Patent Abstract:
An exemplary electrical device manufacturing method includes the following steps. First, a first electronic module is provided. Second, one or more functions of the electronic module are verified. Third, a support module is provided. Fourth, one or more functions of the support module are verified. Fifth, the first electronic module is attached to the support module so as to form a first integrated module. Sixth, one or more functions of the first integrated module are verified.

Full Description:
BACKGROUND 
     1. Technical Field 
     The present application is related to manufacturing, and more particularly to electrical device manufacturing methods. 
     2. Description of Related Art 
     An electrical device such as a consumer electronics device consists of many electronic and mechanical parts. The electrical device must be tested after assembly to ensure operability. At present, functional testing of the electrical device is frequently performed while the electrical device is being fabricated, whereby the electrical device must be repaired or reworked if it fails the testing. 
     In the repair process or the rework process, the electrical device may require disassembly to determine problems of each part therein, a significantly time-consuming requirement. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles of at least one embodiment. 
         FIG. 1  is a flowchart of an electrical device manufacturing method according to a first embodiment of the disclosure. 
         FIG. 2  is a flowchart of an electrical device manufacturing method according to a second embodiment of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments will now be described in detail, with reference to the drawings. 
     Referring to  FIG. 1 , an electrical device manufacturing method according to a first embodiment of the disclosure includes Steps S 01  to S 05 . The electrical device can for example be a consumer electronics device. Examples of such consumer electronics devices include but are not limited to a digital camera, a mobile phone or a game player. 
     In Step S 01 , an electronic module such as an image processing module or a sound and light module is provided. The image processing module can include but is not limited to an image capture unit and an image display unit. The sound and light module can include but is not limited to a lighting unit, a microphone, and an amplifier. The lighting unit may include at least one light emitting diode (LED), organic light emitting diode (OLED), or electroluminescent lamp (EL). 
     In addition, in alternative embodiments, the electronic module can further include a protective shell or cover to protect the electronic components of the electronic module. 
     In Step S 02 , at least one function of the electronic module is verified by testing, the verification items including but not being limited to electrical characteristics, image capture function, image projection function, and optics detection tests. As should be noted, the electrical characteristics test measures impedance, capacitance, and inductance. In addition, the image projection function test typically checks hues, tints or an auto focus function for an image projected from the electronic module onto a surface external to the electronic module. Moreover, the optics detection test measures the brightness or intensity of light emitted by the lighting unit. 
     In Step S 03 , a support module is provided, which may be, but is not limited to, a base or holder. The base may provide support on a horizontal surface, and the holder may provide wall-mount capability. 
     In Step S 04 , at least one function of the support module is verified by testing, the verification items including but not being limited to endurance such as drop and thermal shock tests. 
     In Step S 05 , the electronic module is attached to the support module, resulting in the final electrical device, and at least one electrical function of the electrical device is verified by testing. Such one or more electrical function tests include but are not limited to image capture function, image projection function, and drop and thermal shock tests. 
     It should be noted that, in alternative embodiments, Step S 03  can further include integrating a rotation unit, such as a motor or gear, into the base or holder. In such embodiments, the rotation unit connects the base or holder and the electronic module, providing rotation of the electronic module. 
       FIG. 2  shows an electrical device manufacturing method according to a second embodiment of the disclosure. The electrical device includes a first electronic module, a second electronic module, and a support module. In this exemplary embodiment, the first electronic module is an image processing module and the second electronic module is a sound and light module. The electrical device manufacturing method includes steps as follows. 
     In Step S 11 , the image processing module is provided. The image processing module can include but is not limited to an image display module or an image capture module. The image display module may be a display panel or a projector. The image capture module may be an image sensor or a camera module. 
     In Step S 12 , at least one function of the image processing module is verified by at least one function test. The function test items include but are not limited to electrical characteristics testing. A test result of the function test includes a pass status and a fail status. The image processing module can be repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the image processing module may have to be replaced. 
     In Step S 13 , the support module is provided. The support module may be, but is not limited to, a base or holder. The base may provide support on a horizontal surface, and the holder may provide wall-mount capability. This step can further include integration of a rotation unit into the base or the holder, wherein the rotation unit can be a motor or gear. 
     In Step S 14 , at least one function of the support module is verified by at least one function test. The function test items include but are not limited to endurance such as drop and thermal shock testing. The support module is repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the support module may have to be replaced. 
     In Step S 15 , the image processing module is attached to the support module to form a first integrated module. If present, the rotation unit connects the support module and the image processing module, providing rotation of the image processing module. 
     In Step S 16 , at least one function of the first integrated module is verified by at least one function test. The function test items include but are not limited to one or more image tests or an alignment test. The image tests can include image capture function, display function, or image projection function tests. For example, the image projection function test typically checks hues, tints or an auto focus function for an image projected from the image processing module onto a surface external to the image processing module. The alignment test typically checks resolution or display position of an image which is projected onto a surface external to the image processing module or displayed on a screen. The first integrated module can be repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the first integrated module may have to be replaced. 
     In Step S 17 , a sound and light module is provided. The sound and light module can include but is not limited to a light emitting unit, a microphone or an amplifier. The light emitting unit can include at least one light emitting diode (LED) or organic light emitting diode (OLED). 
     In Step S 18 , at least one function of the sound and light module is verified by at least one function test. The verification items include but are not limited to optics detection, sound (e.g. voice) capture function of the microphone or sound output function of the amplifier tests. It should be noted that the optics detection test measures the brightness or intensity of light emitted by the light emitting unit. The sound and light module can be repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the sound and light module may have to be replaced. 
     In Step S 19 , the first integrated module and the sound and light module are attached to each other, thereby forming a second integrated module. 
     In Step S 20 , at least one function of the second integrated module is verified by at least one function test. The verification items may be same as those in Steps S 16  and S 18 , and may further include synchronization of the first integrated module with the sound and light module. The second integrated module can be repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the second integrated module may have to be replaced. 
     In Step S 21 , a protection module such as a protective shell for covering and protecting the second integrated module is provided. 
     In Step S 22 , the protective shell and the second integrated module are attached together, thereby forming an electrical device. 
     In Step S 23 , at least one function of the electrical device is verified by at least one function test. The verification items may be same as those in Steps S 16 , S 18  and S 20 . The electrical device can be repaired (or reworked) immediately if one of the test results is the fail status. Alternatively, the electrical device may have to be discarded. 
     The yield rate of the electrical device is increased due to pre-assembly verification of the image processing module, the support module, the first integrated module, and the second integrated module, with repair available in each verification process if required. 
     It is to be understood, however, that even though numerous characteristics and advantages of certain inventive embodiments have been set out in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only; and that changes may be made in detail to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

Technology Classification (CPC): 8