PATENT DOCUMENT

Publication Number: US-7687734-B2
Application Number: US-14233308-A
Country: US
Kind Code: B2

Title: Dome switch with integral actuator

Abstract:
A dome switch structure that includes an actuator integrally formed with a dome is disclosed. Advantageously, the actuator can be formed so as to be positioned over and properly aligned with the dome. In one embodiment, the dome switch structure is used by an electronic device to provide user input. When the actuator is pressed by a user, the actuator depresses the dome and induces a switching action. In one embodiment, the dome switch structures can be manufactured (i.e., machined) as a unitary structure. Consequently, since actuators and domes can be formed together, the dome switch structures yield not only consistent accurate alignment but also simplified assembly of dome switches. Given the accurate alignment of an actuator to a corresponding dome, dome switches formed from the dome switch structures can have consistent and reliable tactile feel to users, which thereby provides reliable usage by users.

Claims:
1. A dome-actuator structure for use in a dome switch, said dome-actuator structure comprising:
 a dome; and 
 an actuator feature attached to and positioned over said dome such that depressing of said actuator operates to depress said dome, 
 wherein said dome-actuator structure has a one-piece construction. 
 
   
   
     2. A dome-actuator structure as recited in  claim 1 , wherein said actuator feature is aligned with said dome. 
   
   
     3. A dome-actuator structure as recited in  claim 1 , wherein said actuator feature comprises a nub directed towards and aligned with a center region of said dome. 
   
   
     4. A dome-actuator structure
 for use in a dome switch, said dome-actuator structure comprising:
 a dome; and 
 an actuator feature attached to and positioned over said dome such that depressing of said actuator operates to depress said dome, 
 wherein said dome and said actuator are metal, and wherein said dome and said actuator are integrally formed from a metal sheet. 
 
 
   
   
     5. An electronic device, comprising:
 a substrate having electrical contacts; and 
 at least one switching apparatus including at least a dome and an actuator, the dome being provided on or proximate to said substrate, and the actuator being aligned over and integral with the dome. 
 
   
   
     6. An electronic device as recited in  claim 5 , wherein said substrate is a printed circuit board. 
   
   
     7. An electronic device as recited in  claim 5 , the dome and the actuator are formed from a contiguous sheet of metal. 
   
   
     8. An electronic device as recited in  claim 5 , wherein a center region of the dome is a target zone, and wherein the actuator is aligned over the target zone of the dome. 
   
   
     9. An electronic device as recited in  claim 8 , wherein the actuator comprises an actuation nub for alignment with the target zone. 
   
   
     10. An electronic device as recited in  claim 5 , wherein an arm connects the actuator to the dome. 
   
   
     11. An electronic device as recited in  claim 10 , wherein the arm is bent to align and position the actuator over the dome. 
   
   
     12. A method for forming a dome switch, said method comprising:
 obtaining a metal sheet; 
 forming a dome-actuator structure in the metal sheet; 
 separating the dome-actuator structure from the metal sheet; and 
 manipulating the dome-actuator structure such that the actuator feature is positioned over the dome. 
 
   
   
     13. A method as recited in  claim 12 , wherein following said manipulating the actuator feature is centered above the dome. 
   
   
     14. A method as recited in  claim 12 , wherein said method is performed in a multi-stage manufacturing tool. 
   
   
     15. A method as recited in  claim 12 , wherein said manipulating comprises bending a portion of the dome-actuator structure such that the actuator feature is positioned over the dome. 
   
   
     16. A method as recited in  claim 12 , wherein the dome-actuator structure has an arm that integrally connects the actuator feature to the dome. 
   
   
     17. A method as recited in  claim 16 , wherein said manipulating comprises bending the arm of the dome-actuator structure such that the actuator feature is positioned over the dome. 
   
   
     18. A method as recited in  claim 12 , wherein the metal sheet is stainless steel. 
   
   
     19. A method as recited in  claim 12 , wherein said method further comprises:
 attaching the dome-actuator structure to a substrate having electrical contacts, thereby forming a dome switch. 
 
   
   
     20. A method for forming a dome switch, said method comprising:
 obtaining a metal sheet; 
 forming a dome at a first region of the metal sheet; 
 forming an actuator feature at a second region of the metal sheet; 
 separating the dome and the actuator feature from the metal sheet; and 
 positioning the actuator feature over the dome. 
 
   
   
     21. A method as recited in  claim 20 , wherein said method further comprises:
 attaching the dome to a substrate having electrical contacts, thereby forming a dome switch. 
 
   
   
     22. A method for operating a dome switch, said method comprising:
 receiving a user press of a user input assembly including a dome and an actuator feature; and 
 depressing the dome via the actuator feature in response to the user press so as to make an electrical connection to induce a switching actions 
 wherein the dome and the actuator of the user input assembly have a one-piece construction.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to dome switches suitable for use in electronic devices. 
   2. Description of the Related Art 
   Dome switches are well-known and often used in consumer electronic products to implement buttons. For example, various consumer electronic devices, e.g., a mobile telephone, a personal digital assistant, game controller, or remote controller, typically include a plurality of buttons that a user can press to invoke various operations with respect to such devices. Such buttons can, for example, be used for function (e.g., send, end, navigate, etc.) buttons or for buttons of an alphanumeric keypad/keyboard. These buttons in many cases are implemented by dome switches. 
   A dome switch consists of a dome made from metal or plastic that can be deformed temporarily by a user press to invoke a switching action. Then, when the user press is removed, the dome returns to its original, undeformed shape. Today, with many electronic devices, proper operation of buttons is an important requirement for usability and user satisfaction. With respect to dome switches, the tactile feedback provided by dome switches is often very helpful to users of the consumer electronic products. However, conventional assembly of such buttons implemented by dome switches is inefficient and complicated. Generally, a dome must be placed on a substrate and corresponding structures often provide a button or key structure (with or without an actuation nub) that can be pressed downward to engage the dome during a button or key press. In some designs, activation nubs are provided on the button or key structure or on the peaks of the domes themselves. In any case, the formation of the activation nubs is a separate manufacturing step that is tedious and time-consuming. In addition, the placement of the actuation nubs relative to the domes is not always as accurate as desired. For example, if the actuation nub does not properly align with the center region of a dome, the tactile feedback for such dome switch will be disturbed and therefore not as robust as intended. 
   SUMMARY OF THE INVENTION 
   The invention pertains to a dome switch structure that includes an actuator integrally formed with a dome. Advantageously, the actuator can be formed so as to be positioned over and properly aligned with the dome. In one embodiment, the dome switch structure is used by an electronic device to provide user input. When the actuator is pressed by a user, the actuator depresses the dome and induces a switching action. In one embodiment, the dome switch structures can be manufactured (i.e., machined) as a unitary structure. Consequently, since actuators and domes can be formed together, the dome switch structures yield not only consistent accurate alignment but also simplified assembly of dome switches. Given the accurate alignment of an actuator to a corresponding dome, dome switches formed from the dome switch structures can have consistent and reliable tactile feel to users, which thereby provides reliable usage by users. 
   The invention may be implemented in numerous ways, including, but not limited to, as a system, device, apparatus, or method. Several exemplary embodiments of the present invention are discussed below. 
   As a dome-actuator structure for use in a dome switch, one embodiment of the invention can, for example, include at least: a dome, and an actuator feature attached to and positioned over the dome such that depressing of the actuator operates to depress the dome. 
   As an electronic device, one embodiment of the invention can, for example, include at least: a substrate having electrical contacts; and at least one switching apparatus including at least a dome and an actuator, the dome being provided on or proximate to the substrate, and the actuator being aligned over and integral with the dome. 
   As a method for forming a dome switch, one embodiment of the invention can, for example, include at least: obtaining a metal sheet; forming a dome-actuator structure in the metal sheet; separating the dome-actuator structure from the metal sheet; and manipulating the dome-actuator structure such that the actuator feature is positioned over the dome. 
   As a method for forming a dome switch, another embodiment of the invention can, for example, include at least: obtaining a metal sheet; forming a dome at a first region of the metal sheet; forming an actuator feature at a second region of the metal sheet; separating the dome and the actuator feature from the metal sheet; and positioning the actuator feature over the dome. 
   As a method for operating a dome switch, one embodiment of the invention can, for example, include at least: receiving a user press of a user input assembly including a dome and an actuator feature; and depressing the dome via the actuator feature in response to the user press so as to make an electrical connection to induce a switching action. 
   Various aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, in which: 
       FIG. 1A  is a perspective view representation of a dome-actuator structure according to one embodiment of the invention. 
       FIG. 1B  is a side-view representation of the dome-actuator structure according to one embodiment of the invention. 
       FIG. 1C  is a top-view representation of the dome-actuator structure according to one embodiment of the invention. 
       FIG. 2A  is a cross-sectional side view representation of a dome switch assembly in an uncompressed state according to one embodiment of the invention. 
       FIG. 2B  is a cross-sectional side view representation of a dome switch assembly in a compressed state according to one embodiment of the invention. 
       FIG. 2C  is a cross-sectional side view representation of a dome switch assembly in an uncompressed state according to another embodiment of the invention. 
       FIG. 3  is a flow diagram of a dome switch manufacturing process according to one embodiment of the invention. 
       FIGS. 4A-4D  are top-view diagrams illustrating formation of a dome-actuator structure according to one embodiment of the invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Exemplary embodiments of the present invention are discussed below with reference to the various figures. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes, as the invention extends beyond these embodiments. 
   The invention pertains to a dome switch structure that includes an actuator integrally formed with a dome. Advantageously, the actuator can be formed so as to be positioned over and properly aligned with the dome. In one embodiment, the dome switch structure is used by an electronic device to provide user input. When the actuator is pressed by a user, the actuator depresses the dome and induces a switching action. In one embodiment, the dome switch structures can be manufactured (i.e., machined) as a unitary structure. Consequently, since actuators and domes can be formed together, the dome switch structures yield not only consistent accurate alignment but also simplified assembly of dome switches. Given the accurate alignment of an actuator to a corresponding dome, dome switches formed from the dome switch structures can have consistent and reliable tactile feel to users, which thereby provides reliable usage by users. 
   In one embodiment, the dome switch structure is used by an electronic device to provide user input. When the actuator is pressed by a user, the actuator depresses the dome and induces a switching action. In addition, given the pressure to make electronic devices smaller and thinner, there is a need to make components smaller and thinner. With respect to dome switches, the ability to integrate the actuator with the dome serves to reduce the overall height of the dome and actuator combination. 
   The invention can be utilized in a variety of different devices (e.g., electronic devices) including, but not limited to including, portable and highly compact electronic devices (i.e., portable electronic devices) with limited dimensions and space. In one embodiment, a device may be a laptop computer, a tablet computer, a media player, a mobile phone (e.g., cellular phone), a personal digital assistant (PDA), other handheld electronic devices, a computer mouse, a keyboard, a remote control, a computer accessory, and/or a computer peripheral. Typically, the electronic devices include at least one electrical component inside its housing. The electrical component can, for example, be an integrated circuit or circuit board. Examples of integrated circuits include memory, processor (microprocessor or controller), ASIC, and various others. 
     FIG. 1A  is a perspective view representation of a dome-actuator structure  100  according to one embodiment of the invention. In the dome-actuator structure  100  includes a dome  102 . The dome  102  is designed to be deformable material. In one implementation, the dome  102  can be a thin shell of stainless steel. The dome-actuator structure  100  also includes an actuator  104  that is stably positioned above the dome  102 . The actuator  104  can be formed in a platform  106  (or paddle) which is stably positioned above the dome  102  by an arm  108 . The arm  108  couples the actuator  104  to the dome  102 . In one implementation, the dome  102 , the actuator  104 , the platform  106  and the arm  108  are all integrally formed from a common piece of material, such as stainless steel. 
     FIG. 1B  is a side-view representation of the dome-actuator structure  100  according to one embodiment of the invention. As shown in  FIG. 1B , the curved surface of the dome  102  points upward, while the curved surface of the actuator  104  points downward. Although the actuator  104  is shown as also have a dome shape, in other embodiments the actuator  104  can have other shapes, configurations or profiles. At an interface region  110 , the lower portion of the actuator  104  can contact, or nearly contact, the upper portion of the dome  102 . Typically, the dome-actuator structure  100  can be utilized in a dome switch which is operated by a user pressing upon the dome switch. The dome-actuator structure  100  illustrated in  FIG. 1B  corresponds to the situation in which a user is not pressing upon the dome switch utilizing in the dome-actuator structure  100 . The dome-actuator structure  100  is suitable for thin or low-profile switch designs. In one embodiment, the height of the dome-actuator structure  100  above the dome can be minimal, for example, on the order of 0.20 millimeters. 
     FIG. 1C  is a top-view representation of the dome-actuator structure  100  according to one embodiment of the invention. As shown in  FIG. 1C , the actuator  104  is accurately positioned over the center of the dome  102 . The positioning of the actuator  104  is indicted and stabilized by the platform  106  and the arm  108 . As shown in  FIG. 1C , the arm  108  is relatively thin so that it can be easily bent into the appropriate configuration for the dome-actuator switch  100 . Also, since the platform  106  is relatively thin, the platform  106  does not disturb the tactile responsiveness of the dome  102  to user presses of a dome switch that utilizes the dome-actuator structure  100 . 
   The size of the dome-actuator switch  100  can vary with implementation. In one embodiment, the dome  102  can have a diameter of about 3-8 mm, the actuator  104  can have a diameter of about 0.75-1.5 mm, the width of the platform  106  can be about 1.7-6 mm, and a width of the arm  108  can be about 0.5-2 mm. In one particular embodiment, the dome  102  can have a diameter of about 4.5 mm, the actuator  104  can have a diameter of about 1.0 mm, the width of the platform  106  can be about 2.0 mm, and a width of the arm  108  can be about 0.5 mm. 
     FIG. 2A  is a cross-sectional side view representation of a dome switch assembly  200  in an uncompressed state according to one embodiment of the invention. The dome switch assembly  200  includes a dome-actuator structure  202 . The dome-actuator structure  202  is placed and adhered to a substrate  204 . The substrate  204  typically provides electrical interconnects (not shown) such as metal traces on at least one surface of the substrate  204 . In one implementation, the substrate  204  can pertain to a Printed Circuit Board (PCB). In another implementation, the substrate  204  can pertain to a flexible substrate, such as a flex-circuit. The dome-actuator structure  202  can be adhered to the substrate  204  by any of a number of different ways. As one example, an adhesive (e.g., adhesive tape) can be utilized to adhere to the dome-actuator structure  202  to the surface of the substrate  204 . As another example, the dome-actuator structure  202  can be soldered to the surface of the substrate  204 . 
   The dome-actuator structure  202  includes a dome  206  having an open end adjacent to the surface of the substrate  204 , and a closed end having a curved surface that extends upward away from the surface of the substrate  204 . The thickness of the dome  206  is typically in a range of 0.05-0.1 millimeters. For example, the dome-actuator structure  202  can be stainless steel (e.g., SUS 301), and the thickness of the dome  206  is typically in a range of 0.07 millimeters. The dome-actuator structure  202  also includes an actuator  208 . The actuator  208  can also have a dome-like configuration. The actuator  208  can have an open end that is adjacent to a surface of a platform  210 . In one implementation, the actuator  208  is formed from a portion of the platform  210 . The closed end of the actuator  208  has a curved surface that extends downward towards the dome  206 . As illustrated in  FIG. 2A , the actuator  208  is positioned such that the center of the closed end of the actuator  208  is substantially aligned with the center of the closed end of the dome  206 . The platform  210  is held in position by an arm  212  which is also part of the dome-actuator structure  202 . In the uncompressed state as illustrated in  FIG. 2A , the actuator  208  can be directly adjacent to the dome  206 . In this uncompressed state, the actuator  208  may slightly biased against the dome  206  or there might be a slight gap (e.g., opening) between the actuator  208  and the dome  206 . 
     FIG. 2B  is a cross-sectional side view representation of a dome switch assembly  200 ′ in a compressed state according to one embodiment of the invention. The dome switch assembly  200 ′ represents the dome switch assembly  200  shown in  FIG. 2A  after being compressed. In the compressed state, the dome switch assembly  200 ′ is fully compressed, such as due to a user press on the platform  210 . Typically, there is an intermediate structure (e.g., button cover) between the platform  210  and a user&#39;s finger, but nonetheless, the user press is translated to compress the dome-actuator structure  202 . As shown in  FIG. 2B , upon compression, the platform  210  is forced downward toward the surface of the substrate  204 . As a result, the actuator  208  is forced into the dome  206 . As the actuator  208  is pushed downward into the dome  206 ′, the dome  206 ′ deforms as illustrated in  FIG. 2B . Advantageously, when the platform  210  is compressed downward, the platform  210  ensures that the actuator  208  is pushed downward normal to a target region (e.g., target press region  410 ) on the actuator  208 . In addition, the arm  212 ′ is able to deform when the dome-actuator structure  202  is compressed. When the platform  210  is fully compressed downward such as illustrated in  FIG. 2B , the deformed dome  206 ′ clauses electrical contact with respect to electrical traces (not shown) on the surface of the substrate  204 , thereby inducing a switching action. 
   It should be noted that the compressed state typically requires a downward force to be exerted on the platform  210 . Typically, the downward force is induced by a user press action. Once the downward force is removed, the platform  210  by way of the arm  212 ′ recovers to its uncompressed state and the dome  206 ′ returns to its uncompressed state, such as illustrated in  FIG. 2A . 
     FIG. 2C  is a cross-sectional side view representation of a dome switch assembly  200 ″ in an uncompressed state according to one embodiment of the invention. The dome switch assembly  200 ″ includes a dome-actuator structure  202 ′. The dome switch assembly  200 ″ is generally similar to the dome switch assembly  200  illustrated in  FIG. 2A  except that the dome-actuator structure  202 ′ has an arm  212 ′ that include a bend so that compression of the platform  210  by way of the arm  212 ″ is able to more easily flex when the when the dome-actuator structure  202 ′ is compressed. 
     FIG. 3  is a flow diagram of a dome switch manufacturing process  300  according to one embodiment of the invention. The dome switch manufacturing process  300  can, for example, concern the manufacture of a dome-actuator structure that is utilized in forming a dome switch. 
   The dome switch manufacturing process  300  can initially obtain  302  a metal sheet. For example, the metal sheet can be a sheet of stainless steel (e.g., stainless steel  301 ) with a thickness of about 0.07 millimeters. Next, a dome can be formed  304  in the metal sheet. The formation of the dome into the metal sheet can be done by a progressive die approach in which the dome is gradually formed into the metal sheet in several stages. In addition, an actuator feature can be formed  306  in the metal sheet. The actuator can also be formed utilizing a progressive die approach. In one implementation, the dome and the actuator feature can be concurrently formed. In another implementation, the dome and the actuator feature can be formed sequentially. 
   After the dome and the actuator feature have been formed  304  and  306 , a dome-actuator structure can be separated  308  from the metal sheet. The separation  308  can be performed by a stamping action or a cutting action. For example, the dome-actuator structure can be stamped out of the metal sheet as a unitary structure. As another example, the dome-actuator structure can be cut or diced from the metal sheet using any in a number of conventional approaches. After the dome-actuator structure has been separated  308  from the metal sheet, the dome-actuator structure can be manipulated  310  so that the actuator feature is positioned over the dome. As an example, the dome-actuator structure can include a flexure (e.g., arm) that couples together in the actuator and the dome. The flexure serves to position the actuator relative to the dome. At this point, the dome-actuator structure has been formed by the dome switch manufacturing process  300 . Thereafter, the dome of the dome-actuator structure can be attached  312  to a substrate so as to form a dome switch. Typically, operations  302 - 310  are repeatedly performed using to form a plurality of dome-actuator structures. The various dome-actuator structures can be formed one at a time or more than one at a time. 
     FIGS. 4A-4D  are top-view diagrams illustrating formation of a dome-actuator structure according to one embodiment of the invention. The formation of the dome-actuator structure can be achieved in accordance with the dome switch manufacturing process  300  illustrated in  FIG. 3 . 
   In  FIG. 4A , a metal sheet  400  is provided, and a dome  402  and an actuator feature  404  are formed  304  and  306  into the metal sheet  400 .  FIG. 4B  illustrates a dome-actuator structure after being separated  308  from the metal sheet  400 . Here, the dome-actuator structure is able to be punched or cut from the metal sheet  400 . As shown in  FIG. 4B , the resulting dome-actuator structure includes the dome  402  and the actuator feature  404  as well as a platform  406  and a flexure  408 . For reference, the dome  402  can also be considered to have a target press region  410 , which represents a location on the dome  402  that is a desired point of contact.  FIG. 4C  illustrates a dome-actuator structure midway through the manipulation  310 . As shown in  FIG. 4C , the platform  406  has been rotated approximately ninety degrees (90°) by way of bending the flexure  408  of the dome-actuator structure.  FIG. 4D  illustrates the dome-actuator structure in its final state. As shown in  FIG. 4D , the flexure  408  has been rotated a total of one-hundred and eighty degrees (180°) by way of bending the flexure  408  another approximately ninety degrees (90°) (from the position shown in  FIG. 4C ) so that the platform  406  is provided over the dome  402 . Consequently, the actuator  404  can be positioned over and aligned with the target press region  410  of the dome  402 . 
   In the foregoing description, reference to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment can be included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, the order of blocks in process flowcharts or diagrams representing one or more embodiments of the invention do not inherently indicate any particular order nor imply any limitations in the invention. 
   The advantages of the invention are numerous. Different aspects, embodiments or implementations may, but need not, yield one or more of the following advantages. One advantage of certain embodiment of the invention is that dome structures can have accurately aligned actuator. Another advantage of the invention is that assembly of dome switches is simplified since actuators can be integrally formed with domes. Yet another advantage of the invention is that compact dome switches for low profile electronic devices are facilitated. 
   The many features and advantages of the present invention are apparent from the written description. Further, since numerous modifications and changes will readily occur to those skilled in the art, the invention should not be limited to the exact construction and operation as illustrated and described. Hence, all suitable modifications and equivalents may be resorted to as falling within the scope of the invention.

Metadata:
Filing Date: 20080619
Publication Date: 20100330
Grant Date: 20100330
Priority Date: 20080619
Inventors: WEBER DOUGLAS
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H2221/024", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2217/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/7065", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2235/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2235/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2227/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/024", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2227/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2235/024", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2217/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2235/024", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/7065", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 41430110