PATENT DOCUMENT

Publication Number: US-11694831-B2
Application Number: US-202016935580-A
Country: US
Kind Code: B2

Title: Haptic actuator including outwardly extending terminals from first and second housing shells and related methods

Abstract:
A haptic actuator may include a housing that includes first and second shells coupled together. The first shell may include a first body and first terminals extending outwardly therefrom. The second shell may include a second body and second terminals extending outwardly therefrom with each of the second terminals being secured with a respective one of the first terminals defining pairs of first and second secured-together terminals. The haptic actuator may also include at least one coil carried by the housing and a field member movable within the housing responsive to the at least one coil. A respective flexure may be between adjacent end portions of the housing and the field member.

Claims:
That which is claimed is: 
     
       1. A haptic actuator comprising:
 a housing comprising first and second shells coupled together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals, wherein each first terminal of the first plurality of terminals and second terminal of the second plurality of terminals has a fastener receiving passageway therein; 
 at least one coil carried by the housing; 
 a field member movable within the housing responsive to the at least one coil; and 
 a respective flexure between adjacent end portions of the housing and the field member. 
 
     
     
       2. The haptic actuator of  claim 1  comprising a respective welded joint securing each pair of first and second secured-together terminals. 
     
     
       3. The haptic actuator of  claim 1  wherein the first respective terminal of the first plurality of terminals and the second respective terminal of the second plurality of terminals of each pair of secured-together terminals are coextensive. 
     
     
       4. The haptic actuator of  claim 1  wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively. 
     
     
       5. The haptic actuator of  claim 1  further comprising a respective plastic body between each respective flexure and adjacent end portions of the housing. 
     
     
       6. The haptic actuator of  claim 1  wherein the field member comprises a frame and at least one permanent magnet carried by the frame. 
     
     
       7. The haptic actuator of  claim 1  wherein the housing comprises a magnetic material. 
     
     
       8. The haptic actuator of  claim 1  wherein the flexures have a wishbone shape. 
     
     
       9. The haptic actuator of  claim 1  wherein the at least one coil has a loop shape. 
     
     
       10. An electronic device comprising:
 a device housing; 
 wireless communications circuitry carried by the device housing; 
 a haptic actuator carried by the device housing and comprising,
 an actuator housing comprising first and second shells coupled together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals, wherein each first terminal of the first plurality of terminals and second terminal of the second plurality of terminals has a fastener receiving passageway therein, 
 at least one coil carried by the actuator housing, 
 a field member movable within the actuator housing responsive to the at least one coil, and 
 a respective flexure between adjacent end portions of the actuator housing and the field member; and 
 
 a controller coupled to the wireless communications circuitry and the haptic actuator and configured to perform at least one wireless communications function and selectively operate the haptic actuator, respectively. 
 
     
     
       11. The electronic device of  claim 10  wherein the haptic actuator comprises a respective welded joint securing each pair of first and second secured-together terminals. 
     
     
       12. The electronic device of  claim 10  wherein the first respective terminal of the first plurality of terminals and the second respective terminal of the second plurality of terminals of each pair of secured-together terminals are coextensive. 
     
     
       13. The electronic device of  claim 10  wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively. 
     
     
       14. A method of making a haptic actuator comprising:
 coupling first and second shells of a housing together, the first shell comprising a first body and a first plurality of terminals extending outwardly therefrom, the second shell comprising a second body and a second plurality of terminals extending outwardly therefrom, the first and second shells being coupled so that each of the second plurality of terminals being secured with a respective one of the first plurality of terminals define pairs of first and second secured-together terminals, wherein each first terminal of the first plurality of terminals and second terminal of the second plurality of terminals has a fastener receiving passageway therein; 
 positioning at least one coil carried by the housing; 
 positioning a field member to be movable within the housing responsive to the at least one coil; and 
 positioning a respective flexure between adjacent end portions of the housing and the field member. 
 
     
     
       15. The method of  claim 14  comprising forming a respective welded joint to secure each pair of first and second secured-together terminals. 
     
     
       16. The method of  claim 14  wherein the first respective terminal of the first plurality of terminals and the second respective terminal of the second plurality of terminals of each pair of secured-together terminals are coextensive. 
     
     
       17. The method of  claim 14  wherein the field member comprises a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively. 
     
     
       18. The method of  claim 14  further comprising positioning a respective plastic body between each respective flexure and adjacent end portions of the housing.

Description:
RELATED APPLICATIONS 
     The present application claims the priority benefit of provisional application Ser. No. 62/904,569 filed on Sep. 23, 2019, the entire contents of which are herein incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to the field of electronics, and, more particularly, to the field of haptics. 
     BACKGROUND 
     Haptic technology is becoming a more popular way of conveying information to a user. Haptic technology, which may simply be referred to as haptics, is a tactile feedback based technology that stimulates a user&#39;s sense of touch by imparting relative amounts of force to the user. 
     A haptic device or haptic actuator is an example of a device that provides the tactile feedback to the user. In particular, the haptic device or actuator may apply relative amounts of force to a user through actuation of a mass that is part of the haptic device. Through various forms of tactile feedback, for example, generated relatively long and short bursts of force or vibrations, information may be conveyed to the user. 
     SUMMARY 
     A haptic actuator may include a housing that includes first and second shells coupled together. The first shell may include a first body and a first plurality of terminals extending outwardly therefrom. The second shell may include a second body and a second plurality of terminals extending outwardly therefrom with each of the second plurality of terminals being secured with a respective one of the first plurality of terminals defining pairs of first and second secured-together terminals. The haptic actuator may also include at least one coil carried by the housing and a field member movable within the housing responsive to the at least one coil. A respective flexure may be between adjacent end portions of the housing and the field member. 
     The haptic actuator may also include a respective welded joint securing each pair of first and second secured-together terminals. The first and second respective terminals of each pair of secured-together terminals may be coextensive, for example. 
     Each of the plurality of first and second terminals may have a fastener receiving passageway therein. The field member may include a frame having opposing first and second ends and first and second overmolded endcaps coupled to the first and second ends of the frame, respectively, for example. 
     The haptic actuator may also include a respective plastic body between each respective flexure and adjacent end portions of the housing, for example. The field member may include a frame and at least one permanent magnet carried by the frame. 
     The housing may include a magnetic material. The flexures may have a wishbone shape, for example. The at least one coil may have a loop shape, for example. 
     A method aspect is directed to a method of making a haptic actuator that may include coupling first and second shells of a housing together. The first shell may include a first body and a first plurality of terminals extending outwardly therefrom. The second shell may include a second body and a second plurality of terminals extending outwardly therefrom. The first and second shells may be coupled so that each of the second plurality of terminals being secured with a respective one of the first plurality of terminals define pairs of first and second secured-together terminals. The method may also include positioning at least one coil carried by the housing and positioning a field member to be movable within the housing responsive to the at least one coil. The method may further include positioning a respective flexure between adjacent end portions of the housing and the field member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a schematic diagram of an electronic device in accordance with an embodiment. 
         FIG.  2    is a schematic block diagram of the electronic device of  FIG.  1   . 
         FIG.  3    is a perspective view of an exemplary haptic actuator in accordance with an embodiment. 
         FIG.  4    is a perspective view of the haptic actuator of  FIG.  3    with the first shell of the actuator housing removed. 
         FIG.  5    is an exploded perspective view of a portion of a haptic actuator in accordance with an embodiment. 
         FIG.  6    illustrates assembly of an exemplary haptic actuator in accordance with an embodiment. 
         FIG.  7    is a perspective view of a flexure of a haptic actuator in accordance with an embodiment. 
         FIG.  8    is a cut-away view of a portion of a haptic actuator in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied 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 invention to those skilled in the art. Like numbers refer to like elements throughout. 
     Referring initially to  FIGS.  1 - 2   , an electronic device  20  illustratively includes a device housing  21  and a controller  22  carried by the device housing. The electronic device  20  is illustratively a mobile wireless communications device, for example, a cellular telephone or smartphone. The electronic device  20  may be another type of electronic device, for example, a wearable device (e.g., a watch), a tablet computer, a laptop computer, a gaming device, etc. 
     Wireless communications circuitry  25  (e.g. cellular, WLAN Bluetooth, etc.) is also carried within the device housing  21  and coupled to the controller  22 . The wireless communications circuitry  25  cooperates with the controller  22  to perform at least one wireless communications function, for example, for voice and/or data. In some embodiments, the electronic device  20  may not include wireless communications circuitry  25 . 
     A display  23  is also carried by the device housing  21  and is coupled to the controller  22 . The display  23  may be, for example, a light emitting diode (LED) display, a liquid crystal display (LCD), or may be another type of display, as will be appreciated by those skilled in the art. The display  23  may be a touch display and may cooperate with the controller  22  to perform a device function in response to operation thereof. For example, a device function may include a powering on or off of the electronic device  20 , initiating communication via the wireless communications circuitry  25 , and/or performing a menu function. 
     The electronic device  20  illustratively includes a haptic actuator  40 . The haptic actuator  40  is coupled to the controller  22  and provides haptic feedback or a haptic effect to the user in the form of relatively long and short vibrations. The vibrations may be indicative of a message received, and the duration and type of the vibration may be indicative of the type of message received. Of course, the vibrations may be indicative of or convey other types of information. 
     While a controller  22  is described, it should be understood that the controller  22  may include one or more of a processor and other circuitry to perform the functions described herein. For example, the controller  22  may include a class-D amplifier to drive the haptic actuator  40  and/or sensors for sensing voltage and current. 
     Referring now additionally to  FIGS.  3 - 8   , the haptic actuator  40  includes an actuator housing  41  that may be metal, for example, and more particularly, may include a magnetic material. The actuator housing  41  may be another type of material or include more than one type of material. 
     The actuator housing  41  includes first and second shells  42   a ,  42   b  that are coupled together. The first shell  42   a  includes a first body  71   a  and first terminals  72   a  that extend outwardly from the first body. The first shell  42   a  also includes first tabs  77   a  extending from the first body  71   a . A cosmetic label  81  may be carried by the first shell. 
     The second shell  42   b  includes a second body  71   b  and second terminals  72   b  that extend outwardly from the second body. The second shell  42   b  also includes second tabs  77   b  extending from the second body  71   b.    
     The first tabs  77   a  each define a respective gap with each of the second tabs  77   b . The first and second tabs  77   a ,  77   b  each have a curved shape to define a rounded edge. 
     Each of the second terminals  72   b  is secured with a respective one of the first terminals  72   a  defining pairs of first and second secured-together terminals  72 . Each of the first and second terminals  72   a ,  72   b  has a fastener receiving passageway  75  therein. A respective fastener passes through each fastener receiving passageway  75  to fasten the haptic actuator  40  within the device housing  21 , and more particularly, adjacent the display  23 . 
     The first and second terminals  72   a ,  72   b  of each pair of secured-together terminals  72  are coextensive. A respective welded joint  74  secures each pair of first and second-secured together terminals  72 . 
     The haptic actuator  40  also includes first and second coils  44 ,  45  carried by the actuator housing  41 , for example, the top and the bottom, respectively. The first and second coils  44 ,  45  may each have a loop shape or “racetrack” shape and are aligned in a stacked relation and spaced apart. There may be any number of first and second coils  44 ,  45  as will be appreciated by those skilled in the art. The haptic actuator  40  also includes a field member  50  that is movable within the actuator housing  41  responsive to the first and second coils  44 ,  45 . 
     The field member  50  includes a frame  57  that defines a mass. The frame  57  has opposing first and second ends  53   a ,  53   b . The frame  57  may be metal, for example, tungsten or tungsten powder. The frame  57  may be a different material (e.g., relatively heavy material). The frame  57  illustratively includes cleating  54  at the opposing ends  53   a ,  53   b . Cleating  54  may be included in other areas, for example, relatively high-stress areas. 
     The field member  50  also includes permanent magnets  51  carried by the frame  57  and between the first and second coils  44 ,  45 . More particularly, the permanent magnets  51  are configured in side-by-side relation and carried within a respective magnet receiving opening  64 . An overmolded magnet receiving holder  58  is coupled to the frame  57  and lines corners of the magnet receiving opening  64  to receive the permanent magnets  51  therein. The permanent magnets  51  may be press-fitted to a magnetic center to reduce or minimize magnetic flux bias, as will be appreciated by those skilled in the art. 
     The permanent magnets  51  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. There may be any number of permanent magnets  51  having any shape between the first and second coils  44 ,  45 . In some embodiments, the coils  44 ,  45  may be carried by the field member  50  and the permanent magnets  51  carried by the housing (i.e., movable coils). 
     The field member  50  illustratively includes a first overmolded endcap  55   a  coupled to the first end  53   a  of the frame  57 . More particularly, the first end  53   a  of the frame  57  (e.g., the cleating  54 ) is embedded into the first overmolded endcap  55   a . The first overmolded endcap  55   a  may be plastic, such as a thermosetting or thermoplastic material. The first overmolded endcap  55   a  may be another material or may include additional materials. For example, tungsten powder (to increase the weight) or glass (to increase the strength) may be included within the first overmolded endcap  55   a.    
     A second overmolded endcap  55   b  is coupled to the second end  53   b  of the frame  57 . More particularly, similarly to the first end  53   a , the second end  53   b  of the frame  57  (e.g., the cleating  54 ) is embedded into the second overmolded endcap  55   b . The second overmolded endcap  55   b  may be plastic. The second overmolded endcap  55   b  may be another material or may include additional materials. For example, tungsten powder or glass may be included within the second overmolded endcap  55   b.    
     The haptic actuator  40  also includes a first flexure  60   a  having an inner end coupled to, for example, embedded into, the first overmolded endcap  55   a . The first flexure  60   a  also has an outer end coupled to adjacent portions of the actuator housing  41 . More particularly, a first plastic body  56   a  is coupled to the outer end of the first flexure  60   a  and carried by the actuator housing  41 . The outer end of the first flexure  60   a  is embedded within the first plastic body  56   a.    
     More particularly, the first plastic body  56   a  has recesses  78   a ,  78   b  therein to receive the corresponding first and second tabs  77   a ,  77   b  therein. The first plastic body  56   a  fills the respective gap defined by the first and second tabs  77   a ,  77   b . The first plastic body  56   a  also has a curved shape to define, with respective first and second tabs  77   a ,  77   b , the rounded edges. 
     The first flexure  60   a  illustratively includes two diverging arms  61  joined together by a bend  62  defining a wishbone shape. The two diverging arms  61  have cleating  63  or surface features at distal ends opposite the bend  62 . The cleating  63  is illustratively encapsulated by the first plastic body  56   a  and the first overmolded endcap  55   a . The first flexure  60   a  may be metal, for example. Of course, the first flexure  60   a  may be another material or may include other and/or additional materials. While a single first flexure  60   a  is illustrated, there may be more than one first flexure. 
     The haptic actuator  40  also includes a second flexure  60   b  having an inner end coupled to, for example, embedded into, the second overmolded endcap  55   b . The second flexure  60   b  also has an outer end coupled to adjacent portions of the actuator housing  41 . More particularly, a second plastic body  56   b  is coupled to the outer end of the second flexure  60   b  and carried by the actuator housing  41 . The outer end of the second flexure  60   b  is embedded within the second plastic body  56   b.    
     More particularly, the second plastic body  56   b  has recesses  78   a ,  78   b  therein to receive the corresponding first and second tabs  77   a ,  77   b  therein. The second plastic body  56   b  fills the respective gap defined by the first and second tabs  77   a ,  77   b . The second plastic body  56   b  also has a curved shape to define, with respective first and second tabs  77   a ,  77   b , the rounded edges. 
     The second flexure  60   b , similarly to the first flexure  60   a , illustratively includes two diverging arms  61  joined together by a bend  62  to define a wishbone shape. The two diverging arms  61  have cleating  63  at distal ends opposite the bend  62 . The cleating  63  is illustratively encapsulated by the second plastic body  56   b  and the second overmolded endcap  55   b . The second flexure  60   b  may be metal, for example. Of course, the second flexure  60   b  may be another material or may include other and/or additional materials. While a single second flexure  60   b  is illustrated, there may be more than one second flexure. 
     As will be appreciated by those skilled in the art, the haptic actuator  40  described herein may include a reduced part count, and may include reduced welding, gluing, and inspection operations relative to prior art haptic actuators, for example, by reducing and combining processes. Additionally, complexity of docking or mounting the field member  50  and flexures  60   a ,  60   b  within the actuator housing  41 , may be reduced as the molded components may be considered self-aligning. With respect to volume efficiency, as described above, for example, mold features and tungsten powder compounding may be utilized to increase material volume and shapes. The use of compound materials and mold strategic shapes/locations of the haptic actuator  40  may also optimize resonance and damping characteristics. 
     With respect to drop shock, flexure breakage may be reduced since overmolding is typically done at lower temperatures relative to welding, for example. Moreover, the materials and shapes may be chosen to define moldable shock tolerant features, for example, crash stops. 
     In some embodiments, the frame  57  may be entirely plastic. For example, the frame  57 , as being entirely plastic, may be integrally molded with the first and second overmolded endcaps  55   a ,  55   b . Other and/or additional components may also be plastic and integrally molded with the fully plastic frame  57 . 
     A method aspect is directed to a method of making a haptic actuator  40 . The method includes coupling first and second shells  42   a ,  42   b  of a housing  41  together. The first shell  42   a  includes a first body  71   a  and a first plurality of terminals  72   a  extending outwardly therefrom. The second shell  42   b  includes a second body  71   b  and a second plurality of terminals  72   b  extending outwardly therefrom. The first and second shells  42   a ,  42   b  are coupled so that each of the second plurality of terminals  72   b  being secured with a respective one of the first plurality of terminals  72   a  define pairs of first and second secured-together terminals  72 . The method also includes positioning at least one coil  44  carried by the housing  41  and positioning a field member  50  to be movable within the housing responsive to the at least one coil. The method further includes positioning a respective flexure  60   a ,  60   b  between adjacent end portions of the housing  41  and the field member  50 . 
     Another method aspect is directed to a method of making a haptic actuator  40 . The method includes coupling first and second shells  42   a ,  42   b  of a housing  41  together. The first shell  42   a  includes a first body  71   a  and a first plurality of tabs  77   a  extending therefrom. The second shell  42   b  includes a second body  71   b  and a second plurality of tabs  77   b  extending therefrom. The method includes positioning at least one coil  44  carried by the housing  41  and positioning a field member  50  to be movable within the housing responsive to the at least one coil. The method also includes positioning a respective flexure  60   a ,  60   b  between adjacent end portions of the housing  41  and the field member  50 . Each flexure  60   a ,  60   b  includes a plastic body  56   a ,  56   b  having a plurality of recesses  78   a ,  78   b  therein to receive corresponding ones the first and second pluralities of tabs  77   a ,  77   b  therein. 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Metadata:
Filing Date: 20200722
Publication Date: 20230704
Grant Date: 20230704
Priority Date: 20190923
Inventors: LARSON, NILS E.
Assignee: APPLE INC
CPC Classifications: [{"code": "G08B6/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F7/129", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01F7/081", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F7/127", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/016", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01F7/129", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01F7/1646", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F1/1658", "inventive": true, "first": false, "tree": "[]"}, {"code": "G08B6/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "G08B6/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F7/127", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01F7/081", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 74881181