PATENT DOCUMENT

Publication Number: US-9449770-B2
Application Number: US-201414178800-A
Country: US
Kind Code: B2

Title: Shimless button assembly for an electronic device

Abstract:
Embodiments of the present disclosure are directed to a shimless button assembly. According to such embodiments, a shimless button assembly includes a button component and a switch mechanism. The button component includes a compressible member that is configured to expand and contract in order to occupy a volume of space between the button component and the switch mechanism. The volume of space between the button component and the switch mechanism may be caused by differing tolerances between the various components of the button assembly, such as, for example, the button component and the switch mechanism.

Claims:
We claim: 
     
       1. A button assembly, comprising:
 a button component; 
 a base positioned below the button component; 
 a switch mechanism positioned between the base and the button component; and 
 a compressible member positioned between the base and the button component and defining a cavity; 
 a hardenable material positioned within the cavity, wherein: 
 the compressible element is compressible to expand or contract to occupy a volume within the button assembly; 
 when the hardenable material cures, the hardenable material becomes rigid and maintains a thickness of the volume occupied by the compressible element. 
 
     
     
       2. The button assembly of  claim 1 , wherein the hardenable material comprises a glue. 
     
     
       3. The button assembly of  claim 1 , further comprising a printed circuit coupled to the switch mechanism. 
     
     
       4. The button assembly of  claim 1 , wherein the compressible member is comprised of foam. 
     
     
       5. The button assembly of  claim 1 , wherein the compressible member is comprised of rubber. 
     
     
       6. The button assembly of  claim 1 , wherein the button component comprises a contact plate. 
     
     
       7. The button assembly of  claim 6 , wherein the compressible member is disposed between the button component and the contact plate. 
     
     
       8. A button assembly, comprising:
 a button component; 
 a base positioned below the button component; 
 a switch mechanism positioned between the base and the button component; 
 an expansion component positioned within a volume located between the button component and the switch mechanism or between the switch mechanism and the base; and 
 a glue positioned within a cavity defined within the expansion component, wherein: 
 the expansion component comprises a compressible member that expands or contracts to occupy a thickness of the volume; 
 the glue, once hardened, maintains the thickness after curing. 
 
     
     
       9. The button assembly of  claim 8 , further comprising a printed circuit coupled to the switch mechanism, wherein the printed circuit board is positioned between the switch mechanism and the expansion component. 
     
     
       10. The button assembly of  claim 8 , wherein the compressible member is comprised of foam. 
     
     
       11. The button assembly of  claim 8 , wherein the compressible member is comprised of rubber. 
     
     
       12. The button assembly of  claim 8 , wherein the button component comprises a contact plate. 
     
     
       13. The button assembly of  claim 8 , wherein the compressible member is coupled to a housing component. 
     
     
       14. The button assembly of  claim 13 , wherein the housing component has at least one insertion point, wherein the insertion point enables the glue layer to be disposed within the cavity defined within the expansion component. 
     
     
       15. The button assembly of  claim 8 , wherein the compressible member is comprised of a malleable metal. 
     
     
       16. The button assembly of  claim 8 , wherein the compressible member is a spring. 
     
     
       17. A method for biasing a button assembly, the method comprising:
 placing a glue layer into a cavity defined by a compressible member; 
 inserting the compressible member into a volume of the button assembly to bias a button component away from a base; and 
 hardening enabling the glue layer to maintain a thickness of the volume. 
 
     
     
       18. The method of  claim 17 , wherein the compressible member is disposed between the contact plate and a portion of a button. 
     
     
       19. The method of  claim 17 , wherein the compressible member comprises at least one of foam and rubber. 
     
     
       20. The method of  claim 17 , further comprising enabling the compressible member to expand prior to the glue layer hardening.

Description:
TECHNICAL FIELD 
     The present disclosure is directed to a shimless button assembly for an electronic device. Specifically, one or more embodiments of the present disclosure are directed to a shimless button assembly that biases a button assembly to a switch regardless of varying part tolerances of each of the components of the button assembly. 
     BACKGROUND 
     Some computing devices, particularly portable computing devices, have tactile button interfaces. In such computing devices, the feel of the tactile button can greatly impact a user&#39;s perception of the quality of the computing device as a whole. For example, if the tactile button is too loose or too tight when actuated by a user, the user may perceive the computing device as poorly or cheaply manufactured. 
     It is with respect to these and other general considerations that embodiments have been made. Also, although relatively specific problems have been discussed, it should be understood that the embodiments should not be limited to solving the specific problems identified in the background. 
     SUMMARY 
     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. 
     One or more embodiments of the present disclosure provide a shimless button assembly. According to these embodiments, the shimless button assembly includes a button component and a switch mechanism. The button component includes a compressible member that is configured to expand and contract in order to occupy a volume between the button component and the switch mechanism. In embodiments, the volume between the button component and the switch mechanism is caused by a tolerance stack associated with the button component and the switch mechanism. 
     The present disclosure also provides a shimless button assembly according to one or more additional embodiments. In these embodiments, the button assembly comprises a button component and a switch mechanism. The switch mechanism may be coupled to an expansion component. In embodiments, the expansion component includes a compressible member configured to expand and contract to occupy a volume of space that exists between the button component and the switch mechanism. The volume of space that exists between the button component and the switch mechanism may be caused by a tolerance stack associated with the button component and the switch mechanism. 
     One or more embodiments also provide a method for biasing a button assembly. According to this method, a compressible member is coupled to a contact plate and is used to bias the contact plate to a switch mechanism. Once the contact plate comes in to contact with the switch mechanism, a glue layer may be inserted into an area defined by the compressible member. When the glue layer hardens, the hardened glue layer causes the compressible member to hold the bias established between contact plate and the switch mechanism. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a shimless button assembly according to one or more embodiments of the present disclosure; 
         FIG. 2  illustrates a cross-sectional view of a partial button assembly according to one or more embodiments of the present disclosure; 
         FIG. 3  illustrates a shimless button assembly according to one or more additional embodiments of the present disclosure; 
         FIGS. 4A and 4B  illustrate a close-up view of one or more components of the shimless button assembly according to one or more embodiments of the present disclosure; and 
         FIG. 5  illustrates a method for biasing a button assembly according to one or more embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, embodiments may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the embodiments to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense. 
     One or more embodiments of the present disclosure are directed to a shimless button assembly. Typical button assemblies have various components. For example, a button assembly may have a contact plate that is configured to interact with a switch mechanism when the button is actuated by a user. However, due to differing tolerances between various components of the button assembly, the contact plate may be biased too much against the switch mechanism or too little against the switch mechanism. The differences in the bias may cause the feel of the button to differ from device to device. 
     For example, a contact plate in a first button assembly may have a first thickness while a contact plate in a second button assembly may have a second thickness that is different from the first thickness. Likewise, the other components of the button assembly may also have thicknesses that vary from assembly to assembly. 
     A shim may allow for fine tuning of some button assemblies. However, even with shims, in some cases the button, or a component of the button, may be biased too much against the switch or too little against the switch. This deviation may be caused by different part tolerances of each component of the button assembly such as explained above or by different tolerances of the shims themselves. 
     As will be explained in detail below, the button assembly of the present disclosure is configured to bias one component of a button assembly to another component of the button assembly without the use of a shim. For example, the button assembly of the present disclosure is configured to enable components of the button assembly to be substantially flush or coplanar with respect to a relationship between the surfaces of at least two components. In an embodiment, the button assembly includes a compressible member that is configured to expand and contract to occupy a volume of space within the button assembly. 
     Specifically, the compressible member may be made from a soft foam-like material or a soft rubber-like material. The compressible member may be compressed and placed in the button assembly. Once placed in the button assembly, the compressible member may exert a force on a first button component until the first button component comes into contact with a second button component. Once the first button component comes into contact with the second button component, a glue layer is added within an area defined by the compressible member. When the glue layer hardens, the glue layer prevents the compressible member from further expansion and contraction even when the button is subsequently actuated by a user. As a result, the compressible member will continue to occupy the volume of space in the button assembly. 
       FIG. 1  illustrates a shimless button assembly  100  according to one or more embodiments of the present disclosure. The shimless button assembly  100  of the present disclosure may be used in a variety of computing devices. These computing devices include, but are not limited to, tablet computers, mobile telephones, media players, handheld devices, laptop computers, personal digital assistants, and the like. 
     The shimless button assembly  100  may include a button cover  105 . The button cover  105  may be coupled to a button frame or other button component (not shown). In certain embodiments, the button cover  105  is configured to be flush, or substantially flush, with a housing  110  of a computing device. The button cover  105  may also be configured to receive user actuation which causes the button cover  105  to move within the housing  110 . Although a specific shape and orientation of the button cover  105  is shown in  FIG. 1 , it is contemplated that the button cover  105  may have any desired shape or orientation. Further, it is contemplated that the button cover  105  may sit at least partially above the housing  110  or below the housing  110 . 
     As will be explained in more detail below, the button assembly  100  also includes a contact plate  145 , a switch mechanism  150  and a printed circuit  160  coupled to the switch mechanism  150 . In certain embodiments, the switch mechanism  150  is a tactile switch and the printed circuit  160  may be a flexible printed circuit. As shown in  FIG. 1 , the printed circuit  160  may be coupled to a base portion  165 . The base portion  165  may be a substrate or an inner portion of a housing of a computing device. In embodiments, when the button cover  105  is actuated by a user, the contact plate  145  moves toward the switch mechanism  150  and causes the switch mechanism  150  to come into contact with the printed circuit  160 . The printed circuit  160  then sends a signal to a processor (not shown) of the computing device in which the button assembly  100  is located. 
     In certain embodiments, a volume of space may be located in the button assembly  100  between the contact plate  145  and the switch mechanism  150 . As discussed above, the volume of space may be caused by differing tolerances between one or more components of the button assembly  100 . Accordingly, one or more embodiments of the present disclosure provide for an expansion component that is disposed within the button assembly  100 . As will be explained below, the expansion component is configured to occupy the volume of space caused by the tolerances of each of the components in the button assembly  100 . 
     As shown in  FIG. 1 , the expansion component of the button assembly  100  may include a compressible member  135 . In one or more embodiments, the compressible member  135  is disposed between a portion of the button cover  105  and the contact plate  145 . However, it is contemplated that the compressible member  135  may be placed in different locations within the button assembly  100  such as will be described below with reference to  FIG. 3 . 
     The compressible member  135  may be comprised of a rubber, foam, a spring or other malleable metal. As such, the compressible member  135  may be able to expand and contract based on the volume of space between the contact plate  145  and the switch mechanism  150 . For example, the compressible member  135  may have an uncompressed thickness of 0.4 mm. However, the volume of space between the contact plate  145  and the switch mechanism  150  may be 0.2 mm. Accordingly, during construction of the button assembly  100 , the compressible member  135  may be coupled to the contact plate  145  and to a portion of the button cover  105  as shown in  FIG. 1  and then compressed to a thickness of 0.15 mm. When the compressible member  135  is placed into the button assembly  100  and released or enabled to expand, the compressible member  135  will expand to occupy the 0.2 mm volume of space caused by the tolerances of the contact plate  145  and the switch mechanism  150 . Specifically, the compressible member  135  will expand and exert a force on the contact plate  145  which causes the contact plate  145  to come into contact with the switch mechanism  150 . However, in certain embodiments the compressible member  135  does not exert enough force on the contact plate  145  to cause the contact plate  145  to begin actuating the switch mechanism  150 . In embodiments, the compressible member  135  expands only until the volume of space caused by the tolerances of the various components of the button assembly  100  is occupied. 
     Although specific measurements are discussed above, it is contemplated that the compressible member  135  may have different thicknesses. Further, it is contemplated that the volume of space caused by the tolerances of the various components may vary. For example, one button assembly may have a volume of space of 0.3 mm while another button assembly may have a volume of space of 0.1 mm. Regardless of the volume of space in a given button assembly, the compressible member  135  may cause the contact plate  145  move in a direction toward the switch mechanism  150  to occupy the volume of space so that the contact plate  145  is biased against the switch mechanism  150 . 
     Once the compressible member  135  has expanded to occupy the volume of space, a glue layer  140  is inserted into the button assembly  100 . Although the glue layer may be inserted at this point, it is contemplated that the glue layer  140  may be inserted into the button assembly at any point in the assembly process. In certain embodiments, the glue layer  140  is contained within a boundary defined by the compressible member  135 . For example, the compressible member  135  may have a circular or rectangular shape. Accordingly, the glue layer  140  is inserted into a center “cut-out” portion of the compressible member  135 . As such, the glue layer  140  is prevented from escaping the boundary formed by the compressible member  135 . Once the glue layer  140  hardens, the glue layer  140  prevents the compressible member  135  from further expansion or contraction. Accordingly, the volume of space caused by the tolerance stack of the various components of the button assembly  100  will continuously be occupied by the compressible member  135 , the contact plate  145  and the glue layer  140 . 
       FIG. 2  illustrates a cross-sectional view of a partial button assembly  200  according to one or more embodiments of the present disclosure. In certain embodiments the partial button assembly  200  may be part of the button assembly  100  of  FIG. 1 . As shown in  FIG. 2 , the button assembly  200  comprises a compressible member  210 , a contact plate  230 , a switch mechanism  240  and a printed circuit  250 . The entire button assembly  200  may be coupled to a base layer  260 . In certain embodiments, the base layer may be another circuit board, a substrate or an inner portion of a housing of an electronic device in which the button assembly  200  is located. 
     In embodiments, the compressible member  210  may be comprised of a compressible foam, a compressible rubber or a malleable metal. Although specific examples are given, it is contemplated that the compressible member  210  may be comprised of any material or combinations of materials that may be compressed and expanded such as described herein. As also shown in  FIG. 2 , the compressible member  210  may have a rectangular or square shape that defines an area within the compressible member  210 . The area within the compressible member  210  may be configured to form a boundary in which a glue layer  220  may be deposited. 
     The compressible member  210  may be coupled to a contact plate  230 . As also shown in  FIG. 2 , the compressible member  210 , when coupled to the contact plate  230 , may define an area in which a glue layer  220  may be deposited. As discussed above, the glue layer  220 , when hardened, is configured to hold or secure the compressible member  210  at an expansion point in which the compressible member  210  and the contact plate  230  occupy a volume of space caused by the different tolerances of the various components within the button assembly  200 . Specifically, the glue layer  220  is configured to hold the bias between the contact plate  230  and the switch mechanism  240  established by the compressible member  210 . 
     For example, and as shown in  FIG. 2 , the button assembly  200  may include a switch mechanism  240 . As previously discussed, the compressible member  210  is configured to exert a force on the contact plate  230  which causes the contact plate  230  to be biased against the switch mechanism  240 . In certain embodiments, when the contact plate  230  is biased against the switch mechanism  240 , the contact plate  230  will not begin to actuate the switch mechanism  240 . In certain embodiments, and as will be shown below with respect to  FIG. 3 , the compressible member  210  may be positioned below the switch mechanism  240 . As such, the compressible member  210  may exert a force on a bottom portion of the switch mechanism  240 . As such, the switch mechanism  240  moves toward a contact plate  230  until the switch mechanism  240  occupies a volume of space caused by different tolerances in the button assembly  200 . 
       FIG. 3  illustrates a shimless button assembly  300  according to one or more additional embodiments of the present disclosure. As with the shimless button assembly  100  shown and described above with respect to  FIG. 1 , the shimless button assembly  300  shown and described with respect to  FIG. 3  may also be used in a variety of computing devices. As discussed above, the computing devices may include tablet computers, mobile telephones, media players, handheld devices, laptop computers, personal digital assistants, and the like. 
     Referring to  FIG. 3 , the shimless button assembly  300  may include a button cover  305 . In certain embodiments, the button cover may be coupled to a button frame or other button component (not shown). The button cover  305 , or portions thereof, may be configured to be flush, or substantially flush, with a housing  310  of a computing device in which the button assembly  300  is located. In certain embodiments, the button cover  305  is configured to receive user actuation which causes the button cover  305  to move in the direction of the applied force. 
     The button assembly  300  may also include a contact plate  345 , although in this particular configuration, a contact plate  345  may be optional. The button assembly  300  may also include a switch mechanism  350  and a printed circuit  360  coupled to the switch mechanism  350 . As shown in  FIG. 3 , the button assembly  300  may also include an expansion component located beneath the switch mechanism  350  and the circuit board  360 . The expansion component may be comprised of a compressible member  330  that is configured to expand and contract based on a tolerance stack of various components of the button assembly  300 . For example, a volume of space may exist between the switch mechanism  350  and the contact plate  345  (if present) or a portion of the button cover  305 . 
     In certain embodiments, the compressible member  330  is comprised of a rubber, foam, a spring or other malleable metal. As such, the compressible member  330  is able to expand and contract based on a volume of space between the contact plate  345  or a portion of the button cover  305  and the switch mechanism  350 . As discussed above, the compressible member  330  is configured to exert a force on the switch mechanism  350  to cause the switch mechanism  350  to move toward the contact plate  345  or a portion of the button cover  305 . However, the compressible member  330  does not exert enough force to cause the switch mechanism to being actuating when it comes into contact with the contact plate  345  or the portion of the button cover  305 . In embodiments, the compressible member  330  continues to expand from a compressed state only until the volume caused by the tolerance stack of the various components of the button assembly  300  is occupied. 
     Once the compressible member  330  has expanded to occupy the volume of space, a glue layer  340  may be inserted into a boundary defined by the compressible member  330 . As shown in  FIG. 3 , a base layer  370  of the button assembly  300  may have one or more openings or conduits  335  that enable the glue layer  340  to be inserted into the open center portion or “cut-out” portion of the compressible member  330 . In other embodiments, the glue layer may be inserted or placed on one or more components of the button assembly  300  prior to the button assembly  300  being assembled. In embodiments, the compressible member  330  may prevent the glue layer  340  from escaping a boundary formed by the compressible member  330 . Although an open center portion or “cut-out” portion is specifically mentioned, it is contemplated that the glue layer  340  may be inserted directly into the compressible member  330 . 
     Once the glue layer  340  hardens, the glue layer  340  prevents the compressible member  330  from further expansion or contraction. Accordingly, the volume of space caused by the tolerances of the various components will be continuously occupied by the compressible member  330 , the switch mechanism  350  and the glue layer  340 . 
       FIGS. 4A and 4B  illustrate a close-up view of one or more components of a shimless button assembly  400  according to one or more embodiments of the present disclosure. In certain embodiments, the partial button assembly  400  may be the expansion mechanism described above with respect to  FIG. 3 . 
     Specifically, the partial button assembly  400  may include a tactile switch  410  coupled to a circuit board  420 . As discussed above with respect to  FIG. 3 , a bottom side of the circuit board  420  may be coupled to a compressible member  430  that causes the printed circuit board  420  and the switch mechanism  410  to move from a first position to a second position based on a volume of space between the switch mechanism  410  and a contact plate or a button frame of a button assembly. As also discussed above, a glue layer  440  may be inserted within an area defined by a compressible member  430 . The glue layer, when hard, prevents the compressible member  430  from further expansion and contraction. As such, the partial button assembly  400  would occupy a volume of space caused by differing tolerance levels in the button assembly  400  without the use of one or more shims. 
       FIG. 5  illustrates a method  500  for biasing a button assembly according to one or more embodiments of the present disclosure. In embodiments, the method  500  for biasing a button assembly may be used with one or more embodiments described above with references to  FIGS. 1-4 . Accordingly, one or more references may be made to one or more components described above with respect to  FIGS. 1-4 . 
     Method  500  begins when a glue layer is placed  510  onto one or more components of a button assembly. In certain embodiments, the glue layer may be placed within a boundary defined by one or more components of an expansion component of the button assembly. For example, a compressible member of an expansion component of the button assembly may define an area in which the glue layer is placed. As will be discussed below, once the button assembly has been assembled and the glue layer hardens, the glue layer prevents the expansion component from further expansion and contraction even when the button is subsequently actuated by a user. As a result, and as discussed above, the expansion component continues to occupy the volume of space in the button assembly caused by a tolerance stack between the various components of the button assembly. Although a glue layer is specifically mentioned herein, it is contemplated that materials other than glue may be used so long as the material prevents the expansion component from further expansion and contraction after biasing one or more components of the button assembly. 
     Flow then proceeds to operation  520  in which an expansion component is compressed and inserted  530  into a button assembly. The expansion component may be a compressible member comprised of a foam material, a rubber material, a malleable metal or other such material such as described above. In certain embodiments, the expansion component may be comprised of one or more additional components of the button assembly. For example, the expansion component may be comprised of a compressible member and a contact plate. In another embodiment, the expansion component may be comprised of a compressible member, a printed circuit and a switch mechanism. 
     Once the expansion component has been placed in the button assembly, flow proceeds to operation  540  and the expansion component either expands or further contracts based on a tolerance stack caused by various components in the button assembly. For example, the button assembly may have a 0.3 mm space between the contact plate and the switch mechanism. This space may be caused by a manufacturing tolerance of one or more components of the button assembly. Further, the expansion component may have an uncompressed thickness of 0.4 mm. Accordingly, during construction of the button assembly, the expansion component may be compressed to a thickness of 0.15 mm and inserted into the button assembly. The expansion component is then enabled to expand to occupy the 0.3 mm volume of space caused by the tolerance stack. Specifically, the expansion component will bias one component of the button assembly to a second component of the button assembly such as described above. 
     Once the volume of space has been occupied by the expansion component, the glue layer is allowed to harden such as discussed above. The glue layer then maintains the bias established by the expansion component even when the button is subsequently actuated by a user. 
     The description and illustration of one or more embodiments provided in this disclosure are not intended to limit or restrict the scope of the present disclosure as claimed. The embodiments, examples, and details provided in this disclosure are considered sufficient to convey possession and enable others to make and use the best mode of the claimed embodiments. Additionally, the claimed embodiments should not be construed as being limited to any embodiment, example, or detail provided above. Regardless of whether shown and described in combination or separately, the various features, including structural features and methodological features, are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the spirit of the broader aspects of the embodiments described herein that do not depart from the broader scope of the claimed embodiments.

Metadata:
Filing Date: 20140212
Publication Date: 20160920
Grant Date: 20160920
Priority Date: 20140212
Inventors: SANFORD EMERY A.
MANULLANG TYSON B.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H2221/042", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/044", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/14", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2221/062", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2221/044", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/042", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/14", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2221/062", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 53775516