Patent Description:
Many mechanical assemblies include the mounting of components on a framework or housing in an environment where there are significant constraints on the physical dimensions of a mounting or retention mechanism. Such applications often additionally present considerable difficulties with respect to access for assembly.

Mechanical retention mechanisms for such applications, such as machine screws or heat-stakes, have physical dimensions and/or access requirements such that the retention mechanism itself imposes size restraints on other components of the assembly. This is often the case in the construction of physical components for electronic devices, particularly where space is at a premium such as in wearable electronic devices. Non-mechanical solutions (e.g., gluing or laser welding) are, however, often non-viable options due to unreliability, long-term deterioration of the connection, additional complexity in tooling, and/or cost considerations.

<CIT> describes an electronic device that may be provided with a housing having housing sidewalls. A plate may be connected between a pair of the sidewalls. An audio jack may be mounted to the plate. A microphone may be mounted within the device between the audio jack and a given one of the sidewalls.

<CIT> describes a switch, especially for use in the interior of a vehicle, which is to be embedded at least in part in or on a support that is covered, at least in the area of the switch, with a preferably flexible surface material on the surface thereof.

The invention is an assembly and a method as defined in the appended claims.

Various ones of the appended drawings merely illustrate example embodiments of the present disclosure and cannot be considered as limiting its scope. To facilitate collation of numbered items in the description to the drawings, the first digit of each numbered item corresponds to the figure in which that item first appears. In the drawings:.

The headings provided herein are merely for convenience and do not necessarily affect the scope or meaning of the terms used.

The description that follows includes devices, systems, methods, techniques, instruction sequences, and computing machine program products that embody illustrative embodiments of the disclosure. In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide an understanding of various embodiments of the disclosed subject matter. It will be evident, however, to those skilled in the art, that embodiments of the disclosed subject matter may be practiced without these specific details.

One aspect of the disclosure provides for utilizing a solder joint or connection as a mechanical joint. As will be illustrated with reference to the example embodiment that follows, such a solder joint, e.g., between plate metal components, provides for a low height bond that allows a system of which it forms part to substantially maximize available space for other components.

<FIG> shows an assembly according to one example embodiment, in this example being a housing assembly <NUM> for button-controllable electronics to be incorporated in an electronics-enabled eyewear device such as the example pair of smart glasses <NUM> illustrated in <FIG>. The housing assembly <NUM> comprises a framework in the example form of a generally box-shaped housing <NUM> that defines a housing cavity <NUM> in which electronic components are to be housed.

The housing assembly <NUM> further includes a mounted component in the example form of a button <NUM> mounted on the housing <NUM> for allowing user control of the electronics located within the housing cavity <NUM>, in use. As will be described below, the button <NUM> forms part of a button assembly <NUM> that includes a low-profile solder connection by which the button <NUM> is mounted on the housing <NUM>. As can be seen in <FIG>, the housing <NUM> includes a frame wall on which the button <NUM> is mounted, in this case being an operatively uppermost wall <NUM> defining a roof of the housing cavity <NUM>. The roof wall <NUM> has an exterior surface <NUM> on an outer or obverse side, and has an opposite interior surface <NUM> on an inner or reverse side.

As illustrated schematically in <FIG>, the button assembly <NUM> is mounted on the roof wall <NUM> to be displaceable in a direction transverse to the roof wall <NUM> (in the orientation of <FIG>, being movable relative to the roof wall <NUM> in the up-and-down direction, indicated as the z-dimension), allowing user control of electronic components <NUM> located in the housing cavity <NUM>. In <FIG>, the button assembly <NUM> is shown in a default or dormant condition, while the button assembly <NUM> in <FIG> is shown in a pressed condition in which the button <NUM> is moved maximally downward by manual user engagement therewith. The assembly <NUM> includes a bias mechanism acting on the button assembly <NUM> to urge it to the default condition. In some embodiments, the bias mechanism is provided by interaction of the button assembly with the electronics <NUM>. In one such case, a compression spring is located between the electronics <NUM> and the button assembly <NUM>, expanding resiliently upon release of the button <NUM>. In another embodiment, the bias mechanism comprises a resilient element or compression spring arrangement located in a ring recess <NUM> defined in the upper surface <NUM> of the roof wall <NUM>.

The physical ambit of the electronic components <NUM> is shown in broken lines in <FIG>, from which it will be noticed that the available z-dimensional space for a retention connection to attach the button <NUM> to the roof wall <NUM> (here being shown as the distance between the electronic components <NUM> and the interior surface <NUM> of the roof wall <NUM>) is extremely limited. In the illustrated example embodiment, the space constraints are particularly severe, considering that due to design constraints imposed by the eyewear device <NUM> in which the housing assembly <NUM> is to be incorporated, the available z-dimensional spacing between the roof wall <NUM> and the electronics <NUM> is here about <NUM>. Considering that this spacing must allow also for travel of the button assembly, the value of limiting the z-dimensional extent of the retention mechanism will be appreciated. Various aspects of an example low-profile retention connection that provides for mounting of the button <NUM> on the roof wall <NUM> with sufficiently small z-thickness is further described below.

As can be seen in <FIG>, a button opening <NUM> extends transversely through the roof wall <NUM>, with a cylindrical shank or skirt of the button <NUM> being complementary to the button opening <NUM> and being co-axially received therein to be slidable relative to the roof wall <NUM>. The button <NUM> is in this example embodiment of a hard polymeric plastics material. A generally tubular mild steel connector <NUM> is embedded at its operatively upper end in the plastics material of the button <NUM>, projecting away from the button <NUM> such that its distal end is located somewhat beyond the interior surface <NUM> of the roof wall <NUM>. Observe that the embedded end of the connector <NUM> is flattened or bent inwards to promote positive connection between the steel connector <NUM> and the plastic button <NUM> to which it is thus attached.

A metal retainer in the example form of a mild steel retainer ring <NUM> (best seen in <FIG>) is fastened to the tubular connector <NUM> on the interior side of the roof wall <NUM>, being oriented substantially parallel to the roof wall <NUM>. In this manner, part of the roof wall <NUM> is sandwiched between the retainer ring <NUM> and the button <NUM>, thus retaining the button assembly <NUM> on the roof wall <NUM> with limited z-dimensional travel. As will be described in greater detail with reference to <FIG> below, the retainer ring <NUM> is attached to the tubular connector <NUM> by a solder connection consisting in this example embodiment of four circumferentially spaced solder joints <NUM>.

Referring briefly to <FIG> (in which the relevant components are shown in exploded view and in an inverted orientation), it will be seen that the retention ring <NUM> in this example embodiment has a plurality of connection cavities in the example form of four regularly circumferentially spaced mortise holes <NUM> extending transversely through the sheet metal retainer ring <NUM>. The operatively lower end of the barrel connector <NUM> (i.e., the upper end in the orientation of <FIG>) defines four tenons <NUM> that are complementary to and correspond in spatial arrangement to the mortise holes <NUM>. Inner surfaces <NUM> of the mortise holes <NUM> are provided with a nickel coating, thereby forming respective solder-promoting surfaces. The tenons <NUM> are likewise nickel-coated, providing solder-promoting surfaces on the tenons <NUM>. For clarity of illustration, the solder surfaces <NUM> and <NUM> are hatched in <FIG>. Observe that the remainder of the exposed metal surfaces of the connector ring <NUM> and the connector <NUM> are uncoated. In this manner, the coated surfaces <NUM>, <NUM> define target zones for the respective solder joints that are to be formed in overlapping regions of the retainer ring <NUM> and the connector <NUM>, when the tenons <NUM> are received in the complementary mortise holes <NUM>.

Turning now to <FIG>, therein is shown the button assembly <NUM> mounted on the housing wall <NUM> and being disposed in the default condition, in which the retainer ring <NUM> bears against the inner surface <NUM> of the roof wall <NUM>. Note that the tenons <NUM> are a loose fit in the corresponding mortise holes <NUM>, with solder material of the respective solder joints <NUM> attaching to the parallel solder-promoting interface surfaces <NUM>, <NUM> of the connector <NUM> and the retainer ring <NUM> respectively. The solder joints <NUM> are thus in their dimensional extent (also referred to herein as the height of the solder joints <NUM>) restricted substantially to the thickness dimension of the sheet metal retaining ring <NUM>. In this example embodiment, the thickness of the retainer ring <NUM> is about <NUM>, so that the low-profile soldered connection of the example embodiment similarly has a z-dimensional height (h) of about <NUM>. Referring again briefly to <FIG>, it will be seen that this relatively low profile of the retention mechanism allows for mounting the button <NUM> on the housing <NUM> with relatively minimal effect on available space for the electronic components <NUM> in the housing cavity <NUM>, when compared to existing mounting mechanisms for such applications.

An example method of manufacturing the housing assembly <NUM> according to the previously described example embodiment will now be briefly described with reference to <FIG> and <FIG>. As described previously, <FIG> shows the button assembly <NUM> in pre-assembled condition and in inverted orientation relative to its operative orientation illustrated in <FIG>. Prior to assembly, the solder-promoting surfaces <NUM>, <NUM> are provided on the barrel connector <NUM> and the retainer ring <NUM> by applying the targeted nickel layer or coating previously described. In this example, the nickel layers are deposited by brush application, but in other embodiments the solder-promoting surfaces <NUM>, <NUM> can be formed in any suitable manner, such as dipping or electro-plating.

The inverted orientation of the <FIG> is the orientation in which the retainer ring <NUM> is in this example embodiment soldered to the tubular connector <NUM>, thus utilizing gravity to promote filling of available spaces between the parallel interface surfaces of the tenons <NUM> and the mortise holes <NUM>, and thereby promoting proper solder attachment to the nickel-coated solder surfaces <NUM>, <NUM>. To this end, a hollow plastic cylindrical skirt portion <NUM> that projects from a head <NUM> of the button <NUM> and within which the barrel connector <NUM> is co-axially located has a circumferentially spaced series of recesses <NUM> in register with and located immediately below the respective tenons <NUM> of the connector <NUM>. These recesses <NUM> provide evacuation space for draining of excess solder from the mortise holes <NUM> during assembly.

In a first step of assembly (<FIG>), the housing <NUM> is placed on a substantially horizontal support surface in an inverted position, with the button <NUM> located on the housing <NUM> such that the cylindrical button skirt <NUM> is coaxial with and extends through the button opening <NUM>. In this position, the distal end of the barrel connector <NUM> is substantially flush with the inner surface <NUM> of the roof wall <NUM>. Thereafter, as shown in <FIG>, the retainer ring <NUM> is placed flat on the inner surface <NUM> of the wall <NUM>, the connector tenons <NUM> being received in the complementary mating mortise holes <NUM> with sufficient clearance between the closely spaced, parallel solder-promoting surfaces <NUM>, <NUM> to receive solder material therein.

As shown in <FIG>, a hand solder iron <NUM> and solder wire (not shown) in this condition accesses the mortise holes <NUM> via an open mouth of the housing <NUM>, depositing molten solder material in the respective mortise holes <NUM>. The solder material flows under gravity into the clearance space between the walls of the mortise holes <NUM> and the respective tenons <NUM>, and there solidifies, thus creating a permanent connection between the retainer ring <NUM> and the connector <NUM>. In this example embodiment, Tin-Silver-Copper solder is used, but any suitable solder material may be used in other embodiments. Note that the provision of the respective solder-promoting surfaces <NUM>, <NUM> promotes creation of the solder joints <NUM> at the target interface surfaces defined by the respective solder-promoting surfaces <NUM>, <NUM>. This is due in part to the relatively poor solderability of typical steel sheet metal, which inhibits adherence of the solder material to either the connector <NUM> or the retainer ring <NUM> outside of the solder-promoting surfaces <NUM>, <NUM>.

<FIG> shows a three-dimensional cross-sectional view of two of the solder joints <NUM> after the described assembly operation. Note that in <FIG> and <FIG> of the drawings, each solder joint <NUM> is shown as comprising solder material not only between the side faces of the tenons <NUM> and the parallel interface surfaces of the mortise holes <NUM>, but also includes solder material of about equal thickness on the end faces of the tenons <NUM>. Although the illustrated effect may in some instances occur due to surface tension of the solder material in fluid form during soldering, it is somewhat exaggerated in the drawings and is not of significant importance to the structural integrity of the solder joints <NUM>. In many instances, the extent of solder material in the solder joints <NUM> is limited to the z-dimensional overlap between the tenons <NUM> and the thickness of the retainer ring <NUM>.

After the solder joints <NUM> have been allowed to set, the electronic components <NUM> (<FIG>) are inserted in the housing <NUM> and are operationally coupled to the button assembly <NUM> to allow user control of one or more functionalities of the electronics <NUM> by operation of the button <NUM>. Thereafter, the final housing assembly <NUM> is incorporated in an end product device, in this example embodiment being an eyewear device in the example form of a pair of smart glasses <NUM> illustrated schematically in <FIG>.

<FIG> shows a front perspective view of an eyewear device in the form of a pair of smart glasses <NUM> that includes a housing <NUM> including the low-profile soldered retention mechanism as described with reference to the example embodiment of <FIG>. The glasses <NUM> include a body comprising a front piece or frame <NUM> and a pair of temples <NUM> connected to the frame <NUM> for supporting the frame <NUM> in position on a user's face when the glasses <NUM> are worn. The frame <NUM> can be made from any suitable material such as plastics or metal, including any suitable shape memory alloy.

The glasses <NUM> have a pair of optical elements in the form of a pair of lenses <NUM> held by corresponding optical element holders in the form of a pair of rims <NUM> forming part of the frame <NUM>. The rims <NUM> are connected by a bridge <NUM>. In other embodiments, one or both of the optical elements can be a display (e.g., to provide a virtual reality display), a display assembly, or a lens and display combination (e.g., to provide augmented reality functionalities).

The frame <NUM> includes a pair of end pieces <NUM> defining lateral end portions of the frame <NUM>. In this example, the housing assembly <NUM>, with its internal electronics <NUM> is integrated in one of the lateral end pieces <NUM>. In some embodiments, each end piece <NUM> includes a housing assembly <NUM> as described. The button <NUM> of the housing assembly <NUM> projects through a complementary opening in the end piece <NUM> to be accessible for user operation. In some embodiments, the frame <NUM> is formed of a single piece of material, so as to have a unitary or monolithic construction. In some embodiments, the whole of the body (including both the frame <NUM> and the temples <NUM>) can be of the unitary or monolithic construction.

The temples <NUM> are coupled to the respective end pieces <NUM>. In this example, the temples <NUM> are coupled to the frame <NUM> by respective hinges so as to be hingedly movable between a wearable mode (as shown in <FIG>) and a collapsed mode in which the temples <NUM> are pivoted towards the frame <NUM> to lie substantially flat against it. Each of the temples <NUM> includes a front portion that is coupled to the frame <NUM> and a suitable rear portion for coupling to the ear of the user.

The glasses <NUM> has onboard electronics <NUM> including a computing device, such as a computer, which can in different embodiments be of any suitable type so as to be carried by the eyewear device body. In some embodiments, various components comprising the onboard electronics <NUM> are at least partially housed in one or both of the temples <NUM>. As mentioned, various components of the onboard electronics <NUM> are in this example embodiment housed in the housing <NUM> within the lateral end piece <NUM> of the frame <NUM>. The onboard electronics <NUM> includes one or more processors with memory, wireless communication circuitry, and a power source (this example embodiment being a rechargeable battery, e.g. a lithium-ion battery). The onboard electronics <NUM> comprises low-power, high-speed circuitry, and, in some embodiments, a display processor. Various embodiments may include these elements in different configurations or integrated together in different ways.

As mentioned, the onboard electronics <NUM> includes a rechargeable battery. In some embodiments, the battery is disposed in one of the temples <NUM>. In this example embodiment, however, the battery is housed in one of the end pieces <NUM>, being electrically coupled to the remainder of the onboard electronics <NUM>.

The glasses <NUM> is camera-enabled, in this example comprising a camera <NUM> mounted in one of the end pieces <NUM> and facing forwards so as to be aligned more or less with the direction of view of a wearer of the glasses <NUM>. The camera <NUM> is configured to capture digital as well as digital video content. Operation of the camera <NUM> is controlled by a camera controller provided by the onboard electronics <NUM>, image data representative of images or video captured by the camera <NUM> being temporarily stored on a memory forming part of the onboard electronics <NUM>. In some embodiments, the glasses <NUM> can have a pair of cameras <NUM>, e.g. housed by the respective end pieces <NUM>.

The glasses <NUM> further include one or more input and output devices permitting communication with and control of the camera <NUM>. In particular, the glasses <NUM> include one or more input mechanisms for enabling user control of one or more functions of the glasses <NUM>. In this embodiment, the input mechanism comprises the button <NUM>. In the current example embodiment, a photo capture command can be issued by a single, relatively short button press (e.g., shorter than a second), while a video capture command can be issued by a press-and-hold action.

It is a benefit of the described method of mounting the button <NUM> on the housing <NUM> that it provides a low profile (i.e., relatively small z-thickness) retention solution for bonding to metal parts as part of the button assembly <NUM>. It will be seen from the description of example embodiments that such assemblies are often located in narrow, difficult to access cavities, such as the housing cavity <NUM> of the example embodiment. In such relatively small, limited-access environments, conventional methods of attachment present various challenges that are avoided or overcome by the disclosed connection methods. For example, alternative methods like using machine screws, a heat stake, or laser welding are frustrated by restricted access, and require additional complexity in tooling, fixturing, and cost. Adhesive attachments like gluing are insufficiently robust, being prone to deterioration or creep over time, particularly when exposed to heat such as that generated in use by the electronic components <NUM>.

Problematically, many such conventional attachment methods almost invariably adds significantly to the z-dimensional extent of the mounted assembly (e.g., to the button assembly <NUM>) and/or requires more space to implement. In contrast, the disclosed detection mechanisms uses solder joints <NUM> as a mechanical joint. The low-height bond provided by the solder joints <NUM> allows the system to substantially maximize space available for other components. Thus, the use of the disclosed low-profile (in some cases being substantially zero-height) solder bonding in spatially restricted or difficult to access systems allows greater mechanical freedom, better packaging, and improved miniaturization of consumer products. In some cases, use of the disclosed techniques enables a metal-to-metal bond where screw access is impossible, and where providing larger heatstake or ultrasonic welding fixtures are not feasible or practical.

Note that although the low-profile soldered connection for retaining a mounted component on a support structure is in this example embodiment described with reference to a housing for electronics to be incorporated in the example eyewear device <NUM>, the mounting and retention techniques described herein can be implemented in a variety of different applications. The disclosed mechanism is particularly useful in applications where z-dimensional space is at a premium, with minimal additional space restriction being provided by the low profile soldered joint.

From the above-described example embodiments, it will be observed that one aspect of the disclosure provides for an assembly comprising:.

In some embodiments, the retainer is of sheet metal construction oriented such that a thickness dimension of the retainer is transverse to the frame wall at the mounted component, e.g. comprising a sheet steel ring lying flat against the frame wall. In such embodiments, the retainer has one or more connection cavities or openings in which part of the connector is received tenon/mortise-fashion, the solder joint being located at least in part in the one or more cavities. The solder joint in such embodiments has a height dimension that is oriented transversely to the frame wall at the mounted component, with the height dimension coinciding substantially with an overlap between the retainer and the connector, so that the height dimension of the solder joint is substantially equal to or smaller than the thickness dimension of the retainer. In this manner, the height or z-dimensional thickness of the joint between the retainer and the connector is defined by the thickness of the sheet metal retainer, thus being small relative to the size of the mounted component, the connector, and the frame wall. To this end, the connector projects through the retainer substantially no further than a major outer face of the retainer on the reverse side.

In some embodiments, at least one of the retainer and the connector includes a solder-promoting surface that coincides with an overlap between the connector and the retainer, the solder joint being of a different metal material than both the connector and the retainer, and the solder joint attaching to the solder-promoting surface. In some embodiments, both the connector and the retainer have respective solder-promoting surfaces, the solder joint attaching to the solder-promoting surfaces of both the retainer and the connector. Provision of the solder-promoting surfaces effectively allows for targeting the specific location of the solder joints. The solder-promoting surfaces on the connector and the retainer respectively are in some embodiments localized metal coatings, each localized coating for example comprising a nickel coating.

It will be seen that the foregoing discloses a number of example embodiments. These embodiments include, but are not limited to, the following enumerated list of example embodiments:.

Although an overview of the disclosed matter has been described with reference to specific example embodiments, various modifications and changes may be made to these embodiments without departing from the broader scope of embodiments of the present disclosure. Such embodiments of the inventive subject matter may be referred to herein, individually or collectively, by the term "invention" merely for convenience and without intending to voluntarily limit the scope of this application to any single disclosure or inventive concept if more than one is, in fact, disclosed.

Claim 1:
An assembly (<NUM>) comprising:
a framework (<NUM>) that includes a frame wall (<NUM>) having an outer side (<NUM>) and an opposite reverse side (<NUM>), the framework (<NUM>) defining a housing cavity (<NUM>);
a mounted component (<NUM>) that is mounted on the frame wall (<NUM>) such as to be exposed on the outer side (<NUM>) of the frame wall (<NUM>);
a metal connector (<NUM>) that is held fast by the mounted component (<NUM>) and that projects from the mounted component (<NUM>) transversely through at least part of the frame wall (<NUM>);
a metal retainer (<NUM>) that is located on the reverse side (<NUM>) of the frame wall (<NUM>) within housing cavity (<NUM>) such that part of the frame wall (<NUM>) is sandwiched between the mounted component (<NUM>) and the metal retainer (<NUM>), the metal retainer (<NUM>) being of sheet metal construction oriented such that a thickness dimension of the metal retainer (<NUM>) is transverse to the frame wall (<NUM>) at the mounted component (<NUM>);
electronics components (<NUM>) housed in the housing cavity (<NUM>) for cooperation with the mounted component (<NUM>); and
a solder joint (<NUM>) that fastens the metal retainer (<NUM>) to the metal connector (<NUM>), thereby retaining the mounted component (<NUM>) on the frame wall (<NUM>),
wherein the mounted component (<NUM>) and the metal retainer (<NUM>) fastened thereto are displaceably mounted on the frame wall (<NUM>) to allow travel of the mounted component (<NUM>) in a direction transverse to the frame wall (<NUM>), the extent of travel of the mounted component (<NUM>) away from the frame wall (<NUM>) being limited by abutment of the metal retainer (<NUM>) against the frame wall (<NUM>) on the reverse side (<NUM>) thereof, and
wherein the metal retainer (<NUM>) has one or more connection cavities (<NUM>) in which part of the metal connector (<NUM>) is received, the solder joint (<NUM>) being located at least in part in the one or more cavities (<NUM>).