PATENT DOCUMENT

Publication Number: US-9024250-B2
Application Number: US-201213606726-A
Country: US
Kind Code: B2

Title: Electronic device with light sensor alignment structures

Abstract:
Electronic devices may include light sensors. The light sensors may include alignment features. The light sensors may be optically aligned with an aperture in an opaque structure. The opaque structure may be formed from an opaque material or a transparent material with an opaque coating. The light sensor may be mounted in a support structure that has been optically aligned with the aperture. The light sensor or the support structure may include extended portions that are transparent to ultraviolet light. Ultraviolet light may be transmitted through the extended portions to cure adhesive that attaches the light sensor or the support structure to the opaque structure. The light sensor may be optically aligned with the aperture by viewing the aperture through an opening in the support structure, by viewing the alignment features on the light sensor through the aperture or by gathering alignment data using the light sensor during alignment operations.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a housing structure having at least one opaque portion; 
 a transparent aperture in the opaque portion; and 
 a light sensor mounted against the transparent aperture in the opaque portion so that light passes through the transparent aperture onto the light sensor, wherein the light sensor comprises at least one alignment feature that is visible through the transparent aperture. 
 
     
     
       2. The electronic device defined in  claim 1  wherein the light sensor comprises an ambient light sensor. 
     
     
       3. The electronic device defined in  claim 1  wherein the light sensor comprises a proximity sensor. 
     
     
       4. The electronic device defined in  claim 3  wherein the proximity sensor comprises a light-emitting portion and a light-receiving portion. 
     
     
       5. The electronic device defined in  claim 4  wherein the proximity sensor comprises a first lens in the light-emitting portion and a second lens in the light-receiving portion and wherein the at least one alignment feature comprises first and second alignment marks formed between the first lens and the second lens. 
     
     
       6. The electronic device defined in  claim 5  wherein the first and second alignment marks comprise alignment marks that are molded in a surface of the proximity sensor. 
     
     
       7. The electronic device defined in  claim 1 , further comprising a display, wherein the housing structure comprises a cover layer for the display. 
     
     
       8. The electronic device defined in  claim 7  wherein the cover layer comprises a transparent material and wherein the at least one opaque portion of the housing structure comprises a portion of the transparent material that is covered by an opaque masking layer. 
     
     
       9. The electronic device defined in  claim 1  wherein the light sensor comprises an extended portion that is transparent to ultraviolet light. 
     
     
       10. The electronic device defined in  claim 9 , further comprising an ultraviolet light cured adhesive interposed between the extended portion of the light sensor and the housing structure that attaches the light sensor to the housing structure. 
     
     
       11. An electronic device, comprising:
 a transparent substrate; 
 an opaque masking layer on the transparent substrate; 
 an opening in the opaque masking layer; 
 a support structure having an opening, wherein the support structure is attached to the transparent substrate and wherein the opening of the support structure is aligned with the opening in the opaque masking layer; and 
 a light sensor in the opening of the support structure that receives light through the opening in the opaque masking layer. 
 
     
     
       12. The electronic device defined in  claim 11  wherein the support structure includes an extended portion and wherein the electronic device further comprises adhesive that attaches the extended portion to the transparent substrate. 
     
     
       13. The electronic device defined in  claim 12  wherein the adhesive comprises an ultraviolet light cured adhesive and wherein the extended portion of the support structure comprises a material that is transparent to ultraviolet light. 
     
     
       14. The electronic device defined in  claim 11  wherein the light sensor comprises a light-sensitive element and a lens that focuses the light onto the light-sensitive element. 
     
     
       15. The electronic device defined in  claim 14  wherein the light sensor further comprises a light-generating element. 
     
     
       16. The electronic device defined in  claim 15  wherein the light-generating element comprises a light-emitting diode that generates at least infrared light. 
     
     
       17. A method for mounting a light sensor in an electronic device using a support structure for the light sensor, wherein the support structure includes an opening, and wherein the electronic device includes a housing structure with a transparent aperture, the method comprising:
 gathering images of the support structure; 
 gathering images of the aperture through the opening in the support structure; 
 aligning the support structure with the aperture using the gathered images of the support structure and the gathered images of the aperture; and 
 attaching the support structure to the housing structure. 
 
     
     
       18. The method defined in  claim 17 , further comprising:
 inserting the light sensor into the opening in the support structure. 
 
     
     
       19. The method defined in  claim 18  wherein attaching the support structure to the housing structure comprises curing a light curable adhesive by passing light onto the light curable adhesive through a transparent portion of the support structure. 
     
     
       20. The method defined in  claim 17  wherein aligning the support structure with the aperture using the gathered images of the support structure and the gathered images of the aperture comprises:
 determining a location of an edge of the aperture using the gathered images of the aperture; and 
 determining a location of an edge of the opening in the support structure using the gathered images of the support structure. 
 
     
     
       21. A method for mounting a light sensor having alignment features in an electronic device having a housing structure with a transparent aperture, the method comprising:
 gathering at least one image of the alignment features through the transparent aperture; 
 aligning the light sensor to the transparent aperture using the gathered at least one image of the alignment features; and 
 securing the aligned light sensor to the housing structure. 
 
     
     
       22. The method defined in  claim 21  wherein aligning the light sensor to the transparent aperture using the gathered at least one image of the alignment features comprises:
 determining a location of a center point of the light sensor using the at least one image; and 
 determining at least one location on an edge of the aperture using the at least one image. 
 
     
     
       23. The method defined in  claim 21  wherein securing the aligned light sensor to the housing structure comprises illuminating light-sensitive adhesive by transmitting light through a transparent extended portion of the light sensor. 
     
     
       24. A method for mounting a light sensor in an electronic device having a housing structure with an aperture, the method comprising:
 gathering alignment data using the light sensor; 
 determining an aligned position for the light sensor with respect to the aperture; 
 moving the light sensor to the determined aligned position; and 
 attaching the light sensor to the housing structure in the aligned position. 
 
     
     
       25. The method defined in  claim 24 , wherein gathering the alignment data using the light sensor comprises transmitting light from an external light source onto the light sensor through the aperture. 
     
     
       26. The method defined in  claim 24  wherein gathering the alignment data using the light sensor comprises transmitting light from a light-emitting element in the light sensor onto a camera through the aperture. 
     
     
       27. The method defined in  claim 24  wherein gathering the alignment data using the light sensor comprises transmitting light from a light-generating component of the light sensor through the aperture onto a reflective object. 
     
     
       28. The method defined in  claim 27  wherein gathering the alignment data using the light sensor further comprises receiving a reflected portion of the transmitted light at a light-sensitive component of the light sensor and wherein the reflected portion of the light has passed from the reflective object back through the aperture.

Description:
BACKGROUND 
     This relates generally to electronic devices, and more particularly, to electronic devices with light sensors. 
     Electronic devices often include light sensors. For example, cellular telephones often include a proximity sensor that determines a distance to a user of the device by emitting light toward the user and detecting reflected light from the user. 
     Proximity sensors are often mounted within a device enclosure and transmit and receive the light through a transparent aperture in the enclosure. It can be difficult to align the proximity sensor with the aperture. In some situations, a misalignment with the aperture can lead to diminished signal strength for the proximity sensor. 
     It would therefore be desirable to be able to provide improved methods and structures for mounting light sensors in electronic devices. 
     SUMMARY 
     An electronic device may be provided with one or more light sensors. A light sensor may be an ambient light sensor, a proximity sensor, a camera, or other light sensor. 
     Systems, methods and structures for optically aligning light sensors with associated apertures that allow light to be transmitted through the apertures are provided. An alignment system may include one or more cameras, one or more actuating members, and computing equipment for operating the cameras and actuating members. 
     During assembly operations, in one example, a camera may be used to view the aperture through a mounting structure for the light sensor. The computing equipment may use images gathered by the camera to determine the position of the aperture and the position of the support structure. The actuating members may move the mounting structure into alignment with the aperture based on the detected positions of the aperture and the support structure. When the support structure has been aligned with the aperture, adhesive may be used to secure the support structure to the transparent cover layer. The light sensor may then be secured in the support structure that has been aligned with the aperture. 
     In another example, the light sensor may include alignment features that can be viewed by a camera through the aperture during alignment operations. The computing equipment may use images gathered by the camera to determine the position of the aperture and the position of the alignment features on the light sensor. The actuating members may move the light sensor into alignment with the aperture based on the detected positions of the aperture and the alignment features. When the light sensor has been aligned with the aperture, adhesive may be used to secure the light sensor to the transparent cover layer. 
     In another example, a light-generating element on a proximity sensor may be used to emit light through the aperture and onto a camera while the actuating members move the light sensor among various positions. The light sensor may then be returned to the position at which a maximum amount of light from the proximity sensor was detected. 
     In other examples, alignment data may be gathered using the light sensor itself. For example, an external light source may be used to the emit light onto the light sensor through the aperture while the actuating members move the light sensor among various positions. The light sensor may then be returned to the position at which a maximum amount of light from the external light source was detected. As another example, a light-generating element on a proximity sensor may be used to emit light through the aperture that is reflected from an object back through the aperture onto a light sensitive portion of the proximity sensor while the actuating members move the light sensor among various positions. The light sensor may then be returned to the position at which a maximum amount of reflected light from the object was detected. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a handheld electronic device with a display in accordance with an embodiment of the present invention. 
         FIG. 2  is a cross-sectional side view of an illustrative light sensor that has been optically aligned with an aperture in accordance with an embodiment of the present invention. 
         FIG. 3  is a cross-sectional side view of an illustrative light sensor that is mounted in a support structure that has been optically aligned with an aperture in accordance with an embodiment of the present invention. 
         FIG. 4  is a top view of a portion of an illustrative transparent cover layer for a device display showing how a light sensor may be mounted behind an aperture on the transparent cover layer in accordance with an embodiment of the present invention. 
         FIG. 5  is a perspective view of an illustrative support structure that may be optically aligned with an aperture in accordance with an embodiment of the present invention. 
         FIG. 6  is a cross-sectional side view of an illustrative support structure during alignment operations using an alignment system in accordance with an embodiment of the present invention. 
         FIG. 7  is a cross-sectional side view of an illustrative support structure showing how light may pass through portions of the support structure to cure adhesive that secures the support structure to a housing structure in accordance with an embodiment of the present invention. 
         FIG. 8  is a top view of an illustrative light sensor having alignment features that can be viewed through an aperture in accordance with an embodiment of the present invention. 
         FIG. 9  is a cross-sectional side view of an illustrative light sensor having alignment features during alignment operations using an alignment system in accordance with an embodiment of the present invention. 
         FIG. 10  is a top view of a portion of an illustrative transparent cover layer for a device display showing how alignment features on a light sensor may be viewed through an aperture on a transparent cover layer in accordance with an embodiment of the present invention. 
         FIG. 11  is a cross-sectional side view of an illustrative light sensor showing how light may pass through portions of the light sensor to cure adhesive that secures the light sensor to a housing structure in accordance with an embodiment of the present invention. 
         FIG. 12  is a cross-sectional side view of an illustrative light sensor showing how light from an external light source may be detected by the light sensor during alignment operations using an alignment system in accordance with an embodiment of the present invention. 
         FIG. 13  is a cross-sectional side view of an illustrative light sensor showing how light emitted by a light source on the light sensor may be detected by a camera during alignment operations using an alignment system in accordance with an embodiment of the present invention. 
         FIG. 14  is a cross-sectional side view of an illustrative light sensor showing how light emitted by a light source on the light sensor may be reflected from an object and detected by a light sensing portion on the light sensor during alignment operations using an alignment system in accordance with an embodiment of the present invention. 
         FIG. 15  is a cross-sectional side view of an illustrative light sensor showing how light may be used to cure adhesive that secures a light sensor that has been optically aligned to an aperture to a housing structure in accordance with an embodiment of the present invention. 
         FIG. 16  is a flow chart of illustrative steps involved in aligning a light sensor to an aperture by viewing the aperture through an opening in a support structure for the light sensor in accordance with an embodiment of the present invention. 
         FIG. 17  is a flow chart of illustrative steps involved in aligning a light sensor to an aperture by viewing alignment features on the light sensor through the aperture in accordance with an embodiment of the present invention. 
         FIG. 18  is a flow chart of illustrative steps involved in aligning a light sensor to an aperture by gathering alignment data using the light sensor in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     An electronic device may be provided with light sensors. A light sensor may be an ambient light sensor, a proximity sensor, a camera, or other light sensor. 
     The electronic device may include a display. The display may have display layers for displaying images and a touch-sensitive layer for gathering user touch input. A display touch-sensitive layer may include touch-sensitive electrodes based on capacitive, resistive, or other technologies. 
     The electronic device may include processing circuitry that gathers light sensor data and changes settings for the display based on the light sensor data. For example, proximity sensor data may be used to determine that a cellular telephone has been placed against a user&#39;s face. The processing circuitry may disable touch-sensitive portions of the display when the device is against a user&#39;s face to avoid unintentional user input during a telephone call. As another example, ambient light sensor data may be used to determine that a light has been turned on or off in a room containing the device or that the device has been moved into bright sunlight. The processing circuitry may increase or decrease the brightness of the display based on detected decreases or increases in ambient light. 
     The electronic device may include an enclosure such as a housing. The enclosure may include a transparent cover layer such as a glass layer or transparent plastic layer for the display. Portions of the transparent cover layer may be covered by an opaque masking layer such as a black ink layer that prevents internal components from being viewed by a user of the device. 
     Light sensors such as proximity sensors and ambient light sensors may be mounted against a portion of the housing. The housing may include an aperture that allows light to pass through the housing to and/or from the light sensor. For example, the light sensor may be mounted against a portion of the transparent cover layer that is covered by the opaque masking layer. The opaque masking layer may include a portion that forms the aperture. As examples, the portion that forms the aperture may be an opening in the opaque masking layer that allows visible and/or infrared light to pass through the aperture or may include a portion of the opaque masking layer that is configured to allow infrared light to pass while preventing visible light from passing. 
     Light sensor performance may depend on the accuracy of the alignment of the light sensor with the aperture. The light sensor may therefore be optically aligned with the aperture or may be mounted in a support structure that has been optically aligned with the aperture. 
     An illustrative electronic device that may be provided with one or more optically aligned light sensors is shown in  FIG. 1 .  FIG. 1  shows how electronic device  10  may be a handheld device such as a cellular telephone, music player, gaming device, navigation unit, or other compact device. In this type of configuration for device  10 , device  10  may include housing  12  having opposing front and rear surfaces and a peripheral edge portion (sometimes referred to as a band). The front surface of housing  12  may be formed from a cover layer for a display such as display  14 . 
     Display  14  may be a liquid crystal display, an organic light-emitting diode (OLED) display, or other suitable display. Display  14  may include display pixels formed from light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), plasma cells, electronic ink elements, liquid crystal display (LCD) components, and/or other suitable display pixel structures. Display  14  may, if desired, include capacitive touch sensor electrodes for a capacitive touch sensor array or other touch sensor structures (i.e., display  14  may be a touch screen). 
     Display  14  may be mounted on a front face of housing  12 . Display  14  may, if desired, have a display cover layer such as a glass layer, plastic layer, or other exterior layer that forms a portion of an enclosure for device  10 . An outer display cover layer may include openings for components such as button  16  and for speaker port  18 . 
     Display  14  may be characterized by an active region such as rectangular active region AA and an inactive region such as peripheral inactive region IA. Rectangular active region AA may be bounded by rectangular border  19 . Inactive region IA may have the shape of a rectangular ring that surrounds the periphery of active region AA. If desired, some of the edges of display  14  may be borderless (i.e., the width of the inactive region on one or more edges may be zero or may be negligibly small). The illustrative configuration of  FIG. 1  in which display  14  is surrounded by an inactive border region is merely illustrative. 
     The underside of a display cover layer in inactive area IA may be provided with an opaque masking layer such as a layer of black ink to help hide internal components such as components from view by a user of device  10 . If desired, openings may be provided in the opaque masking layer to allow light to reach light-sensitive components such as camera  20  or light sensor  22  (e.g., a proximity sensor or an ambient light sensor) through the cover layer for display  14 . 
     Device  10  may have a housing enclosure such as housing  12 . Electronic components such as light sensor  22  and camera  20  may be mounted within housing  12 . Housing  12 , which is sometimes referred to as a case or enclosure, may be formed of materials such as plastic, glass, ceramics, carbon-fiber composites and other composites, metal, aluminum, other materials, or a combination of these materials. Device  10  may be formed using a unibody construction in which most or all of housing  12  is formed from a single structural element (e.g., a piece of machined metal or a piece of molded plastic) or may be formed from multiple housing structures (e.g., outer housing structures such as glass or plastic portions that have been mounted to internal frame elements or external housing members such as a peripheral band that runs around an edge of device  10 ). 
     Touch-sensor components such as an array of capacitive touch-sensor electrodes formed from transparent materials such as indium tin oxide may be formed on the underside of a display cover layer, may be formed on a separate display layer such as a glass or polymer touch-sensor substrate, or may be integrated into other display layers (e.g., substrate layers such as a thin-film transistor layer). 
     The configuration for device  10  shown in  FIG. 1  is merely illustrative. In general, electronic device  10  may be a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, equipment that implements the functionality of two or more of these devices, or other electronic equipment. 
     A cross-sectional side view of an illustrative configuration that may be used for light sensor  22  of device  10  is shown in  FIG. 2 . As shown in  FIG. 2 , light sensor  22  may be implemented as a proximity sensor that includes light emitting portion  22 E and light detecting portion  22 D. Light sensor  22  may be mounted against a transparent cover layer such as glass layer  14 A of display  14 . Display  14  may also include display layers  14 B for generating images to be displayed on display  14 . Display layers  14 B may include polarizer layers, color filter layers, transistor layers, adhesive layers, layers of liquid crystal material, other layers for generating display images, and/or one or more layers of touch-sensitive components such as an array of capacitive touch-sensor electrodes formed from transparent materials such as indium tin oxide. 
     An opaque masking layer such as black mask  24  may be formed on an inner surface of glass layer  14 . Aperture  64  for light sensor  22  may be formed from an opening in opaque masking layer  24 . If desired, opaque masking layer  24  may include central portion  24 C that separates aperture  64  into multiple portions. However, this is merely illustrative. If desired, aperture  64  may be formed without any central masking portions. 
     Aperture  64  may be a circular aperture, a rectilinear aperture, or an aperture having any suitable shape (e.g., edge  68  of aperture  64  may have shape that defines a circle, a rectangle, a square, or any other suitable shape). 
     Light sensor  22  may emit light  26  from light emitting portion  22 E through aperture  64  and receive light  28  at light-sensitive portion  22 D through aperture  64 . 
     Light sensor  22  may include multiple layers such as circuitry layer  36 , light processing layer  38 , lens layer  40 , and spacer layer  42 . Circuitry layer  36  may include electrical contacts  44  that are coupled to associated electrical contacts  34  on a printed circuit such as flexible printed circuit  32 . Flexible printed circuit  32  may be used to route signals to and from light sensor  22  to processing circuitry for device  10 . Circuitry in circuitry layer  36  may be used to operate a light sensitive element such as light sensor  48 . Light sensor  48  may be a single light-sensitive element or an array of light-sensitive elements. 
     Circuitry in circuitry layer  36  may also be used to operate a light-emitting element such as light source  46 . Light source  46  may, for example, be a light-emitting diode. Light source  46  may be configured to emit light such as infrared light  26  through aperture  64 . Some of infrared light  26  may be reflected by an object in the vicinity of device  10  and reflected portion  28  of light  26  may pass through aperture  64  and be detected by light sensitive element  48 . 
     Lenses  50  in lens layer  40  may help focus outgoing light  26  through aperture  64  and incoming light  28  onto sensor  48 . Lens layer  40  may include extended portions  52  that extend beyond the edges of other layers of light sensor  22 . Extended portions  52  may be formed from a material that is transparent to ultraviolet light so that ultraviolet light may be used to cure adhesive  54 . Adhesive  54  may be an ultra-violet light cured adhesive that secures light sensor  22  to cover layer  14 A. 
     As shown in  FIG. 2 , light sensor  22  may include alignment features such as alignment marks  90  that are visible through aperture  64 . During assembly operations for device  10 , light sensor  22  may be optically aligned with aperture  64  by viewing alignment marks  90  and edge  68  of aperture  64  while positioning sensor  22  behind aperture  64 . 
     The arrangement of  FIG. 2  in which light sensor  22  has alignment marks  90  and extended portions  52  on lens layer  40  is merely illustrative. If desired, light sensor  22  may be mounted behind aperture  64  by inserting light sensor  22  into a structure such as support structure  60  (sometimes referred to herein as a sensor bracket) that has been optically aligned with aperture  64  as shown in  FIG. 3 . 
     Support structure  60  may be formed from plastic, metal, or other suitable materials. Support structure  60  may include extended portions  62 . Adhesive such as adhesive  54  may be interposed between extended portions  62  and cover layer  14 A so that adhesive  54  attaches structure  60  to cover layer  14 A. Light sensor  22  may be attached to support structure  60  using mechanical members such as screws or fasteners, using adhesive, or may fit tightly within structure  60  so that pressure from structure  60  on light sensor  22  holds light sensor  22  within structure  60 . 
     As shown in the top view of cover layer  14 A in  FIG. 4 , light sensor  22  (and, if desired, support structure  60 ) may be mounted behind an aperture such as aperture  64  that has a lateral width that is less that the lateral width of light sensor  22 . 
     As shown in the perspective view of support structure  60  in  FIG. 5 , extended portion  62  of structure  60  may be extend around all four edges of a rectilinear (e.g., square) support structure. Support structure  60  may include an opening such as central opening  66 . Opening  66  may be designed to receive light sensor  22 . The portion of structure  60  that surrounds opening  66  may have an inner edge  70  and an outer edge  71 . Inner edge  70  and or outer edge  71  may be detected by alignment equipment for aligning structure  60  with aperture  64  during device assembly operations for device  10 . 
     As shown in  FIG. 6 , support structure  60  may be aligned with aperture  64  using alignment equipment such as alignment system  80 . Alignment system  80  may include computing equipment  82 , one or more cameras such as camera  84 , and actuating members  86 . Alignment system  80  may also include masking structure for camera  84  and/or a reflective structure that reflects light from light sensor  22 . Computing equipment  82  may be used to operate cameras  84  and actuating members  86  and to process alignment data from camera  84  (or, if desired, from sensor  22 ). 
     Actuating members  86  may be used to hold and move support structure  60  based on alignment data obtained using camera  84 . Cameras  84  may be used to gather images of support structure  60  and aperture  64  through opening  66  in support structure  60 . Actuating members  86  may move structure  60  in a direction parallel to the x-y plane of  FIG. 6  until edge  70  of structure  60  is in a suitable (aligned) position with respect to edge  68  of aperture  64 . 
     Actuating members  86  may also move structure  60  along a direction parallel to the z-direction of  FIG. 6  into a position adjacent to cover layer  14 A. Prior to alignment operations, a light-curable liquid adhesive such as liquid adhesive  54 ′ (i.e., adhesive  54  of  FIG. 3  in liquid (uncured) form) may be applied to structure  60 . 
     Following alignment and placement of structure  60 , structure  60  may be secured to cover layer  14 A using liquid adhesive  54 ′ by illuminating adhesive  54 ′ as shown in  FIG. 7 . One or more light sources such ultraviolet (UV) light sources  88  may be used to illuminate adhesive  54 ′ with UV light  89  to cure adhesive  54 ′. Light sources  88  may be operated by a technician or may be automatically operated using computing equipment  82 . 
     As described above in connection with  FIG. 2 , if desired, light sensor  22  may be optically aligned with aperture  64  and attached to layer  14 A without the use of a support structure. As shown in  FIG. 8 , light sensor  22  may be provided with alignment features such as alignment marks  90  on a top surface of sensor  22 . Alignment features  90  may be molded features in a plastic portion of sensor  22 , printed features on the top surface of sensor  22 , embedded reflective objects such as metal in the top surface of sensor  22  or other visible alignment marks on sensor  22 . 
     In the example of  FIG. 8 , sensor  22  includes two alignment marks  90  having a triangular shape. A line such as line  96  that is equidistant from alignment marks  90  and a line such as line  94  that is perpendicular to line  96  and passes through the opposing points of triangular alignment marks  90  may indicate center point  92  of sensor  22 . 
     As shown in  FIG. 9 , camera  84  may be used to view alignment marks  90  of sensor  22  through aperture  64  during alignment operations. Camera  84  may be used to gather images of aperture  64  and of alignment marks  90  through aperture  64 . Computing equipment  82  may be used to determine the location of edge  68  of aperture  64  using the gathered images of aperture  64 . Computing equipment  82  may be used to determine the location of center point  92  of sensor  22  using the gathered images of alignment marks  90 . 
     During alignment operations, actuating members  86  may be used to hold and move light sensor  22  based on the determined locations of edge  68  of aperture  64  and center point  92 . Actuating members  86  may move sensor  22  in a direction parallel to the x-y plane of  FIG. 9  until center point  92  is at a suitable (aligned) position with respect to edge  68 . 
     For example, as shown in the top view of aperture  64  in  FIG. 10 , sensor  22  may be positioned so that center point  92  is equidistant from all points on edge  68  of a circular aperture  64  as viewed through aperture  64 . However, this is merely illustrative. If desired, aperture  64  may have a shape other than a circular shape, point  92  may be aligned at a predetermined distance from one or more specific points on edge  68 , or sensor  22  may be aligned with aperture  64  using alignment marks  90  without determining a center point of sensor  22 . 
     Actuating members  86  may also move sensor  22  along a direction parallel to the z-direction of  FIG. 9  into a position adjacent to cover layer  14 A. Prior to alignment operations, a light-curable liquid adhesive such as liquid adhesive  54 ′ (i.e., adhesive  54  of  FIG. 3  in liquid (uncured) form) may be applied to sensor  22  (e.g., to extended portions  52  of sensor  22 . 
     Following alignment and placement of sensor  22 , sensor  22  may be secured to cover layer  14 A using liquid adhesive  54 ′ by illuminating adhesive  54 ′ as shown in  FIG. 11 . One or more light sources such ultraviolet (UV) light sources  88  may be used to illuminate adhesive  54 ′ with UV light  89  to cure adhesive  54 ′. Light sources  88  may be operated by a technician or may be automatically operated using computing equipment  82 . 
     The examples of  FIGS. 6 ,  7 ,  8 ,  9 ,  10 , and  11 , in which sensor  22  has been optically aligned with aperture  64  by viewing aperture  64  though an opening in structure  30  or by viewing alignment marks on sensor  22  through aperture  64  are merely illustrative.  FIGS. 12 ,  13 , and  14  show examples of ways in which sensor  22  may be optically aligned with aperture  64  by gathering alignment data using sensor  22  during alignment operations. As shown in  FIGS. 12 ,  13 , and  14 , flexible printed circuit  32  may be attached to sensor  22  prior to alignment operations for sensor  22 . 
     Alignment data may be gathered using sensor  22  and transmitted to processing circuitry in device  10  using circuit  32 . The alignment data may be processed using processing circuitry in device  10  or may be transmitted to computing equipment  82  for processing. Processing alignment data may include determining an optimally aligned position for sensor  22  based on the gathered alignment data. 
     In the example of  FIG. 12 , alignment data is gathered using an external light source such as light source  97  to emit light such as light  98  onto cover layer  14 A. Some of light  98  may pass through aperture  64  onto light-sensitive element  48  of sensor  22 . Element  48  may be a light-sensitive element of an ambient light sensor that does not include a light source or may be a light-sensitive element of a proximity sensor that includes a light source such as an LED in addition to element  48 . 
     Actuating members  86  may be used to move sensor  22  in a direction parallel to the x-y plane of  FIG. 12  while alignment data such as light intensity data is gathered using sensor  22 . The intensity of light  98  may remain constant during alignment operations. The detected intensity of light  98  by sensor  22  may change due to the changing position of sensor  22  with respect to aperture  64 . 
     Sensor  22  may be moved to a predetermined set of positions or may be continuously moved until the detected light intensity of light  98  reaches a predetermined minimum. Light intensity data may be gathered at each position for sensor  22  or may be continuously gathered. An optimal sensor position (i.e., an aligned position) for sensor  22  may be determined from the gathered intensity data. 
     The aligned position may be a position at which the detected light intensity in the gathered light intensity data is a maximum intensity. This type of maximum intensity position may be determined by selecting a position at which the intensity data is a maximum intensity, by fitting a mathematical function to the intensity data and determining an extremum of the mathematical function, by selecting a midpoint between two equal intensity data points or using other suitable maximum determining procedures. 
     In the example of  FIG. 13 , alignment data is gathered by generating light  26  using a light-emitting component such as light-generating component  46  (e.g., an LED or an infrared LED) so that light  26  passes through aperture  64  and onto camera  84 . If desired, camera  84  may be mounted to a masking structure such as structure  100  that prevents light other than light  26  from being detected by camera  84 . Camera  84  may be a fully integrated device with an imaging sensor or may be an imaging sensor having one or more light-sensitive elements without integrated structures such as a housing and a lens. 
     Actuating members  86  may be used to move sensor  22  in a direction parallel to the x-y plane of  FIG. 13  while alignment data such as light intensity data is gathered using camera  84 . The intensity of light  26  from light-generating element  46  may remain constant during alignment operations. The detected intensity of light  26  by camera  84  may change due to the changing position of sensor  22  with respect to aperture  64 . 
     Sensor  22  may be moved to a predetermined set of positions or may be continuously moved until the detected light intensity of light  26  reaches a predetermined minimum. Light intensity data may be gathered by camera  84  at each position for sensor  22  or may be continuously gathered. An aligned position for sensor  22  may be determined from the gathered intensity data. 
     The aligned position may be a position at which the detected light intensity in the gathered light intensity data is a maximum intensity as described above in connection with  FIG. 12 . 
     In the example of  FIG. 14 , alignment data is gathered by generating light  26  using a light-emitting component such as light-generating component  46  (e.g., an LED or an infrared LED) so that light  26  passes through aperture  64  and a portion  28  of light  26  is reflected back through aperture  64  onto light-sensitive component  48  of sensor  22 . If desired, light-reflecting structure  102  (e.g., a metal plate or other infrared-reflective structure) may be placed over aperture  64  during alignment operations to increase reflected portion  28  of light  26 . Light  26  may be emitted from element  46  onto structure  102  and reflected portion  28  of light  26  may be reflected back through aperture  64 . 
     Actuating members  86  may be used to move sensor  22  in a direction parallel to the x-y plane of  FIG. 14  while alignment data such as light intensity data is gathered using element  46  and element  48  of sensor  22 . The intensity of light  26  from light-generating element  46  may remain constant during alignment operations. The detected intensity of reflected portion  28  by element  48  may change due to the changing position of sensor  22  with respect to aperture  64 . 
     Sensor  22  may be moved to a predetermined set of positions or may be continuously moved until the detected light intensity of reflected light  28  reaches a predetermined minimum. Light intensity data may be gathered by element  48  at each position for sensor  22  or may be continuously gathered. An aligned position for sensor  22  may be determined from the gathered intensity data. 
     The aligned position may be a position at which the detected light intensity in the gathered light intensity data is a maximum intensity as described above in connection with  FIG. 12 . 
     Following determination of an optimally aligned position for sensor  22  as described above in connection with  FIGS. 12 ,  13 , and/or  14 , sensor  22  may be moved vertically (i.e., along the z-direction) so that structure  60  is adjacent to cover layer  14 A. 
     As shown in the examples of  FIGS. 12 ,  13 , and  14 , support structure  60  may have a shape that is different from the shape shown in  FIGS. 3 ,  5 ,  6 , and  7 . In the examples of  FIGS. 12 ,  13 , and  14  support structure  60  includes a portion that is formed along edges of sensor  22  and a portion that wraps over a portion of a top surface of sensor  22  (e.g., a surface that interfaces with cover layer  14 A). During assembly operations, liquid adhesive  54 ′ may be applied to the portion that wraps over a portion of the top surface of sensor  22 . 
     As shown in  FIG. 15 , light sources  88  may be used to illuminate liquid adhesive  54 ′ that has been applied to the portion that wraps over a portion of the top surface of sensor  22  with light such as UV light  89 . In this way, structure  60  may be attached to layer  14 A. In the configuration show in  FIG. 15 , structure  60  may be formed from a UV transparent material or a material that is substantially opaque to UV light. Light  89  may illuminate adhesive  54 ′ directly or some or all of light  89  may pass through UV transparent portions of structure  60  onto adhesive  54 ′. However this is merely illustrative. A support structure having the shape of structure  60  of  FIG. 5  or any other suitable shape may be used during the alignment and assembly operations for sensor  22  and device  10  described above in connection with  FIGS. 12 ,  13 , and/or  14 . 
       FIG. 16  is a flow chart of illustrative steps that may be used in mounting a light sensor adjacent to an aperture using a support structure having an opening as described above in connection with, for example,  FIGS. 6 and 7 . 
     At step  120 , a curable adhesive such as a light curable adhesive (e.g., a UV light curable adhesive) may be applied to a support structure such as a sensor bracket for a light sensor such as sensor  22  (e.g., a proximity sensor or an ambient light sensor). The curable adhesive may be provided on an extended portion of the support structure, on a portion of the support structure that wraps onto a top surface of the sensor, or elsewhere on the support structure. The curable adhesive may be provided on a portion of the support structure that is transparent to UV light. 
     At step  122 , the support structure (sensor bracket) may be placed near a transparent aperture in an opaque portion of a housing structure such as a cover layer for a display. 
     At step  124 , alignment data such as images may be gathered of the support structure and of the aperture through the support structure. 
     At step  126 , the position of sensor bracket features such as one or more edges of the support structure and the position of one or more edges of the aperture may be determined using the gathered images. 
     At step  128 , the support structure (sensor bracket) may be moved into alignment with the aperture based on the determined positions of the edge(s) of the support structure and the edge(s) of the aperture. 
     At step  130 , light such as ultraviolet light may be applied to the curable adhesive to secure the support structure to the housing structure in the aligned position. The ultraviolet light may be applied to the curable adhesive through a UV transparent portion of the support structure. 
     At step  132 , a light sensor such as a proximity sensor or an ambient light sensor may be attached to the support structure (e.g., by inserting the light sensor into an opening in the support structure). 
     At step  134 , a printed circuit such as a flexible printed circuit may be attached to the light sensor (e.g., by soldering electrical contacts on the flexible printed circuit to electrical contacts on the light sensor using a hot bar). 
       FIG. 17  is a flow chart of illustrative steps that may be used in mounting a light sensor adjacent to an aperture using alignment marks on the light sensor as described above in connection with, for example,  FIGS. 8 ,  9 ,  10 , and  11 . 
     At step  140 , a curable adhesive such as a light curable adhesive (e.g., a UV light curable adhesive) may be applied to a light sensor such as sensor  22  (e.g., a proximity sensor or an ambient light sensor). The curable adhesive may be provided on an extended portion of the light sensor that is transparent to UV light. 
     At step  142 , the light sensor may be placed near a transparent aperture in an opaque portion of a housing structure such as a cover layer for a display. 
     At step  144 , alignment data such as images may be gathered of the aperture and the alignment features on the light sensor as viewed through the aperture. 
     At step  146 , the position of light sensor features such as a center point of the light sensor and the position of one or more edges of the aperture may be determined using the gathered images. 
     At step  148 , the light sensor may be moved into alignment with the aperture based on the determined positions of light sensor features and the edge(s) of the aperture. 
     At step  150 , light such as ultraviolet light may be applied to the curable adhesive to secure the light sensor to the housing structure in the aligned position. The ultraviolet light may be applied to the curable adhesive through a UV transparent portion of the light structure. 
     At step  152 , a printed circuit such as a flexible printed circuit may be attached to the light sensor (e.g., by soldering electrical contacts on the flexible printed circuit to electrical contacts on the light sensor using a hot bar). 
       FIG. 18  is a flow chart of illustrative steps that may be used in mounting a light sensor adjacent to an aperture by gathering alignment data using the light sensor as described above in connection with, for example,  FIGS. 12 ,  13  and  14 . 
     At step  160 , a curable adhesive such as a light curable adhesive (e.g., a UV light curable adhesive) may be applied to a support structure such as a sensor bracket for a light sensor such as sensor  22  (e.g., a proximity sensor or an ambient light sensor). The curable adhesive may be provided on an extended portion of the support structure, on a portion of the support structure that wraps onto a top surface of the sensor, on elsewhere on the support structure. The curable adhesive may be provided on a portion of the support structure that is transparent to UV light. 
     At step  162 , the light sensor may be placed into an opening in the sensor bracket. If desired step  162  may be performed prior to step  160 . 
     At step  164 , the sensor assembly (i.e., the light sensor and support structure) with the flexible printed circuit attached may be placed near a transparent aperture in an opaque portion of a housing structure such as a cover layer for a display. 
     At step  166 , alignment data such as light intensity data may be gathered using the light sensor while moving the sensor assembly with respect to the aperture. Gathering alignment data using the light sensor while moving the sensor assembly with respect to the aperture may include operating and external light source and gathering intensity data using the light sensor (see, e.g.,  FIG. 12 ), operating a light-emitting component of the light sensor while operating an external sensor such as a camera (see, e.g.,  FIG. 13 ), or gathering alignment data using a light-sensitive component of the light sensor while operating the light-emitting component of the light sensor (see, e.g.,  FIG. 14 ). 
     At step  168 , an optimal sensor position (i.e., an aligned position for the light sensor) may be determined using the gathered alignment data. The optimal sensor position may be a position at which the detected light intensity in the gathered alignment data is a maximum intensity. This type of maximum intensity position may be determined by selecting a position at which the intensity data is a maximum intensity, fitting a mathematical function to the intensity data and determining an extremum of the mathematical function, by selecting a midpoint between two equal intensity data points or using other suitable maximum determining procedures. 
     At step  170 , the sensor assembly may be moved into the optimal sensor position. 
     At step  172 , light such as ultraviolet light may be applied to the curable adhesive to secure the sensor assembly to the housing structure in the optimal sensor position. The ultraviolet light may be applied to the curable adhesive through a UV transparent portion of the support structure or may be applied directly to the adhesive. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20120907
Publication Date: 20150505
Grant Date: 20150505
Priority Date: 20120907
Inventors: SPRAGGS IAN A.
WITTENBERG MICHAEL B.
KOLE JARED M.
SHUKLA ASHUTOSH Y.
Assignee: APPLE INC
CPC Classifications: [{"code": "H04M1/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0271", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0233", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J2001/0257", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/4204", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0219", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0437", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01J1/0488", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0266", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49826", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0488", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0437", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01J1/0219", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0271", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/4204", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0247", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J2001/0257", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01J1/0233", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0266", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 50232275