PATENT DOCUMENT

Publication Number: US-8913394-B2
Application Number: US-201213409623-A
Country: US
Kind Code: B2

Title: Electrical components coupled to circuit boards

Abstract:
The present invention can facilitate the coupling between electrical components and a circuit board after the circuit board is inserted into a housing of an electronic device. An electrical component can be integrated with a flexible circuit of another electrical component. The flexible circuit can be electrically and mechanically coupled to the circuit board after the circuit board is inserted into the housing. Alternatively, electrical contacts can be disposed on a body of the electrical component and a complementary set of electrical contacts can be disposed on the circuit board. When the circuit board is disposed within a receptacle of the electrical component, the electrical contacts on the electrical component are coupled directly to the electrical contacts on the circuit board.

Claims:
What is claimed is: 
     
       1. A system comprising:
 a circuit board comprising:
 a first circuit board surface; 
 a second circuit board surface; 
 a third circuit board surface extending between the first circuit board surface and the second circuit board surface; and 
 a slot disposed in the second circuit board surface and extending towards the first circuit board surface; and 
 an electrical component comprising a circuit board receptacle, the circuit board receptacle comprising:
 a first receptacle surface; 
 a second receptacle surface; 
 a third receptacle surface extending between the first receptacle surface and the second receptacle surface; and 
 a flange extending from the first receptacle surface and towards the second receptacle surface, wherein, when a portion of the circuit board is disposed within the circuit board receptacle, at least a portion of the flange is disposed within at least a portion of the slot. 
 
 
 
     
     
       2. The system of  claim 1 , wherein, when the portion of the circuit board is disposed within the circuit board receptacle:
 the first and second receptacle surfaces constrain the portion of the circuit board within the circuit board receptacle in at least a first direction; and 
 
       the flange and slot constrain the portion of the circuit board within the circuit board receptacle in at least a second direction. 
     
     
       3. The system of  claim 2 , wherein:
 the portion of the circuit board is configured to be moved in a third direction with respect to the circuit board receptacle for disposing the portion of the circuit board within the circuit board receptacle; and 
 the third direction is perpendicular to at least one of the first direction and the second direction. 
 
     
     
       4. The system of  claim 3 , wherein the third direction is perpendicular to both the first direction and the second direction. 
     
     
       5. The system of  claim 2 , wherein, when the portion of the circuit board is disposed within the circuit board receptacle:
 a first reference feature of the first circuit board surface is coupled to a first reference feature of the first receptacle surface; and 
 the first reference feature of the first circuit board surface and the first reference feature of the first receptacle surface constrain the portion of the circuit board within the circuit board receptacle in at least a third direction. 
 
     
     
       6. The system of  claim 5 , wherein the third direction is perpendicular to at least one of the first direction and the second direction. 
     
     
       7. The system of  claim 6 , wherein the third direction is perpendicular to both the first direction and the second direction. 
     
     
       8. The system of  claim 1 , wherein the first receptacle surface, the second receptacle surface, the third receptacle surface, and the flange of the circuit board receptacle combine to surround a cross-section of the portion of the circuit board by more than 180 degrees when the portion of the circuit board is disposed within the circuit board receptacle. 
     
     
       9. The system of  claim 8 , wherein the first receptacle surface, the second receptacle surface, the third receptacle surface, and the flange of the circuit board receptacle combine to surround the cross-section of the portion of the circuit board by less than 360 degrees when the portion of the circuit board is disposed within the circuit board receptacle. 
     
     
       10. The system of  claim 1 , wherein the portion of the flange is configured to be moved along and within the slot for disposing the portion of the circuit board within the circuit board receptacle. 
     
     
       11. The system of  claim 1 , wherein:
 the system comprises an electronic device; and 
 the electrical component comprises an input/output component of the electronic device. 
 
     
     
       12. The system of  claim 11 , wherein the input/output component comprises an audio jack receptacle. 
     
     
       13. The system of  claim 1 , wherein a first electrical contact of the first circuit board surface is electrically coupled to a first electrical contact of the first receptacle surface when the portion of the circuit board is disposed within the circuit board receptacle. 
     
     
       14. A system comprising:
 a circuit board comprising a first feature; and 
 an electrical component comprising a circuit board receptacle comprising a second feature, wherein, when a portion of the circuit board is disposed within the circuit board receptacle:
 the circuit board receptacle constrains the portion of the circuit board in at least a first direction with respect to the circuit board; 
 the first and second features constrain the portion of the circuit board in at least a second direction with respect to the circuit board; and 
 the first direction is perpendicular to the second direction. 
 
 
     
     
       15. A system comprising:
 a circuit board comprising: 
 a first circuit board surface; 
 a second circuit board surface; and 
 a third circuit board surface extending between the first circuit board surface and the second circuit board surface; and 
 an electrical component comprising a circuit board receptacle, the circuit board receptacle comprising:
 a first receptacle surface; 
 a second receptacle surface; and 
 a third receptacle surface extending between the first receptacle surface and the second receptacle surface, wherein:
 a portion of the circuit board is configured to move with respect to the electrical component along a first axis for positioning the portion of the circuit board at a first position within the circuit board receptacle; and 
 
 the portion of the circuit board is configured to move with respect to the electrical component along a second axis that is perpendicular to the first axis for re-positioning the portion of the circuit board from the first position to a second position within the circuit board receptacle. 
 
 
     
     
       16. The system of  claim 15 , wherein a first reference feature of the first circuit board surface is coupled to a first reference feature of the first receptacle surface when the portion of the circuit board is at the second position. 
     
     
       17. The system of  claim 16 , wherein the first reference feature of the first circuit board surface is not coupled to the first reference feature of the first receptacle surface when the portion of the circuit board is at the first position. 
     
     
       18. The system of  claim 15 , wherein a first electrical contact of the first circuit board surface is electrically coupled to a first electrical contact of the first receptacle surface when the portion of the circuit board is at the second position. 
     
     
       19. The system of  claim 18 , wherein the first electrical contact of the first circuit board surface is not electrically coupled to the first electrical contact of the first receptacle surface when the portion of the circuit board is at the first position. 
     
     
       20. The system of  claim 15 , wherein the third circuit board surface contacts the third receptacle surface when the portion of the circuit board is at the first position. 
     
     
       21. The system of  claim 20 , wherein the third circuit board surface contacts the third receptacle surface when the portion of the circuit board is at the second position. 
     
     
       22. The system of  claim 15 , wherein: 
       the circuit board receptacle further comprises a first opening between the first receptacle surface and the second receptacle surface;
 the first opening opposes the third receptacle surface; and 
 a portion of the third circuit board surface is configured to move through the first opening and towards the third receptacle surface along the first axis for positioning the portion of the circuit board at the first position. 
 
     
     
       23. The system of  claim 22 , wherein:
 the circuit board receptacle further comprises a second opening between the first receptacle surface and the second receptacle surface; and 
 the portion of the circuit board is configured to move through the second opening along the second axis for positioning the portion of the circuit board at the second position. 
 
     
     
       24. The system of  claim 23 , wherein the first opening is perpendicular to the second opening. 
     
     
       25. The system of  claim 22 , wherein:
 the circuit board receptacle further comprises a fourth receptacle surface extending between the first receptacle surface and the second receptacle surface; 
 the circuit board receptacle further comprises a second opening between the first receptacle surface and the second receptacle surface; 
 the second opening opposes the fourth receptacle surface; and 
 the portion of the circuit board is configured to move through the second opening and towards the fourth receptacle surface along the second axis for positioning the portion of the circuit board at the second position. 
 
     
     
       26. The system of  claim 15 , wherein, when the portion of the circuit board is at the second position, the first and second receptacle surfaces constrain the portion of the circuit board within the circuit board receptacle in a first direction that is perpendicular to at least one of the first axis and the second axis. 
     
     
       27. The system of  claim 15 , wherein:
 a first reference feature of the first circuit board surface is coupled to a first reference feature of the first receptacle surface when the portion of the circuit board is at the second position; and 
 when the portion of the circuit board is at the second position, the first reference feature of the first circuit board surface and the first reference feature of the first receptacle surface constrain the portion of the circuit board within the circuit board receptacle in a first direction that is parallel to one of the first axis and the second axis. 
 
     
     
       28. The system of  claim 15 , wherein:
 the system comprises an electronic device; and 
 the electrical component comprises an input/output component of the electronic device. 
 
     
     
       29. The system of  claim 28 , wherein the input/output component comprises an audio jack receptacle. 
     
     
       30. A system comprising:
 a circuit board including a portion having a plurality of electrical contacts; and 
 an electrical component, wherein the electrical component comprises a receptacle that mates with the portion having the plurality of electrical contacts, a first additional plurality of electrical contacts in the receptacle on a first inner surface of the receptacle, and a second additional plurality of electrical contacts in the receptacle on a second inner surface of the receptacle that opposes the first inner surface; and 
 a slot in the circuit board adjacent to the first and second additional plurality of electrical contacts, wherein the receptacle mates with the slot. 
 
     
     
       31. The system defined in  claim 30 , wherein the electrical component comprises an audio connector. 
     
     
       32. The system defined in  claim 30 , wherein the receptacle is defined by a first inner surface, a second inner surface, and a third inner surface that extends from the first inner surface to the second inner surface, and wherein the portion having the plurality of electrical contacts is constrained by the first, second, and third inner surfaces of the receptacle. 
     
     
       33. The system defined in  claim 32 , wherein the receptacle is further defined by a fourth inner surface that extends from the first inner surface to the second inner surface, wherein the first, second, third, and fourth inner surfaces completely enclose the portion having the plurality of electrical contacts. 
     
     
       34. The system defined in  claim 33 , wherein the portion having the plurality of electrical contacts comprises a protruding neck structure. 
     
     
       35. A system comprising:
 a circuit board including a portion having a plurality of electrical contacts; 
 an electrical component, wherein the electrical component comprises a receptacle that mates with the portion having the plurality of electrical contacts; and 
 a multiple-pin connector coupled to the circuit board, wherein the portion having the plurality of electrical contacts is adjacent to the multiple-pin connector. 
 
     
     
       36. A system comprising:
 a circuit board including a portion having a plurality of electrical contacts; and 
 an electrical component, wherein the electrical component comprises a receptacle that mates with the portion having the plurality of electrical contacts, wherein the circuit board comprises a slot having a first longitudinal axis, the receptacle mates with the slot, and each electrical contact of the plurality of electrical contacts has a second longitudinal axis that is substantially perpendicular to the first longitudinal axis.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is continuation of U.S. patent application Ser. No. 12/634,114 filed Dec. 9, 2009, which is a divisional of U.S. patent application Ser. No. 11/519,388 filed Sep. 11, 2006 (now U.S. Pat. No. 7,660,127), each of which is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention can relate to methods and apparatus for coupling electrical components to a circuit board. 
     BACKGROUND OF THE INVENTION 
     An electronic device may include a housing with one or more openings through which electrical components of the device are assembled into the housing. The electrical components can be electrically coupled to a circuit board so that it may communicate data to and from other electrical components that may be electrically coupled to the circuit board. 
     In some electronic devices, electrical components may be mechanically and electrically coupled to the circuit board before the assembly is disposed into the housing. The electrical components may be coupled to the circuit board by discrete wires soldered to the components. However, as electronic devices become smaller and thinner, such electronic devices may be challenging to manufacture. 
     For example, an electronic device housing may be designed so that it may be more desirable or practical for some electrical components to be mechanically and electrically coupled to the circuit board after the circuit board is disposed within a housing of the device. This may occur when the size or design of the housing or obstructions within the housing prevents one of the electrical components from being preassembled to the circuit board before the circuit board is inserted into the housing. 
     Furthermore, when discrete wires are used to couple components to a circuit board, the electronic device may be difficult to manufacture because each discrete wire may need to be hand-soldered to the electrical components. Once the wires are soldered to the components, it may be difficult to neatly insert the wires into the housing. Indeed, the wires may occupy precious space within the housing when space is at a premium. 
     There also may be reliability concerns. For example, solder joints may be compromised when the circuit board and the electrical component are inserted into the housing. The solder joints also may be compromised as a result of damage from regular use of the electronic device or from external forces applied to the electronic device. 
     SUMMARY OF THE INVENTION 
     The present invention can permit electrical components to be coupled electrically to a circuit board after the circuit board is disposed in a housing. 
     In one embodiment, the present invention can accomplish this by electrically integrating an electrical component to a flexible circuit of another electrical component. The integrated flexible circuit then may be coupled both electrically and mechanically to the circuit board after the circuit board is inserted into the housing. The integrated flexible circuit can be coupled to the circuit board using a board-to-board connector. Advantageously, the flexible circuit can fit neatly into the housing, and may act as a mechanical stop to reinforce the board-to-board connection. 
     In another embodiment of the present invention, electrical contacts can be disposed on a body of the electrical component and a complementary set of electrical contacts can be disposed on the circuit board. When the circuit board is disposed within a receptacle of the electrical component, the electrical contacts on the electrical component can be coupled directly to the electrical contacts on the circuit board. 
     Advantageously, electronic devices employing the present invention may be more reliable and facilitate assembly because discrete wires need not be hand-soldered to the electrical component. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an exemplary electronic device that can incorporate the present invention; 
         FIG. 2A  illustrates an exploded view of a first embodiment in accordance with the present invention; 
         FIG. 2B  provides an exemplary flowchart of steps for assembling the electronic device of  FIG. 2A  in accordance with the present invention; 
         FIG. 3  illustrates an enlarged view of input/output (I/O) components and a flexible circuit in accordance with the present invention; 
         FIG. 4  illustrates assembly of the I/O components and the flexible circuit of  FIGS. 2A and 3  within a housing of  FIG. 2A  in accordance with the present invention; 
         FIG. 5  illustrates assembly of the I/O components, the flexible circuit, and a circuit board of  FIGS. 2A and 3  within the housing of  FIG. 2A  in accordance with the present invention; 
         FIGS. 6A-B  illustrate an assembly of the I/O components, the flexible circuit, and the circuit board of  FIG. 2A , with the flexible circuit coupled to the circuit board in accordance with the present invention; 
         FIGS. 7A-C  illustrate a second embodiment in accordance with the present invention; 
         FIG. 7D  provides an exemplary flowchart of steps for assembling the electronic device of  FIGS. 7A-C  in accordance with the present invention; 
         FIG. 8  illustrates a third embodiment in accordance with the present invention; and 
         FIGS. 9A-B  illustrate a fourth embodiment in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
       FIGS. 1-2  illustrate an exemplary electronic device that can incorporate the present invention. Electronic device  10  can be any electronic device that has electrical components coupled to a circuit board, including portable, mobile, hand-held, or miniature consumer electronic devices. Illustrative electronic devices can include, but are not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, calculators, cellular phones, other wireless communication devices, personal digital assistances, programmable remote controls, pagers, laptop computers, printers, or combinations thereof. Miniature electronic devices may have a form factor that is smaller than that of hand-held devices. Illustrative miniature electronic devices can include, but are not limited to, watches, rings, necklaces, belts, accessories for belts, headsets, accessories for shoes, virtual reality devices, other wearable electronics, accessories for sporting equipment, accessories for fitness equipment, key chains, or combinations thereof. 
     Electronic device  10  can have multiple input/output (I/O) components  12   a - d  disposed within housing  16 . The I/O components can include any type of component that receives and/or transmits digital and/or analog data, e.g., audio data, video data, other types of data, or a combination thereof. For example, I/O component  12   a  may be a display that provides graphic images to a user, I/O component  12   b  may be a user input component that can permit a user to input data into the electronic device, I/O component  12   c  may be a multiple-pin connector that can permit electronic device  10  to interact with a computer, and I/O component  12   d  may be a media output connector that can output media data to an accessory. Accessories can include docks, printers, external storage devices, external displays, speakers, lanyards having headphones coupled thereto, and other audio and/or visual output devices. 
     In one embodiment of the present invention, user input component  12   b  may be a trackwheel similar to that used by the iPod™ device sold by Apple Computer, Inc. of Cupertino, Calif. The trackwheel can include one or more buttons for selecting software entries and a capacitive touchpad. The touchpad may permit a user to scroll through software menus by running the user&#39;s finger in circles around the track of the trackwheel. In alternative embodiments, user input component  12   b  may include, for example, one or more buttons, a touchpad, a touchscreen display, electronics for accepting voice commands, antennas, infrared ports, or combinations thereof. 
     In one embodiment of the present invention, multiple-pin connector  12   c  may have 30 pins that transmit data to and from the electronic device. Multiple-pin connector  12   c  may be similar to that described in U.S. Pat. No. 6,776,660 to Kubota et al., which is incorporated herein by reference in its entirety. Multiple-pin connector  36  also may have an interface system similar to that described in U.S. Pat. No. 7,441,062 to Novotney et al., which is incorporated herein by reference in its entirety. In alternative embodiments, multiple-pin connector  12   c  may have any configuration known in the art or otherwise. 
     In one embodiment of the present invention, media output connector  12   d  can include an audio connector that transmits audio data to speakers or headphones. In alternative embodiments, media output connector  12   d  can output, for example, video data, still image data, games data, or other media data known in the art or otherwise. Media output connector also can output combinations of media data. 
     Housing  16  of electronic device  10  may be designed to have a closed back and openings  18   a,b  disposed at different sides (e.g., opposing ends) of housing  16 . Components of the device may be inserted into housing  16  through one or more openings  18   a,b . Manufacturing and/or design constraints may deem it more desirable or practical that audio connector  12   d  be coupled electrically to circuit board  14  after the circuit board is inserted into housing  16  via opening  18   a . That is, it may be more desirable for circuit board  14  to be inserted into housing  16  separately from audio connector  12   d . Once circuit board  14  is enclosed within housing  16 , it may become difficult to access the circuit board to electrically couple audio component  12   d  to the circuit board. 
     The present invention can permit the audio connector, or other electrical components, to be coupled electrically to the circuit board after the circuit board is inserted into the housing. The present invention can accomplish this by electrically integrating the audio connector to a flexible circuit of another electrical component. The integrated flexible circuit then may be coupled both electrically and mechanically to the circuit board after the circuit board is inserted into the housing. Alternatively, the audio connector can have a receptacle and the circuit board may slide directly therein. Electrical contacts disposed on the audio connector and the circuit board can establish direct electrical contact between the two components when the circuit board is disposed within the receptacle of the audio connector. 
       FIGS. 2A and 3  show a first embodiment of the present invention. Electronic device  10  can include, among other things, circuit board assembly  11  and flexible circuit assembly  13 . 
     Circuit board assembly  11  can include circuit board  14  coupled to multiple-pin connector  12   c . Circuit board assembly  11  also can include other components that are not shown in  FIG. 2A  for simplicity of illustration, e.g., display  12   a  of  FIG. 1  and a battery. 
     Flexible circuit assembly  13  can include user input component  12   b , audio component  12   d , integrated flexible circuit  22 , and board-to-board connector  20 . Flexible circuit  22  can include user input component portion  22   a  and audio connector portion  22   b  to which user input component  12   b  and audio connector  12   d  can be coupled respectively. User input component portion  22   a  and audio connector portion  22   b  can electrically and mechanically couple user input component  12   b  and audio connector  12   d  to board-to-board connector  20 . Board-to-board connector  20  may be designed to mate with complementary board-to-board connector  24  disposed on circuit board  14 , thereby coupling assembly  13  to circuit board  14 . Board-to-board connectors  20  and  24  may have connectors that can transmit data to and receive data from each other when the electrical contacts are in contact. By integrating audio connector  12   d  to user input component  12   b , board-to-board connectors  20  and  24  may incorporate more contacts than board-to-board connectors coupled to one electrical component only. 
     In one embodiment, user input component  12   b  and audio connector  12   d  can be coupled to flexible circuit  22  using surface mount technology (SMT), which may be more reliable than hand-soldered joints. In alternative embodiments, the user input component and the audio connector may be electrically coupled to the flexible circuit using other methods known in the art or otherwise. 
     Flexible circuit  22  can include any flexible printed circuit (FPC), including one-sided, double-sided, multi-layer FPCs, or combinations thereof. In alternative embodiments, flexible circuit  22  can be replaced with ribbon cables, other types of cables, wires, other types of data transmission lines, or combinations thereof. 
       FIG. 2B  provides a flowchart of steps for assembling electronic device  10  in accordance with one embodiment of the present invention. In step  21 , flexible circuit assembly  13  can be inserted into housing  16  through opening  18   b . In step  23 , user input component  12   b  then may be aligned with and coupled to opening  26  in housing  16  so that the user input component can be accessed externally by a user. This may dispose the user input component between the housing and the circuit board either directly or indirectly through other components of the electronic device. 
       FIG. 4  illustrates flexible circuit  13  coupled to housing  16  of electronic device  10  in accordance with one embodiment of the present invention. Audio component portion  22   b  of flexible circuit  22  may have a length that disposes audio component  12   d  outside of housing  16  when user input component  12   b  is coupled to opening  26 . Advantageously, this can keep audio component  12   d  from interfering with assembly of other components of electronic device  10 , e.g., circuit board assembly  11 , into housing  16 . 
     Once flexible circuit assembly  13  is disposed within housing  16 , circuit board assembly  11  may be inserted into housing  16  through opening  18   a  in accordance with step  25 . Because audio component  12   d  is disposed outside of housing  16 , circuit board assembly  11  can be inserted into housing  16  without interference or obstruction. However, if audio component  12   d  had been soldered onto circuit board  14  before inserting the circuit board assembly into housing  16 , it may have been difficult or impossible to insert the assembly fully into the housing, for example, due to obstructions. Such obstructions may include components already disposed within the housing (e.g., user input component  12   b ), protrusions or narrowing inside the housing, a small cross-sectional area of opening  18   a , a small z-height in the interior of the housing, or combinations thereof. As used herein, the z-height of a component may be the thickness of the component in the z-direction as indicated in  FIG. 4 . 
     The obstructions may make it impossible or impractical from a manufacturing standpoint to pre-assemble audio connector  12   d  to the circuit board before the circuit board is inserted into the housing. For example, user input component  12   b  may be disposed within housing  16  before circuit board assembly  11  is inserted into the housing. If the z-height of user input component  12   b  reduces the effective z-height of portions of the housing interior to a value that is less than the z-height of audio connector  12   d  and less than the z-height of portions of circuit board assembly  11 , it may be more desirable and practical to insert circuit board assembly  11  and audio connector  12   d  from different openings  18   a,b  and thereafter couple the two together. Furthermore, if the z-height of the audio component is only slightly less than that of the housing interior, it may not be practical from a manufacturing standpoint to attempt to slide the audio connector through the interior length of the housing. 
     Accordingly, manufacturing and/or design constraints may deem it more desirable for circuit board assembly  11  to be inserted into housing  16  via first opening  18   a  and audio connector  12   d  to be inserted into housing  16  via second opening  18   b . Thereafter, audio connector  12   d  can be electrically and mechanically coupled to circuit board  14  either directly or indirectly. 
     A cross-sectional area of circuit board assembly  11  may be equal to or less than that of opening  18   a  in order for the circuit board assembly to be inserted therethrough. Accordingly, the cross-sectional area of the opening through which the circuit board assembly is inserted may be large enough also to accommodate additional electrical components that may be preassembled to the circuit board, e.g., a display or battery. 
       FIG. 5  illustrates flexible circuit assembly  13  and circuit board assembly  11  inserted into housing  16  of electronic device  10  in accordance with the present invention. 
     Once circuit board assembly  11  is disposed within housing  16 , user input component  12   b  and audio connector  12   d  can be coupled to circuit board  14  in accordance with step  27 . Board-to-board connector  20  of flexible circuit  22  can mate with board-to-board connector  24  of circuit board  14 , thereby electrically and mechanically coupling flexible circuit assembly  13  to the circuit board. Thereafter, audio connector portion  22   b  of flexible circuit  22  can be folded over itself. In step  29 , audio connector  12   d  and audio connector portion  22   b  can be inserted into housing  16  through opening  18   b . One skilled in the art can appreciate that a cross-sectional area of audio connector  12   d  may be equal to or less than that of opening  18   b  in order for the audio connector to be inserted therethrough. 
     To provide structural stability to audio connector  12   d  within housing  16 , audio connector  12   d  can be mechanically coupled to electronic device  10  in accordance with U.S. Pat. No. 7,751,198 to Weber et al., which is incorporated herein by reference in its entirety. 
       FIGS. 6A-6B  illustrate audio connector portion  22   b  of flexible circuit  22  in its folded configuration. While housing  16  has been removed from  FIGS. 6A-6B  for clarity of illustration, audio connector portion  22   b  of flexible circuit  22  may be disposed between housing  16  and board-to-board connector  20  either directly or through other components of electronic device  10 . 
     Audio connector portion  22   b  of flexible circuit  22  can act as a mechanical stop for board-to-board connector  20 . When audio connector portion  22   b  of the flexible circuit is folded, the elasticity of the material from which the flexible circuit is made can cause the flexible circuit to impose normal forces against both housing  16  and board-to-board connector  20  as the flexible circuit attempts to expand out of the folded configuration. Accordingly, the folded configuration of audio connector portion  22   b  can impose a compressive force against board-to-board connector  20 . The compressive force can reinforce both the mechanical and electrical board-to-board connection between flexible circuit  22  and circuit board  14 . 
     To further reinforce the board-to-board connection between flexible circuit  22  and circuit board  14 , shim  30  may be directly or indirectly disposed between housing  16  and board-to-board connector  20 . Shim  30  can augment the compressive force imposed by the folded configuration of audio connector portion  22   b  on board-to-board connector  20 . Thus, shim  30  also can act as a mechanical stop for board-to-board connector  20 . 
     Shim  30  may include a compressible material, e.g., gel, foam, or sponge, or include a compressive device, e.g., a spring. The damping effect of the compressible material or device may protect the electronic device from compressive forces applied to the electronic device. 
       FIGS. 7A-C  illustrate a second embodiment of the electronic device of the present invention. Electronic device  31  of  FIGS. 7A-C  can differ from the embodiment described with respect to  FIGS. 2A-6B  in that the device&#39;s audio connector couples directly to the circuit board. Audio connector  32  can include circuit board receptacle  34  disposed within body  52  of the audio connector. In one embodiment, circuit board receptacle  34  and audio jack receptacle  50  can have parallel longitudinal axes. 
     Electrical contacts  36  can be disposed within circuit board receptacle  34 . Complementary electrical contacts  40  on circuit board  38  can be electrically coupled to electrical contacts  36  in circuit board receptacle  34  when the circuit board is disposed within the circuit board receptacle. Circuit board receptacle  34  can be dimensioned to permit audio jack  32  to slide onto circuit board  38  without damaging electrical contacts  36  or  40  and without compromising the electrical connection between contacts  36  and  40 . 
     Circuit board receptacle  34  can constrain the position of audio connector  32  in the z-direction with respect to circuit board  38 . While  FIGS. 7A-C  illustrate circuit board receptacle  34  as having a rectangular shape to accommodate the shape of the circuit board, circuit board receptacle  34  can have any shape that constrains audio connector  32  in the z-direction. The portion of circuit board  38  that can be coupled to receptacle  34  may have a complementary shape. 
       FIG. 7D  provides a flowchart of steps for assembling electronic device  31  in accordance with one embodiment of the present invention. In step  33 , user input component  12   b  can be inserted into housing  16 . In step  35 , user input component  12   b  can be coupled to the housing. Then, in step  37 , circuit board assembly  11  can be inserted into housing  16  from opening  18   a . Thereafter, in step  39 , audio component  32  can be inserted into housing  16  from opening  18   b . As the audio component is inserted into the housing, circuit board  38  can slide into circuit board receptacle  34  in step  41  until electrical contacts  36  disposed on the audio connector are directly coupled to electrical contacts  40  disposed on the circuit board. 
     While the audio connector of  FIGS. 7A-C  incorporates electrical contacts on two opposing surfaces of circuit board receptacle  34 , contacts can be incorporated on one surface only or additional surfaces, e.g., surface  42  or the backplane of the circuit board receptacle. Complementary contacts on circuit board  38  can be removed or added accordingly. 
     To help position or align audio connector  32  with respect to circuit board  38  so that proper contact is made between the electrical contacts, audio connector  32  can incorporate one or more reference features  44   a  that can couple to complementary reference features  44   b  disposed in circuit board  38 . For example, reference feature  44   a  may be circular divots and reference features  44   b  may be circular protuberances (or vice versa). When audio connector  32  is slid onto circuit board  38 , the audio connector can be located accurately with respect to the circuit board by coupling reference features  44   a  to reference features  44   b.    
     Reference features  44   a  and  44   b  can include divots and complementary protuberances of any shape, slots and complementary protuberances, or any other features that would help position or align the audio connector and the circuit board. Audio connector  32  also may be aligned with circuit board  38  by coupling the connector to other structures in the electronic device. For example, reference feature  49  may be coupled to a locating bracket coupled to multiple-pin connector  12   c . See, e.g., U.S. Pat. No. 7,751,198 to Weber et al., which is incorporated by reference above. 
     Surface  42  of audio connector  32  also may be used to help position circuit board  38  with respect to the audio connector. For example, contact of circuit board  38  with surface  42  may indicate that audio connector  32  is properly positioned with respect to circuit board  38  along the x-axis. Thereafter, audio connector  32  can be moved along the y-axis until reference features  44   a  couple to reference features  44   b.    
       FIG. 8  illustrates a third embodiment of the present invention. Audio connector  54  can be similar to audio connector  32  of  FIGS. 7A-C , except that the internal surfaces of circuit board receptacle  56  may enclose or surround neck  58  of circuit board  60  when neck  58  is disposed within the circuit board receptacle. 
     A portion of audio connector  54  has been cut out in  FIG. 8  to show electrical contacts  62  disposed in circuit board receptacle  56 . When neck  58  is inserted into receptacle  56 , electrical contacts  64  disposed on neck  58  can be coupled directly to contacts  62 . 
     Because circuit board receptacle  56  may enclose neck  58 , the audio connector can be constrained to the circuit board in both the y and z directions, depending on the cross-sectional shapes of the circuit board receptacle and the neck of the circuit board. For example, if the cross-sectional shapes of the receptacle and neck are polygonal, the audio connector can be constrained to the circuit board in the y and z directions. 
     To help position the audio connector in the x-direction with respect to the circuit board, audio connector  54  can incorporate one or more reference features  66   a  and neck  58  can incorporate complementary reference features  66   b . Like reference features  44   a  and  44   b  of  FIGS. 7A-B , reference features  66   a  and  66   b  can be divots, slots, protuberances, or any other features that would help position or align the audio connector with respect to the circuit board. 
       FIGS. 9A-B  illustrate a fourth embodiment of the present invention. The fourth embodiment of the present invention may be similar to the embodiments illustrated in  FIGS. 7A-C , except that circuit board  72  may include blind slot  74  and circuit board receptacle  76  may be configured differently. Blind slot  74  may be disposed in the top or bottom surface of circuit board  72 . Audio connector  70  may incorporate at least one flange  78  having a cross-sectional shape that complements that of blind slot  74 . When the circuit board is disposed within circuit board receptacle  76 , the circuit board receptacle may surround portions of circuit board  72  by more than 180 degrees. As a result, blind slot  74  and flange  78  may constrain the audio connector to the circuit board in both the y and z directions, thereby serving as reference features. 
     When audio connector  70  is inserted into the housing, flange  78  can guide the audio connector along the track formed by blind slot  74 . Electrical contacts  80  and  82  can be positioned within circuit board  72  and audio connector  70  (respectively) so that the electrical contacts are directly coupled when flange  78  reaches the end of blind slot  74 . 
     Electronic devices that incorporate the audio components and circuit boards of  FIGS. 8-9B  can be assembled in a manner similar to that described with respect to  FIG. 7D . 
     While the embodiments of  FIGS. 7A-9B  illustrate circuit board receptacles having cross-sectional shapes that are rectangular or square, the cross-sections of the receptacles may have any shape, e.g., circular or polygonal, as long as the receptacles can accommodate the circuit board. 
     Although particular embodiments of the present invention have been described above in detail, it will be understood that this description is merely for purposes of illustration. Alternative embodiments of those described hereinabove also are within the scope of the present invention. For example, the present invention can be applied to any electrical components that may need to be coupled to circuit boards after the circuit boards. 
     Furthermore, while the embodiment of  FIGS. 2-7D  may have two components coupled to flexible circuit  22 , the teachings of the present invention may be applied to couple any number of components to the flexible circuit. 
     Combinations of the above-described embodiments of the present invention or portions thereof may be provided in one electronic device unit. 
     One of ordinary skill in the art will understand that, while the above-described embodiments of the present invention may facilitate certain manufacturing techniques and/or housing designs, those embodiments are not necessarily limited thereto. For example, while the described embodiments of the present invention may facilitate assembly of components into the electronic device housing from openings disposed on opposing ends of the housing, the embodiments also may be incorporated into an electronic device having housings in which the main body of the housing includes multiple parts. An example of such a multi-part housing includes a clamshell housing. The housing of an electronic device of the present invention also may include housings in which the main body includes only one piece. An example of such a housing includes, e.g., the housings of  FIGS. 2A ,  4 ,  5 , and  7 A. A housing of the present invention may provide only one opening through which components are inserted or multiple openings that can be disposed, for example, on multiple sides of the housing. 
     The above described embodiments of the present invention are presented for purposes of illustration and not of limitation. The present invention is limited only by the claims which follow.

Metadata:
Filing Date: 20120301
Publication Date: 20141216
Grant Date: 20141216
Priority Date: 20060911
Inventors: WEBER DOUGLAS JOSEPH
MOOLSINTONG PINIDA JAN
MURPHY ROBERT SEAN
LYNCH STEPHEN BRIAN
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/186", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K1/147", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/186", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K2201/10189", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K1/189", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 39170261