal ring of the push-to-talk assembly. 
         FIG. 9  is a cross-sectional view of the portable communication device of  FIG. 1 , taken along lines  9 - 9  in  FIG. 3 , illustrating a catch element on the metal ring of the push-to-talk assembly. 
         FIG. 10  is a perspective, exploded view of a ground metal plate and reinforcement metal plate of the push-to-talk assembly. 
         FIG. 11  is a perspective view of a dome array assembly of the push-to-talk assembly, coupled to the ground metal plate. 
         FIGS. 12 through 14  are perspective, partial views of the portable communication device of  FIG. 1 , illustrating portions of the push-to-talk assembly that have been coupled to a housing and a printed circuit board. 
         FIG. 15  is an illustration of a circuitry of the push-to-talk assembly. 
         FIG. 16  is a perspective view of a dome array assembly according to another embodiment. 
         FIG. 17  is a cross-sectional view of the portable communication device of  FIG. 1 , taken along lines  17 - 17  in  FIG. 3 , illustrating an adhesive sealing element that seals the push-to-talk assembly to the housing. 
         FIG. 18  is a cross-sectional view of a portable communication device according to another embodiment, illustrating a rubber sealing element that seals the push-to-talk assembly to the housing. 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present invention. 
     The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. 
     DETAILED DESCRIPTION OF THE INVENTION 
     A portable communication device includes a metal ring defining an interior aperture and including at least one exterior protrusion configured to couple the metal ring to a surface of the portable communication device. The push-to-talk assembly further includes a button coupled to the metal ring and including a flexible polymer material disposed within the interior aperture and co-molded to the metal ring. The button includes a first side configured to be contacted and pressed, and a second, opposite side configured to face an interior of the portable communication device. The push-to-talk assembly further includes a metal backing plate coupled to the second side of the button. 
       FIGS. 1 through 3  illustrate one example of a portable communication device  10 . In the example illustrated, the portable communication device  10  includes a housing  14 . In some embodiments the housing  14  defines an enclosure of the portable communication device  10 . The portable communication device  10  also includes an antenna  18  coupled to and extending from the housing  14 , a display area  22  positioned on a front  26  of the housing  14 , a power button  30  positioned along a top  34  of the housing  14 , a toggle button  38  positioned along the top  34  of the housing  14 , a first programmable button  42  positioned along a side  46  of the housing  14 , a volume control button  50  positioned along the side  46  of the housing  14 , a second programmable button  54  positioned along the side  46  of the housing  14 , and a push-to-talk assembly  58  positioned along the side  46  of the housing  14 . Other embodiments include different locations for the antenna  18 , the display area  22 , the power button  30 , the toggle button  38 , the first and second programmable buttons  42 ,  54 , and/or the push-to-talk assembly  58  other than that illustrated. In some embodiments one or more of the antenna  18 , the display area  22 , the power button  30 , the toggle button  38 , and the programmable buttons  42 ,  54  are not provided. 
     With reference to  FIG. 4 , the push-to-talk assembly  58  includes a button  62 , a metal ring  66  coupled to the button  62 , a dome array assembly  70 , a ground metal plate  74 , and a reinforcement metal plate  78 . As illustrated in  FIGS. 1 and 2 , once assembled the push-to-talk assembly  58  is positioned along the side  46  of the housing  14  such that the push-to-talk assembly  58  is generally flush with the side  46  of the housing  14 , and does not protrude from the housing  14 . 
     With reference to  FIG. 5 , the metal ring  66  defines an interior aperture  82 , and includes at least one exterior protrusion  86  configured to couple the metal ring  66  to a surface of the portable communication device  10 . In the illustrated embodiment, the metal ring  66  includes four exterior protrusions  86 , each forming an undercut that acts as a catch element to engage a portion of the housing  14 . Other embodiments include different numbers of exterior protrusions  86 , or other structures that are configured to couple the metal ring  66  to a surface of the portable communication device  10 . As illustrated in  FIG. 5 , the metal ring  66  has a generally elongate shape with rounded ends, and includes a main ring portion  90  and a ledge  94  that extends from the main ring portion  90  inwardly toward the interior aperture  82 . In the illustrated embodiment the metal ring  66  is made of stainless steel sheet metal. Other embodiments of the metal ring  66  include different shapes and sizes than those illustrated, as well as different materials. 
     With reference to  FIGS. 6 through 9 , when the button  62  and metal ring  66  are assembled on the housing  14 , the metal ring  66  generally sits into a recessed area  84  ( FIG. 8 ) of the housing  14 , such that an outermost portion of the metal ring  66  is flush or generally flush with an outermost portion of the housing  14 , and such that the exterior protrusions  86  grip onto one or more areas of the housing  14 . As illustrated in  FIGS. 7 through 9 , in the illustrated embodiment the metal ring  66  includes an exterior protrusion  86  along a top of the metal ring  66  and another exterior protrusion  86  along a bottom of the metal ring  66  (as seen in  FIG. 7 ), as well as an exterior protrusion  86  along each side of the metal ring  66  (as seen  FIG. 9 , with only one of the exterior protrusions  86  visible in  FIG. 9  due to the offset nature of the exterior protrusions  86  illustrated in  FIG. 5 ). As illustrated in  FIG. 8 , each of the exterior protrusions  86  has a bent, or C-shaped profile that allows the exterior protrusion  86  to act as a catch element that engages the housing  14  and couples the metal ring  66  and the button  62  to the housing  14  (for example in a snap-fit manner). The metal ring  66 , including its exterior protrusions  86 , provide stability to the overall push-to-talk assembly  58 , and strengthen the housing  14  in the region of the recessed area  84 . Other embodiments include different shapes and sizes for the exterior protrusions  86 , as well as different locations for the exterior protrusions  86  than that illustrated. Other embodiments also include different locations along the portable communication device  10  for the metal ring  66  and the button  62  than that illustrated. 
     With reference to  FIGS. 5 and 6 , the button  62  is made of a flexible polymer material (e.g., silicone rubber) and includes a collapsible region  100 . The button  62  is disposed within the interior aperture  82 , and is co-molded to the metal ring  66 , such that portions of the button  62  wrap around and/or otherwise engage the ledge  94  (as seen in  FIG. 6 ). Other embodiments of the button  62  are made of different materials, or are coupled to the metal ring  66  in a different manner (for example via an adhesive). 
     With continued reference to  FIG. 6 , the button  62  includes a first side  102  and a second, opposite side  106 . The first side  102  is configured to be contacted and pressed by a user, in the collapsible region  100 . The second side  106  faces an interior of the portable communication device  10 . 
     With reference to  FIGS. 5 and 6 , the push-to-talk assembly  58  also includes a metal backing plate  110 . The metal backing plate  110  is coupled to the second side  106  of the button  62 . The metal backing plate  110  provides added stability behind the button  62 , such that when a user presses on the first side  102 , the force is distributed across generally the entire button  62 . Thus, even if the user fails to press the button  62  in a center of the button  62 , the push-to-talk assembly  58  is still activated. 
     In the illustrated embodiment the metal backing plate  110  is adhesively bonded to the second side  106  of the button  62 . In other embodiments the metal backing plate  110  is co-molded with the button  62 , or is coupled to the second side  106  in another manner. As illustrated in  FIG. 5 , the illustrated metal backing plate  110  is a generally elongate plate with rounded ends. However, other embodiments include different shapes and sizes than that shown. 
     With reference to  FIG. 10 , the ground metal plate  74  includes a first planar body portion  114  and a first tab  118  that extends at a non-zero angle (for example 90 degrees) from the first planar body portion  114 . The reinforcement metal plate  78  includes a second planar body portion  122  and a second tab  126  that extends at a non-zero angle (for example ninety degrees) from the second planar body portion  122 . The reinforcement metal plate  78  further includes a rigid, stationary terminal  127  having a free end  128  that defines a hard contact area. The free end  128  is disposed at an opposite end of the reinforcement metal plate  78  from the second tab  126 . As illustrated in  FIG. 10 , in an assembled state the ground metal plate  74  is spaced at all points from the reinforcement metal plate  78 , and the first and second tabs  118 ,  126  are positioned adjacent one another. 
     In the illustrated embodiment both the ground metal plate  74  and the reinforcement metal plate  78  are made of titanium copper alloy sheet metal, plated with gold. In other embodiments the ground metal plate  74  and the reinforcement metal plate  78  are made of different materials and/or have different types of plating, including nickel plating, or any other electrical conductor material with appropriate plating finishing to provide electrical connection properties. In the illustrated embodiment both the ground metal plate  74  and the reinforcement metal plate  78  have a thickness of no greater than 0.20 mm. Other embodiments include different values or ranges of thicknesses. 
     With reference to  FIG. 11 , the dome array assembly  70  is coupled to the ground metal plate  74 . The dome array assembly  70  includes a third planar body portion  130 , and a dome-shaped portion  134  that extends from the third planar body portion  130 . The third planar body portion  130  is coupled directly to the first planar body portion  114  (for example with adhesive), such that the dome-shaped portion  134  extends away from the ground metal plate  74  in a first direction, and the first tab  118  extends away from the dome array assembly  70  in a second, opposite direction. 
     With reference to  FIGS. 10 through 12 , the ground metal plate  74 , the reinforcement metal plate  78 , and the dome array assembly  70  each include a plurality of apertures  138 , at least one of which is used to receive a heat stake  142  (as seen in  FIG. 12 ) on the housing  14 . In some embodiments the heat stakes  142  are plastic, although other embodiments include different materials. To assemble the ground metal plate  74 , the reinforcement metal plate  78 , and the dome array assembly  70  to the housing  14 , the apertures  138  on the ground metal plate  74  the dome array assembly  70  are aligned with one another and placed over one or more heat stakes  142 , and the apertures  138  on the reinforcement metal plate  78  are placed over one or more heat stakes  142  (as seen in  FIG. 12 ). The heat stakes  142  are then heated and allowed to cool, thereby rigidly fixing and mounting the ground metal plate  74 , the reinforcement metal plate  78 , the dome array assembly  70  in place. Other embodiments include different structures and methods by which to fix the ground metal plate  74 , the reinforcement metal plate  78 , and the dome array assembly  70  onto the portable communication device  10 . 
     With reference to  FIGS. 1 through 12 , when a user presses on the first side  102  of the button  62 , the second side  106  of the button  62  contacts the dome-shaped portion  134  and forces the dome-shaped portion  134  to flex relative to the first planar body portion  114  until the dome-shaped portion  134  contacts the free end  128  of the reinforcement metal plate  78 . In the illustrated embodiment the dome-shaped portion  134 , as well as the first planar body portion  114 , are made of stainless steel, providing a tactile feedback to the user when the dome-shaped portion  134  is pressed. In some embodiments, the dome-shaped portion  134  includes electrical connection properties that are achieved by using plating finishing. Other embodiments of the dome-shaped portion  134  and the first planar body portion  114  are made of different materials. 
     With reference to  FIGS. 13 through 15 , the first tab  118  is coupled to a first electrical contact  146  ( FIGS. 13 and 14 ) on a printed circuit board  150  (the boundaries of which are shown partially in  FIG. 14 ). The first electrical contact  146  may be for example a spring contact, pogo pin, or other electrical contact. The printed circuit board  150  is positioned within the housing  14 , and is coupled to an electrical processor  154  (shown schematically in  FIG. 14 ). The second tab  126  is coupled to a second electrical contact  158  on the printed circuit board  150 . The second electrical contact  158  may be for example a spring contact, pogo pin, or other electrical contact. In some embodiments, the ground metal plate  74  and/or the reinforcement metal plate  78  are alternatively etched by laser direct structuring onto a substrate of the housing  14 , as opposed to being separate metal plates that are attached to the housing  14 . 
     With continued reference to  FIGS. 13 through 15 , when the dome-shaped portion  134  contacts the free end  128 , an electrical connection ( FIG. 15 ) is completed between the first electrical contact  146 , the first tab  118 , the first planar body portion  114 , the dome-shaped portion  134 , the free end  128 , the second planar body portion  122 , the second tab  126 , and the second electrical contact  158 . In some embodiments this completed electrical connection causes the electrical processor  154  to activate a speaker or electrical component (not shown) within the portable communication device, thus allowing a user to speak to another portable communication device  10 . 
     Use of the separate ground metal plate  74  and reinforcement metal plate  78  provides stability and backing strength during pressing of the button  62 . In some embodiments, however, the portable communication device  10  includes a flexible printed circuit board (not shown) positioned within the housing  14 , and does not use the separate ground metal plate  74  and reinforcement metal plate  78  described above. Rather, the flexible printed circuit board itself includes ground and life terminals (for example with gold or nickel plating) inside the flexible printed circuit board with a separation between the ground and life terminals. With reference to  FIG. 16 , in this embodiment, the portable communication device  10  uses a dome array assembly  162  in place of the ground metal plate  74  and the reinforcement metal plate  78 . The dome array assembly  162  is configured to be coupled to the housing  14 , and includes a first, planar portion  166  and a dome-shaped portion  170  (for example made of stainless steel sheet metal). When a user presses on the first side  102  of the button  62 , the second side  106  of the button  62  contacts the dome-shaped portion  170 , causing the dome-shaped portion  170  to flex and contact an electrical contact on the flexible printed circuit board, thus completing an electrical connection between the ground and life terminals. 
     With reference to  FIGS. 17 and 18 , in some embodiments the push-to-talk assembly  58  is sealed to the housing  14  with a sealing element to inhibit or prevent the inflow of water or other materials into the portable communication device  10 . For example, in some embodiments the sealing element is an adhesive  174  (for example pressure-sensitive adhesive or liquid adhesive) and is applied between the push-to-talk assembly  58  and the housing  14  (as seen in  FIG. 17 ). In some embodiments the button  62  itself includes a sealing element in the form of at least one protrusion  178  (for example a rib made of silicone rubber) that extends from the button  624  and presses and forms a seal against the housing  14  when the push-to-talk assembly  58  is assembled onto the portable communication device  10  (as seen in  FIG. 18 ). In some embodiments, the sealing element is molded together with the button  62 . In some embodiments the sealing element is made of flexible, polymeric material. Other embodiments include different sealing elements and materials for the sealing elements, as well as different locations for the sealing elements than that illustrated in  FIGS. 17 and 18 . 
     With reference to  FIG. 7 , the push-to-talk assembly  58  has an overall thickness  182  (not including the first and second tabs  118 ,  126 ) measured along a direction that is perpendicular to the outer housing  14  along the side  46  of the portable communication device  10 . In some embodiments the thickness  182  is less than 3 mm. In some embodiments, the thickness is less than 2.5 mm. In some embodiments, the thickness is between 2.0 mm and 2.5 mm. In some embodiments, the thickness is 2.1 mm. Other embodiments include different thicknesses and ranges of thicknesses. 
     In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings. 
     The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The invention is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. 
     Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has,” “having,” “includes,” “including,” “contains,” “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a,” “has . . . a,” “includes . . . a,” or “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially,” “essentially,” “approximately,” “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed. 
     It will be appreciated that some embodiments may be comprised of one or more generic or specialized processors (or “processing devices”) such as microprocessors, digital signal processors, customized processors and field programmable gate arrays (FPGAs) and unique stored program instructions (including both software and firmware) that control the one or more processors to implement, in conjunction with certain non-processor circuits, some, most, or all of the functions of the method and/or apparatus described herein. Alternatively, some or all functions could be implemented by a state machine that has no stored program instructions, or in one or more application specific integrated circuits (ASICs), in which each function or some combinations of certain of the functions are implemented as custom logic. Of course, a combination of the two approaches could be used. 
     Moreover, an embodiment can be implemented as a computer-readable storage medium having computer readable code stored thereon for programming a computer (e.g., comprising a processor) to perform a method as described and claimed herein. Examples of such computer-readable storage mediums include, but are not limited to, a hard disk, a CD-ROM, an optical storage device, a magnetic storage device, a ROM (Read Only Memory), a PROM (Programmable Read Only Memory), an EPROM (Erasable Programmable Read Only Memory), an EEPROM (Electrically Erasable Programmable Read Only Memory) and a Flash memory. Further, it is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of generating such software instructions and programs and ICs with minimal experimentation. 
     The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.