PATENT DOCUMENT

Publication Number: US-9153391-B2
Application Number: US-201213679673-A
Country: US
Kind Code: B2

Title: Aluminum oxide control mechanism

Abstract:
A control mechanism comprises a housing defining an interior and an exterior, an aperture formed in the housing and extending from the interior to the exterior thereof, an actuator on the interior of the housing, proximate the control aperture, and a control member positionable within the aperture to operate the actuator. The control member comprises a first surface exposed to the exterior of the housing, a second surface proximate the actuator within the housing, and a body portion extending therebetween, the body portion being formed of a substantially single crystal aluminum oxide material. A bias member is configured to bias the body portion of the control member toward an inner surface of the housing, such that the control member is retained within the aperture in operation of the actuator.

Claims:
I claim: 
     
       1. A control mechanism comprising:
 a control aperture defined in a device housing, the control aperture extending through the device housing from an interior to an exterior thereof; 
 a control actuator on the interior of the device housing, proximate the control aperture; 
 a control member positionable within the control aperture to operate the control actuator, the control member formed from a substantially single crystal aluminum oxide material and comprising:
 a first surface exposed to the exterior of the device housing; 
 a second surface proximate the control actuator within the device housing; and 
 a body portion extending therebetween;and 
 
 a bias member configured to bias the body portion of the control member against the device housing, such that the control member is retained within the control aperture in operation of the control actuator; wherein 
 the first and second surfaces of the control member oriented along parallel crystal planes the substantially single crystal aluminum oxide material. 
 
     
     
       2. The control mechanism of  claim 1 , wherein the body portion of the control member comprises a flange, and wherein the bias member is configured to bias the flange against an inner surface of the device housing to retain the control member within the control aperture. 
     
     
       3. The control mechanism of  claim 1 , wherein the control member further comprises one or more side surfaces extending between the first and second surfaces of the control member, the one or more side surfaces oriented along orthogonal crystal planes of the aluminum oxide material, as defined with respect to the substantially parallel crystal planes of the first and second surfaces. 
     
     
       4. The control mechanism of  claim 3 , further comprising one or more facets formed between the side surfaces and the first surface of the control member. 
     
     
       5. The control mechanism of  claim 4 , wherein the one or more facets are oriented along skew crystal planes of the aluminum oxide material, as defined with respect to the parallel crystal plane orientations of the first and second surfaces and the orthogonal crystal plane orientations of the side surfaces. 
     
     
       6. The control mechanism of  claim 1 , wherein the substantially single crystal aluminum oxide material comprises a metal component selected for light transmission properties, the metal component comprising one or more of iron, titanium, chromium, copper, and magnesium. 
     
     
       7. The control mechanism of  claim 6 , wherein the light transmission properties comprise a substantially transparent or translucent color or hue in combination with a desired surface hardness, wherein the surface hardness is greater than that of amorphous silica/alumina glass. 
     
     
       8. A portable electronic device comprising the control mechanism of  claim 1 , wherein the control member is configured as one or more of a pushbutton member, a sliding switch member, or a rocker switch member for operating the control actuator within the portable electronic device. 
     
     
       9. The portable electronic device of  claim 8 , further comprising a light emitting indicia proximate the control surface of the control member, wherein the light emitting indicia is visible through the contact surface by light transmission through the body portion of the control member. 
     
     
       10. A device comprising:
 a housing extending about the device; 
 an aperture defined in the housing; 
 an actuator positioned proximate the aperture and within the device; 
 a control member positionable within the aperture, the control member formed of a substantially single crystal aluminum oxide material and comprising:
 a control surface portion for actuating the actuator within the device; 
 a body extending from the control surface portion to a contact surface portion exposed to an exterior of the device; and 
 a flange portion extending laterally from the body of the control member; and 
 
 a biasing element configured to bias the flange portion of the control member toward an inner surface of the housing, such that the body of the control member is retained within the aperture when the control surface is positioned to actuate the actuator; wherein 
 the surface and contact surface of the control member are oriented along substantially parallel crystal planes of the aluminum oxide material. 
 
     
     
       11. The device of  claim 10 , further comprising side surfaces defined on the control member and extending between the control and contact surfaces thereof, wherein the side surfaces are oriented along substantially orthogonal crystal planes of the aluminum oxide material, as defined with respect to the substantially parallel crystal planes of the control and contact surfaces. 
     
     
       12. The device of  claim 11 , further comprising facets formed in the control member between the side surfaces and the contact surface thereof, wherein the facets are oriented along skew crystal planes of the aluminum oxide material, as defined with respect to the substantially parallel crystal planes of the contact and control surfaces and the substantially orthogonal crystal planes of the side surfaces. 
     
     
       13. The device of  claim 10 , further comprising an indicia formed in the control surface of the control member, wherein the aluminum oxide material comprises a metal component selected for light transmission properties, such that the indicia is visible through the contact surface of the control member. 
     
     
       14. The device of  claim 13 , wherein the indicia comprises a light emitting device operable to display a user definable alert visible on the contact surface by light transmission through the body of the control member. 
     
     
       15. A mobile device comprising:
 a housing comprising a front glass, a back glass, and a side housing extending circumferentially between the front glass and the back glass; 
 an aperture defined in the housing and extending from an interior to an exterior thereof; 
 an actuator on the interior of the housing, proximate the aperture; 
 a sapphire control member positionable within the aperture to operate the actuator, the sapphire control member comprising:
 a control surface for actuating the actuator inside the housing; and 
 a body portion extending from the control surface to a contact surface exposed to the exterior of the housing; wherein 
 the control surface and the contact surface are oriented along substantially parallel crystal planes of the sapphire control member; and 
 
 the body portion of the sapphire control member is configured to retain the control member within the aperture in operation of the actuator. 
 
     
     
       16. The mobile device of  claim 15 , further comprising a flange formed on the body portion of the sapphire control member, wherein the flange is biased toward an inner surface of the housing to retain the sapphire control member within the aperture in operation of the actuator. 
     
     
       17. The mobile device of  claim 16 , wherein the aperture is defined in the front glass of the housing and the control member is configured as a button for operating the actuator in response to a force applied to the contact surface. 
     
     
       18. The mobile device of  claim 17 , wherein the aperture is defined in the side housing and the control member is configured as one or more of a button, rocker switch or slide member for operating the actuator in response to a force applied to the contact surface. 
     
     
       19. The mobile device of  claim 18 , further comprising side surfaces defined on the body portion of the sapphire control member and extending between the control and contact surfaces thereof, the side surfaces having a substantially elliptical or circular geometry defined independently of a crystal plane geometry of the body portion of the sapphire control member. 
     
     
       20. The device of  claim 15 , further comprising an indicia proximate the control surface of the sapphire control member, wherein the indicia comprises a light emitting device operable to display an alert, wherein the alert is visible on the contact surface of the control member by light transmission through the body portion thereof.

Description:
TECHNICAL FIELD 
     This subject matter of this disclosure relates generally to control components for electronic devices. In particular, the disclosure relates to buttons, switches, and other control mechanisms suitable for use in electronic devices, including, but not limited to, cellular phones, tablet computers, personal computers, personal digital assistants, media players, and other stationary and portable electronic devices. 
     BACKGROUND 
     Depending on application, electronic devices may utilize a wide variety of different control mechanisms, including buttons, pushbuttons, slide and toggle switches, and other devices for power, volume, home, hold, reset and other control and input functions. In use, these components are subject to a wide range of different environmental effects, including temperature extremes, humidity, contamination, physical and electrical contact, scratching, and impact, for which durability and reliability are critical engineering factors. 
     Environmental factors are particularly relevant in devices subject to both operational extremes and high performance demands, including portable electronics and mobile devices, where both internal and external control components must withstand heat, cold, moisture, humidity, shock and impact. The associated design and engineering considerations include tradeoffs between stress and strain resistance, machinability, temperature stability, and thermal properties, including surface hardness and resistance to scratching, cracking, thermal deformation, and other effects. Thus, there is a need for improved control mechanisms, particularly in the area of consumer electronics, including, but not limited to, portable electronics and mobile devices. 
     SUMMARY 
     This disclosure relates to control mechanisms with an aluminum oxide or sapphire control member for actuating or operating an actuator, and electronic devices utilizing such control mechanisms. In various applications and embodiments, a control aperture is defined in a device housing, extending from the interior to the exterior of the device. An actuator is positioned on the interior of the housing, proximate the control aperture, and the control member is positioned within the aperture to operate the actuator. 
     Depending on configuration, the control member may include a first surface exposed to the exterior of the housing, a second surface proximate the actuator on the interior of the housing, and a body portion extending between the first and second surfaces. The body portion of the control member is formed of a substantially single crystal aluminum oxide material, for example sapphire, corundum, or ruby. A biasing member is configured to bias the body portion of the control member against an inner surface of the housing, so that the control member is retained within the aperture when positioned to actuate the actuator. 
     In various examples and aspects of the control mechanism, the body portion of the control member can include a flange, where the bias member biases the flange against an inner surface of the housing to retain the control member within the aperture. The first and second surfaces of the control member may be oriented along parallel crystal planes. One or more side surfaces may extend between the first and second surfaces, oriented along orthogonal crystal planes. Facets can be formed between the side surfaces and the first surface of the control member, with skew crystal plane orientations. 
     The aluminum oxide material may include a metal component selected for light transmission properties, for example one or more of iron, titanium, chromium, copper, and magnesium. The light transmission properties may include a substantially transparent or translucent color or hue. In additional examples, a portable electronic device may include the control mechanism, for example with the control member configured as a pushbutton, sliding switch member, or rocker-type switch member. 
     Alternatively, a housing may extend about the electronic device, with an aperture defined in the housing. An actuator can be positioned within the housing, in combination with a control member positioned in the aperture. The control member can be formed of a substantially single crystal aluminum oxide material, with a control surface portion for actuating the actuator, a body portion extending from the control surface portion to a contact surface portion exposed to the exterior of the device, and a flange portion extending laterally from the body portion. 
     The control surface portion and the contact surface portion of the control member are formed with control and contact surfaces, respectively, which can be oriented along substantially parallel crystal planes of the aluminum oxide material. A biasing element can be configured to bias the flange portion of the control member against an inner surface of the housing, so that the body of the control member is retained within the aperture when actuating the actuator. 
     Side surfaces can be defined on the control member, extending between the control and contact surfaces and oriented along substantially orthogonal crystal planes, as defined with respect to the substantially parallel planes of the control and contact surfaces. Facets can be formed between the side surfaces and the contact surface, oriented along skew crystal planes. An indicia can be formed in the control surface, where the aluminum oxide material comprises a metal component selected for light transmission properties, such that the indicia is visible through the contact surface. 
     In other examples, a mobile device includes a housing with front glass, a back glass, and a side housing. Generally, the side housing can extend circumferentially about the mobile device, between the front glass and the back glass. A control aperture can be defined in the housing, extending from the interior to the exterior of the device, with a control actuator proximate the aperture, on the interior of the housing. 
     A sapphire control member may be positioned within the control aperture, with a control surface for actuating the actuator and a body portion extending from the control surface to a contact surface, which is exposed to the exterior of the housing. The control surface and the contact surface can be oriented along substantially parallel crystal planes, and the body portion can be configured to retain the control member within the control aperture. 
     Depending on application, a flange may be formed on the body portion of the sapphire control member, with the flange being biased against an inner surface of the housing to retain the sapphire control member within the aperture during operation. The aperture may be defined in the front glass of the device, with the control member configured as a pushbutton for actuating the control actuator based on a force applied to the contact surface, from the exterior of the housing. 
     Alternatively, the control aperture may be defined in the side housing, with the control member configured as a pushbutton, slide member, or rocker switch member. Side surfaces may be defined on the body portion of the control member, extending substantially perpendicularly between the control and contact surfaces. The side surfaces may have a substantially elliptical or circular geometry, as defined independently of the sapphire crystal plane geometry of the body portion. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a front perspective view of an electronic device, in a communications embodiment, with a single crystal aluminum oxide control mechanism. 
         FIG. 1B  is a rear perspective view of the device in  FIG. 1A , showing additional single crystal control mechanisms. 
         FIG. 2A  is a front perspective view of the electronic device, in an alternate communications configuration. 
         FIG. 2B  is a rear perspective view of the device in  FIG. 2A . 
         FIG. 3A  is a front perspective view of the electronic device, in a media player configuration. 
         FIG. 3B  is a side perspective view of the electronic device, in a tablet computer configuration. 
         FIG. 4  is a block diagram illustrating internal and external components of the electronic device. 
         FIG. 5A  is a cross-sectional view of a control mechanism for the electronic device, with a single crystal aluminum oxide control member. 
         FIG. 5B  is a schematic view illustrating internal elements of the control mechanism. 
         FIG. 6  is a schematic view of representative crystal plane orientations for the single crystal control member. 
         FIG. 7A  is a cross-sectional view of the control device, showing the control member in a dual actuator or rocker switch configuration. 
         FIG. 7B  is a cross-sectional view of the control device, showing the control member in a sliding switch configuration. 
     
    
    
     DETAILED DESCRIPTION 
       FIG. 1A  is a perspective view of electronic device  10 , in a communications embodiment, for example a portable phone or digital assistant.  FIG. 1A  is a front view of device  10 , showing front cover (or cover glass)  12 A.  FIG. 1B  is an alternate perspective view of device  10 , showing rear cover (or cover glass)  12 B. In this particular example, display window  14  is defined in front cover glass  12 A, for example between opaque border regions  15 . 
     Front and back cover glass components  12 A and  12 B are coupled to housing  16  to enclose electronic device  10 , for example using a bezel or frame assembly  18  to couple front and back glass components  12 A and  12 B between bottom and top portions  16 A and  16 B of cover  16 . Depending on configuration, front cover glass  12 A may also accommodate one or more interactive control mechanisms  20 , for example with a hold button or other control member formed of a single crystal aluminum oxide or sapphire material to provide scratch and impact resistance, durability, and increased surface hardness, as described below. 
     Electronic device  10  may also be configured for a range of different applications, including not only portable phones, digital assistants and other communications devices, as illustrated in  FIGS. 1A and 1B , but also personal computers, tablet computers, computer displays, media players, and other portable and stationary electronic devices. A variety of additional control features may also be provided, for example one or more audio buttons or other control mechanisms  21  in housing  16 , including one or more volume button mechanisms  21 A and  21 B or mute switch mechanisms  21 C in top portion  16 B of housing  16 , as shown in  FIG. 1B . Device  10  may also include additional features and accessories, including, but not limited to, audio features  22  (e.g., speakers and microphones), front and back cameras  24 A and  24 B, and lighting or indicator features  26  (e.g., a flash unit, light emitting diode, or other indicator or illumination device). 
     Housing  16  and frame  18  are typically formed of metals or other durable materials, for example aluminum or stainless steel, or a durable plastic or composite material. Housing  16  and frame  18  may also be configured to accommodate additional accessory features, including, but not limited to, speaker or microphone apertures  28 , connector apertures  30  for power and data communications, mechanical fasteners  32 , and access ports  34  (e.g., for a subscriber identity module, flash memory device, or other internal component). These features may be variously arranged on front and back cover glasses  12 A and  12 B, and on the different components of housing  16 , for example along bottom housing  16 A and top housing  16 B, as shown in  FIGS. 1A and 1B , or in any combination of the other configurations described below. 
       FIG. 2A  is a front view of electronic device  10  in an alternate configuration, for example an advanced portable device or smart phone. As shown in  FIG. 2A , single crystal sapphire control button or member  20  is provided in front glass  12 A, with display window  14  defined within borders  15 .  FIG. 2B  is a back view of device  10 , showing back glass  12 B as two separate inlay or inset components, with or without a separate cover glass element  12 C for back camera  24 B. 
     As shown in  FIGS. 2A and 2B , housing  16  can be provided in a multi-piece beveled configuration, with bottom housing  16 A, top housing  16 B, and middle plate  16 C. Middle plate  16 C extends across the back of device  10 , between back glass insets  12 B, forming side housing portions  16 D between top and bottom housings  16 A and  16 B. Device  10  may also accommodate a range of different control members  20  and  21 A- 21 C, as described above, including buttons, slide switches, and rocker switch components. Additional control features may also be included on device  10 , for example hold button mechanism  20 A in top housing  16 B, along with various accessories and other features  22 ,  24 A-B,  26 ,  28 ,  30 , and  32 . 
       FIG. 3A  is a front view of electronic device  10 , in a media player embodiment, showing display window  14  within frame  15  in front glass  12 A. Control member  20 B is provided in a side portion of housing  16 . As illustrated by  FIG. 3A , the horizontal and vertical orientations of device  10  are arbitrary, and the various top, bottom, and side designations of the different components of device  10  can be interchanged, without loss of generality. 
     In one particular configuration, housing  16  may have a substantially unitary construction, formed together with the back cover of device  10 . One or both of housing  16  and frame  18  can also be formed of a plastic or other durable polymer material, or using a combination of metal, polymer, plastic and composite materials, and front glass  12 A can be attached to housing  16  via adhesive coupling to frame  18 . 
       FIG. 3B  is a front view of electronic device  10 , in a computer embodiment, for example a tablet computer, pad computer, or other hand-held computing device, or a computer monitor or display. Front glass  12  accommodates display window  14 , as described above. One or more control features such as rocker-type volume switch members  21  and sliding mute switch members  21 C are provided in the top, bottom or side portions of housing  16 . As shown in  FIG. 3B , housing  16  may be coupled to front glass  12 A with a beveled frame assembly  18 , or utilizing an internal bezel groove in either frame  18  or housing  16 . 
       FIG. 4  is a block diagram illustrating various internal and external components of electronic device  10 , including controller  42 , display  43  within display window  14 , accelerometer  44 , and internal accessories  45 . Hard-wired or wireless connections  46  may be provided to various external accessories  47 , host devices  48 , or networks  49 . One or more control mechanisms  50  are provided in cover glass  12  or housing  16 , or both, including, but not limited to, home buttons and other pushbutton-type control mechanisms  20 , and different rocker, toggle, and slide switch or button mechanisms  20 A- 20 B,  21 , and  21 A-D. Control mechanisms  50  may utilize single crystal sapphire control members or switch elements, as described below, providing improved surface hardness, scratch resistance and durability. 
     Device  10  encompasses a range of different portable and stationary electronic applications, as well as hybrid devices such as mobile telephones with media player capabilities, game players, remote global positioning and telecommunications devices, laptop, desktop, notebook, handheld and ultraportable computer devices, and other portable and stationary electronic devices  10 . Depending on embodiment, cover glass  12  may be configured as one or more of a front glass  12 A, back glass  12 B, or a specialty (e.g., camera or lens) cover glass  12 C, as shown in  FIGS. 1A-3B . Internal accessories  45  may include one or more cameras  24 A and  24 B, microphone or speaker features  22  and  28 , and audio/visual features such as a flash or indicator/display feature  26 . 
     Additional sensor and internal accessory components may also be provided, for example accelerometer or motion sensor  44 , a GPS system, or a haptic feedback mechanism such as a vibration motor or haptic actuator. Available external accessories  47  include headphones, speakers, displays, and other external components. 
     Controller  42  is electronically coupled to display  43 , accelerometer  44 , internal accessories  45 , and one or more control mechanisms  50 . Controller  42  includes various microprocessor (μp) and memory components, which can be configured to control device  10  by executing a combination of operating system and application software. 
     Depending on application, controller  42  is configurable to provide a range of functionality for device  10 , including, but not limited to, voice communications, internet browsing, messaging, email, media playback and development, gaming, security, transactions, navigation, and personal assistant functions. Control components  42  may also include communication interfaces and other input-output (IO) devices configured to support voice control and other hard-wired and wireless communications features, including audio, visual, infrared (IR), and radio frequency (RF) connections  46  for external accessories  47 , host devices  48 , and network systems  49 . 
       FIG. 5A  is a cross-sectional view of control mechanism  50  for electronic device  10 . Control mechanism  50  includes a single crystal aluminum oxide control button or switch control member  52 , positioned within control aperture  54 , as defined in housing or cover component  56 . Housing  56  may comprise a bottom, top, front, side or back housing  16  or  16 A-C, or a front or back cover glass  12 A or  12 B. Control mechanism  50  may comprise control member  52  for a pushbutton, rocker, or slide switch control mechanism  20 ,  20 A-B,  21  or  21 A- 21 C, as described above with respect to  FIGS. 1A-3B . 
     Pushbutton or switch control member  52  comprises a body portion extending longitudinally along sides  52 S from control surface portion  52 A, into and through control aperture  54  to contact surface portion  52 B. Control surface portion  52 A is mechanically coupled to (or otherwise operably connected to) control actuator  58 , on the interior of device  10 , proximate aperture  54 . Contact surface portion  52 B is exposed for user manipulation, on the exterior of housing  56 . 
     As shown in  FIG. 5A , contact surface portion  52 B of control member  52  may be proud of exterior surface  56 A of housing  56 , projecting above or out of aperture  54 . Alternatively, contact surface portion  52 B of control member  52  may be flush or recessed with respect to exterior surface  56 A of housing  56 , within aperture  54 . 
     Button or switch control member  52  may also include one or more bevels or facets  52 C, for example adjacent to or on control surface portion  52 A. One or more seal elements  57  may be provided to seal aperture  54  in housing  56  about control member  52 , for example O-rings or other seal components  57 , located between lateral sides  52 S of control member  52  and inner sides  56 S of housing  56 , along the inside of aperture  54 . 
     Retention flange  52 F extends transversely from the body of control member  52 , inside aperture  54  in device housing  56 . A spring, inverted dome, or other resilient bias element  60  can be provided to bias retention flange  52 F and the body of control member  52  in an upward or outward direction (arrow  60 A), against or proximate one or more interior surfaces  56 B of housing  56 . Thus, single crystal aluminum oxide button or switch control member  52  may be retained within control aperture  54  during operation of actuator  58 , with the body of control member  52  positioned between interior sides  56 S of housing  56 . 
     In operation of control mechanism  50 , an external (e.g., inward or downward) force or pressure can be applied to button or switch member  52 , for example using finger  62 , or a stylus, pen, pencil or other device. When the external force on contact surface portion  52 B overcomes the outward bias from resilient spring or inverted dome element  60  (arrow  60 A), button or switch member  52  moves in an inward direction (arrow  62 A) causing actuator  58  to complete an electrical contact, for example via one or more conducting base members  63  and inner and outer conducting pads  64 . 
     Thus, control member  52  is positionable within aperture  54  to operate actuator  58 , and to toggle control mechanism  50  between different states, for example ON and OFF. Alternatively, control member  52  operates actuator  58  to select a particular digital or logical state for control mechanism  50  (e.g., 0 or 1), or to scale control mechanism  50  across a digital or analog range. Additional insulator, shim, and contact structures  65 ,  66 , and  67  may also be provided, depending on the coupling configuration and operational arrangement of switch or control member  52  and actuator  58 . 
       FIG. 5B  is a schematic diagram illustrating internal elements of control mechanism  50 , including single crystal control member  52  and actuator  58 , as shown in  FIG. 5A . In general, actuator  58  can be coupled to a controller or other circuit element  42  utilizing flex circuit (or other connector)  68 , with terminals  68 A. When button or switch member  52  is depressed against bias element  60 , one or more pads or other contact elements  64  are positioned in electrical contact, generating a control signal through connector  68 . Controller  42  determines the control state of mechanism  50  by sensing the signal across terminals  68 A, in order to set or control various operational features such as volume, mute, power, and application status. 
       FIG. 6  is a schematic diagram illustrating the crystal plane orientation of aluminum oxide control member  52 , in a substantially single crystal (e.g., corundum, sapphire or ruby) embodiment. As shown in  FIG. 6 , single crystal aluminum oxide control member  52  exhibits a multi-faceted (e.g., rhombohedral) crystal structure, with individual crystal planes oriented at different angles, including, but not limited to, crystal planes N, C, R, A, and M, respectively. 
     The angular orientations of the different crystal planes can be defined in terms of perpendicular vectors, for example angle θ NC  of about 61° between perpendiculars [n] and [c] to planes N and C, and angle θ CR  of about 57.6° between perpendiculars [c] and [r] to planes C and R. Additional planar orientations are also shown in  FIG. 6 , including angle θ RM  of about 32.4° between perpendiculars [r] and [m] to planes R and M, and angle θ MA  of about 30° between perpendiculars [m] and [a] to planes M and A. 
     Some crystal planes have substantially perpendicular orientations, for example crystal planes A and C, and crystal planes M and C. In the three-dimensional crystal structure of control member  52 , however, orthogonal plane relationships are not necessarily transitive, as shown in  FIG. 6 . For example, while crystal plane A is perpendicular to crystal plane C, and crystal plane C is perpendicular to crystal plane M, crystal plane M is not necessarily perpendicular to crystal plane A. 
     Control member  52  may be formed by sintering and fusing aluminum oxide (alumina; Al 2 O 3  or α-Al 2 O 3 ) in an inert atmosphere, in order to produce a single crystal (or substantially single crystal) sapphire, ruby or corundum boule. Typical synthesis processes include, but are not limited to, Verneuil processes, Czochralski processes, and flux methods. The sapphire boule may be cut (e.g., using industrial diamond tools) to produce control component  52  in the form of a substantially single crystal pushbutton, slide or switch control member, as described above. 
     In general, the use of a single crystal aluminum oxide materials (e.g., sapphire, corundum, or ruby) provides button or switch member  52  with increased hardness, as compared to plastics and metals such as aluminum and steel, and even as compared to relatively hard glass materials such as silica glass and amorphous silica/alumina glass. The crystal plane orientations of the aluminum oxide material can also be selected to provide particular combinations of stress and strain resistance, depending on the relative orientation of the crystal planes with respect to the different surfaces of control member  52 . 
     In particular, the crystal plane orientations of control member  52  may be selected for strength, surface hardness, and stress and strain resistance. For example, substantially parallel contact and control surfaces  52 A and  52 B of control member  52  may be oriented along a mechanically strong crystal plane (e.g., plane A or C), and substantially perpendicular side surfaces  52 S may be oriented along one or more orthogonal planes (e.g., A, C or M). Similarly, faceted surfaces  52 C may also be formed along one or more crystal plane orientations, for example planes N or R. 
     These particular examples, however, are merely representative. In additional configurations, contact and control surfaces  52 A and  52 B of single crystal control member  52  may be formed or oriented along any set of substantially parallel crystal planes, including, but not limited to, planes C, N, R, A, or M, or other crystal planes. Similarly, side surfaces  52 S of single crystal control member  52  may be formed along any orthogonal (or substantially orthogonal) planes C, N, R, A, or M, as defined with respect to the parallel (or substantially parallel) crystal planes of control and contact surfaces  52 A and  52 B. 
     Alternatively, one or more of side and contact surfaces  52 A,  52 B, and  52 S may also be formed or cut across the crystal planes, or in an arbitrary direction, for example to form one or more surfaces  52 A,  52 B,  52 C and  52 S of control member  52  into square, rectangular, oblong, circular, elliptical, polygonal, or other shapes, irrespective of the crystal orientation of the aluminum oxide material. Similarly, faceted surfaces  52 C may be formed along crystal planes such as C, N, R, A, or M, or faceted surfaces  52 C may be formed in arbitrary directions with respect to the crystal plane orientation of control member  52 . 
     In additional applications, two or more substantially single crystal components may be fused together to form button or switch member  52 , for example by bonding control surface portion  52 A with flange  52 F to contact surface portion  52 B via thermal fusion. In fused embodiments, an interface layer of polycrystalline or substantially amorphous aluminum oxide may be provided between adjacent single crystal portions  52 A and  52 B of control member  52 , in order to improve thermal bonding. Alternatively, hydrophilic (OH) surfaces may be formed on adjacent single crystal portions  52 A and  52 B of control member  52 , in order to provide hydrogen bonding along the interface, or adjacent single crystal portions  52 A and  52 B of control member  52  may be bonded by a cold working process, or via a mechanical or adhesive bond. 
     The aluminum oxide material of control member  52  can also be doped or implanted with a range of different materials to provide desired physical properties, including, but not limited to, color, density, hardness, thermal or electrical conductivity and resistivity, and magnetic permeability or reluctance. For example, the aluminum oxide material of control member  52  may include one or more of iron, titanium, chromium, copper, magnesium and other metal or non-metal components, dopants, or impurities, in order to provide a desired tint or color cast, such as red, orange, yellow, green, blue, violet or purple, or other physical properties such as hardness, conductivity, or permeability. Where chromium impurities are present, for example, control member  52  may be formed as a single crystal ruby structure, or a combination of two or more such structures. Alternatively, control member  52  may be formed as a single crystal ruby, corundum or sapphire structure, or a combination of such structures, in a range of colors or hues, with a range of translucent, transparent, and substantially opaque color densities, and with other selected physical properties, as described above. 
     One or more indicia  52 I or  52 J may also be provided, for example as formed in or on control surface  52 A or contact surface  52 B, respectively, as shown in  FIG. 6 . Indicia  52 I and  52 J may be formed by cutting, abrasion, or other subtractive machining technique, or in the form of an applied pigment, coating, or mechanical component, such as a metal or plastic indicia. Alternatively, indicia  52 I or  52 J may include a light emitting indicator coupled to controller  42  in order to provide alerts and other operational indicator functionality, as described below. 
     Particular forms of indicia  52 I and  52 J include, for example, volume, mute, and hold indicators, and other identifying marks related to the operational function of control member  52 . Where control member  52  is provided as a substantially clear, transparent, or translucent structure, moreover, the color density of control member  52  can be selected such that any internal indicia  52 I in or on control surface  52 A may be visible as external indicia  52 J, through contact surface  52 B, via selecting the impurities or dopants for light transmission (L) through the body of control member  52 . Thus, internal indicia  52 I may be protected from wear and other environmental effects, while visible for use as external indicia  52 J during operation of control member  52 . 
     In additional examples, indicia  52 I or  52 J may take the form of an LED or other light emitting indicator. Thus, any incoming call, message, reminder, alert, alarm or other notification that might otherwise be shown in a display screen or indicated using a vibration motor or other haptic device can also be presented as a light emitting indicia  52 I or  52 J, for example a flashing LED or steady indicator light  52 I in combination with a clear or substantially transparent or translucent control member  52 , such that internal indicia  52 I may also be visible as external indicia  52 J. 
     In this configuration, custom notifications can also be sent to individual buttons or other control members  52  on different control mechanisms  50 , using different lighted indicia  52 I and  52 J. For example, user-definable control parameters can be provided for controller  42  to set internal hold button indicators  52 I for high, medium, or low priority messages, calls, reminders, and other alerts or alarms, in combination with different levels of priority indicators  52 I for other control mechanisms  50 , including volume buttons, mute switch, home buttons, and other control members  52 . In substantially clear, transparent, or translucent configurations of control member  52 , such internal indicia  52 I may also be visible as external indicia  52 J, by transmission of light L through the body of control member  52 . Thus, besides scratch resistance and durability, another potential application of the present disclosure is to leverage the optical properties of control member  52 , in order to provide additional user alert and signal communications capability based on illuminated indicia  52 I and  52 J. 
       FIG. 7A  is a cross-sectional view of control device  50 , with control member  52  provided in a dual actuator or rocker switch type configuration. In this particular example, control member  52  has a substantially elongated geometry, with one or more contact surface portions  52 B extending across two separate, independently operable actuator mechanism  52 A and  52 B. Pressure or force may be applied to control member  52  in two separate locations (e.g., arrows  62 A), in order to overcome the bias force in one or more spring or bias elements  60  (arrows  60 A), operating one or both of actuator mechanisms  56 A and  56 B. 
       FIG. 7A  also illustrates that while aperture  54  may be provided in a “stepped” configuration within housing  56 , for example as shown in  FIG. 5A  (and  FIG. 7B , below), with separate inner surfaces  56 B and side surfaces  56 S at different positions along aperture  54 , this is merely representative. In other designs, aperture  54  may be formed in a substantially straight or beveled (unstepped) configuration, as shown in  FIG. 7A , with side surfaces  52 S forming additional inner surfaces  52 B of housing  56 . Further, flange portion  52 F of control member  52  can also be configured accordingly, in order to retain the body of control member  52  within control aperture  54  during operation of actuator  58 , for example by biasing side surfaces  52 S of control member  52  against or toward side (or inner) surfaces  52 S (or  52 B) of housing  56 , along the corresponding sides of aperture  54 . 
       FIG. 7B  is a cross-sectional view of control device  50 , with control member  52  provided in a sliding switch type actuator configuration. In this particular example, control member  52  is configured to slide transversely within control aperture  54 , from a first lateral position along sliding member or switch translation surface  72 , in which control member  52  operates or actuates first control actuator  58 A, to a second lateral position along sliding member or switch translation surface  72 , in which control member  52  operates or actuates second control actuator  58 B. 
     In sliding switch configurations, as illustrated in  FIG. 7B , the actuation direction of control member  52  (arrow  62 B) is substantially lateral, along the plane of housing  56  within control aperture  54 . Control member  52  can be retained within aperture  54  by the biasing force of one or more springs or resilient members  60 , which bias flange portion  52 F on the body of control member  52  against one or more inner surfaces  56 B of housing  56 , as described above for the button configuration of  FIGS. 5A and 5B , and as shown for the rocker switch configuration of  FIG. 7A . 
     In particular, the sliding switch actuation direction (arrow  62 B) can be considered to extend in or out of the plane of  FIG. 5A , with flange portions  52 F on either side, and with control aperture  54  extending laterally along the actuation direction, as shown in  FIG. 7B . Depending on desired control functionality, sliding switch and rocker type control mechanisms  50  can also be configured with a single bias-activated control actuator  52 , as shown in  FIGS. 5A and 5B , or with two or more independent control actuators  52 A and  52 B, as shown in  FIGS. 7A and 7B . 
     While this invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes can be made and equivalents may be substituted for elements thereof, without departing from the spirit and scope of the invention. In addition, modifications may be made to adapt the teachings of the invention to particular situations and materials, without departing from the essential scope thereof. Thus, the invention is not limited to the particular examples that are disclosed herein, but encompasses all embodiments falling within the scope of the appended claims.

Metadata:
Filing Date: 20121116
Publication Date: 20151006
Grant Date: 20151006
Priority Date: 20121116
Inventors: KWONG KELVIN
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K5/0217", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/03", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H9/161", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H9/161", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/023", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K5/0017", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H9/161", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 50726877