PATENT DOCUMENT

Publication Number: US-10038361-B2
Application Number: US-201615222511-A
Country: US
Kind Code: B2

Title: Haptic actuator including flexible flexure bearings having a wishbone shape and related methods

Abstract:
A haptic actuator may include a housing, at least one coil carried by the housing, and a field member having opposing first and second sides. The haptic actuator may also include a respective at least one flexure bearing mounting each of the first and second sides of the field member to be reciprocally movable within the housing responsive to the at least one coil. Each flexure bearing may include at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the housing.

Claims:
That which is claimed is: 
     
       1. A haptic actuator comprising:
 a housing; 
 at least one coil carried by the housing; 
 a field member having opposing first and second sides; and 
 a respective at least one flexure bearing mounting each of the first and second sides of the field member to be reciprocally movable within the housing responsive to the at least one coil; 
 each flexure bearing comprising at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the housing. 
 
     
     
       2. The haptic actuator of  claim 1  wherein the at least one flexible member has a bend therein joining together the two diverging arms at the proximal ends. 
     
     
       3. The haptic actuator of  claim 1  wherein the two diverging arms include respective portions being spaced apart adjacent the proximal ends. 
     
     
       4. The haptic actuator of  claim 1  wherein the two diverging arms are coupled together at the proximal ends. 
     
     
       5. The haptic actuator of  claim 1  wherein the at least one flexible member comprises a plurality thereof. 
     
     
       6. The haptic actuator of  claim 1  wherein each flexure bearing further comprises at least one anchor member coupled to the adjacent portion of the housing and spaced from the adjacent portion of the field member. 
     
     
       7. The haptic actuator of  claim 6  wherein the at least one flexible member is coupled between the at least one anchor member and the field member. 
     
     
       8. An electronic device comprising:
 a housing; 
 wireless communications circuitry carried by the housing; 
 a haptic actuator carried by the housing and comprising
 an actuator housing, 
 at least one coil carried by the actuator housing, 
 a field member having opposing first and second sides, and 
 a respective at least one flexure bearing mounting each of the first and second sides of the field member to be reciprocally movable within the actuator housing responsive to the at least one coil, 
 each flexure bearing comprising at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the actuator housing; 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 operating the haptic actuator. 
 
     
     
       9. The electronic device of  claim 8  wherein the at least one flexible member has a bend therein joining together the two diverging arms at the proximal ends. 
     
     
       10. The electronic device of  claim 8  wherein the two diverging arms include respective portions being spaced apart adjacent the proximal ends. 
     
     
       11. The electronic device of  claim 8  wherein the two diverging arms are coupled together at the proximal ends. 
     
     
       12. The electronic device of  claim 8  wherein the at least one flexible member comprises a plurality thereof. 
     
     
       13. The electronic device of  claim 8  wherein each flexure bearing further comprises at least one anchor member coupled to the adjacent portion of the housing and spaced from the adjacent portion of the field member. 
     
     
       14. The electronic device of  claim 13  wherein the at least one flexible member is coupled between the at least one anchor member and the field member. 
     
     
       15. A method of making a haptic actuator comprising:
 positioning a respective at least one flexure bearing to mount each of first and second sides of a field member to be reciprocally movable within a housing responsive to at least one coil, each flexure bearing comprising at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the housing. 
 
     
     
       16. The method of  claim 15  wherein the at least one flexible member has a bend therein joining together the two diverging arms at the proximal ends. 
     
     
       17. The method of  claim 15  wherein the two diverging arms include respective portions being spaced apart adjacent the proximal ends. 
     
     
       18. The method of  claim 15  wherein the two diverging arms are coupled together at the proximal ends. 
     
     
       19. The method of  claim 15  wherein the at least one flexible member comprises a plurality thereof. 
     
     
       20. The method of  claim 15  wherein each flexure bearing further comprises at least one anchor member coupled to the adjacent portion of the housing and spaced from the adjacent portion of the field member.

Description:
RELATED APPLICATIONS 
     The present application claims the priority benefit of provisional application Ser. No. 62/220,705 filed on Sep. 18, 2015 and provisional application Ser. No. 62/329,364 filed on Apr. 29, 2016, the entire contents of each of which are herein incorporated in their entirety 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, at least one coil carried by the housing, and a field member having opposing first and second sides. The haptic actuator may also include a respective at least one flexure bearing mounting each of the first and second sides of the field member to be reciprocally movable within the housing responsive to the at least one coil. Each flexure bearing may include at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the housing. In another embodiment, at least one permanent magnet may be carried by the housing and the field member may include at least one coil cooperating with the at least one permanent magnet. 
     The at least one flexible member may have a bend therein joining together the two diverging arms at the proximal ends. The two diverging arms may include respective portions being spaced apart adjacent the proximal ends, for example. 
     The two diverging arms may be coupled together at the proximal ends. The at least one flexible member may include a plurality thereof, for example. 
     Each flexure bearing may further include at least one anchor member coupled to the adjacent portion of the housing and spaced from the adjacent portion of the field member. The at least one flexible member may be coupled between the at least one anchor member and the field member, for example. 
     A method aspect is directed to a method of making a haptic actuator. The method may include positioning a respective at least one flexure bearing to mount each of first and second sides of a field member to be reciprocally movable within a housing responsive to at least one coil, wherein each flexure bearing may include at least one flexible member having a wishbone shape with two diverging arms joined together at proximal ends and having spaced distal ends operatively coupled between adjacent portions of the field member and the housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an electronic device including a haptic actuator according to an embodiment of the present invention. 
         FIG. 2  is a schematic block diagram of the electronic device of  FIG. 1 . 
         FIG. 3  is a schematic block diagram of a portion of the haptic actuator of  FIG. 2 . 
         FIG. 4  is a perspective view of a portion of the haptic actuator of  FIG. 1 . 
         FIG. 5  is an enlarged perspective view of the anchor member of the haptic actuator of  FIG. 3 . 
         FIG. 6 a    is a top view of a parallel spaced apart flexible arm in accordance with an embodiment. 
         FIG. 6 b    is a side view of a parallel spaced apart flexible arm in accordance with an embodiment. 
         FIG. 6 c    is a side view of a portion of a parallel spaced apart flexible arm in accordance with an embodiment. 
         FIG. 7  is a schematic block diagram of an electronic device including a haptic actuator according to another embodiment. 
         FIG. 8  is an enlarged perspective view of a portion of a haptic actuator according to another embodiment. 
         FIG. 9  is a side view of a portion of a parallel spaced apart flexible arm in accordance with an embodiment. 
         FIG. 10  is an enlarged perspective view of a haptic actuator in accordance with an embodiment. 
         FIG. 11  is a perspective view of a portion of a haptic actuator according to an embodiment. 
         FIG. 12  is another perspective view of a portion of the haptic actuator in  FIG. 11 . 
         FIG. 13  is a perspective view of a haptic actuator according to another embodiment. 
         FIG. 14  is a perspective view of a portion of a haptic actuator according to an embodiment. 
         FIG. 15  is a perspective view of another portion of the haptic actuator in  FIG. 14 . 
         FIG. 16  is a perspective view of a portion of a haptic actuator in accordance with another embodiment. 
         FIG. 17  is a perspective view of a portion of a haptic actuator according to an embodiment. 
         FIG. 18  is an enlarged perspective view of the flexible member of  FIG. 17 . 
         FIG. 19  is an enlarged perspective view of a flexible member according to another embodiment. 
         FIG. 20  is a perspective view of a portion of a haptic actuator according to an embodiment. 
         FIG. 21  is an enlarged perspective view of a flexure bearing for use with a field member 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, and prime and multiple prime notation is used to refer to like elements in different embodiments. 
     Referring initially to  FIGS. 1 and 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 wearable wireless communications device, and includes a band  28  or strap for securing it to a user. The electronic device  20  may be another type of electronic device, for example, a cellular telephone, a tablet computer, a laptop computer, 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 a liquid crystal display (LCD), for example, or may be another type of display, as will be appreciated by those skilled in the art. 
     Finger-operated user input devices  24   a ,  24   b , illustratively in the form of a pushbutton switch and a rotary dial are also carried by the device housing  21  and are coupled to the controller  22 . The pushbutton switch  24   a  and the rotary dial  24   b  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 to the user in the form of relatively long and short vibrations or “taps”, particularly when the user is wearing the electronic device  20 . The vibrations may be indicative of a message received, and the duration 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. More particularly, the controller  22  applies a voltage to move a moveable body or masses between first and second positions in a y-axis. 
     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. 3-5 , the haptic actuator  40  includes an actuator housing  41 . The actuator housing  41  illustratively has a dimension in a length direction greater than a width direction. The actuator housing  41  may be ferritic. More particularly, the top and bottom of the actuator housing  41  may be ferritic. Of course other and/or additional portions of the actuator housing  41  may be ferritic. 
     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  each illustratively have a loop shape or “racetrack” shape and are aligned in a stacked relation and spaced apart. 
     The haptic actuator  40  also includes a field member  50  carried by the actuator housing  41 . The field member  50 , similarly to the actuator housing  41 , has a dimension in a length direction greater than a width direction. Thus, the field member  50  is reciprocally movable in the width direction (i.e., the y-direction). While the movement of the field member  50  is described as being moveable in one direction, i.e., a linear haptic actuator, it should be understood that in some embodiments, the field member may be movable in other directions, i.e., an angular haptic actuator, or may be a combination of both a linear and an angular haptic actuator. 
     The field member  50  illustratively includes permanent magnets  51 ,  52  between the first and second coils  44 ,  45 . The permanent magnets  51 ,  52  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. 
     The permanent magnets  51 ,  52  also have a rectangular shape and are aligned along a length of the first and second coils  44 ,  45 . While a pair of rectangular shaped permanent magnets is illustrated, it will be appreciated that there may be any number of permanent magnets having any shape between the first and second coils  44 ,  45 . 
     The field member  50  also includes a mass  57  between the permanent magnets  51 ,  52 . The mass  57  may be tungsten, for example. The mass  57  may be a different material and there may be more than one mass. 
     The haptic actuator  40  also includes respective flexure bearings  60   a ,  60   b  mounting each of first and second sides  53 ,  54  of the field member  50  to be reciprocally movable within the actuator housing  41  responsive to the first and second coils  44 ,  45 . Each flexure bearing  60   a ,  60   b  includes a first end member  61   a ,  61   b , and a second end member  62   a ,  62   b . The second end member  61   a ,  61   b  is coupled to an adjacent side  53 ,  54  of the field member  50 . The second end member  62   a ,  62   b  has a slot  59   b  therein ( FIG. 5 ) receiving the adjacent side  53 ,  54  of the field member  50  therein. 
     Each flexure bearing  60   a ,  60   b  also includes a pair of parallel spaced apart flexible arms  63   a ,  63   b  coupled between the first and second end members  61   a ,  61   b ,  62   a ,  62   b . Each flexure bearing  60   a ,  60   b  may have more than one pair of parallel spaced apart flexible arms. 
     The pair of parallel spaced apart flexible arms  63   a ,  63   b  illustratively has a non-uniform thickness. Referring briefly to  FIGS. 6 a , 6 b , and 6 c   , in some embodiments, the pair of parallel spaced apart flexible arms  63   a ′ may include an enlarged width medial portion  67   a ′ ( FIG. 6 a   ), enlarged width end portion&#39;s  68   a ″ and  68   b ″ ( FIG. 6 b   ), and/or one or more openings  69   a ′″ ( FIG. 6C ) therein. By having a non-uniform thickness or having an opening therethrough, stress areas, which may be referred to as “stress hot spots,” may be reduced by reducing the amount of material, thereby also increasing displacement. 
     Additionally, it may be desirable for the pair of parallel spaced apart flexible arms  63   a ,  63   b  to have a thickness that is a few times smaller than the height thereof. This may maintain a reasonable stiffness in directions other than along the motion axis, for example, as will be appreciated by those skilled in the art. More particularly, the pair of parallel spaced apart flexible arms  63   a ,  63   b  may have a thickness that is greater than or equal to half of the distance of the travel thereof (i.e., displacement) to reduce nonlinear stiffening. Reasonable nonlinear stiffening may be particularly advantageous for widening the spectrum, as will be appreciated by those skilled in the art. 
     Each flexure bearing  60   a ,  60   b  also includes an anchor member  64   a ,  64   b  coupled to the first end member  61   a ,  61   b  and coupled to the actuator housing  41 . The anchor member  64   a ,  64   b  is also spaced from the second end member  62   a ,  62   b . The anchor member  64   a ,  64   b  includes a T-shaped anchor body  65   a ,  65   b  and a pair of parallel spaced apart flexure arms  66   a ,  66   b  extending between the anchor body and the first end member  61   a ,  61   b . In some embodiments, the anchor body  65   a ,  65   b  may have another shape. 
     The flexure bearings  60   a ,  60   b  mount each of the first and second sides  53 ,  54  of the field member  50  to be reciprocally movable within the actuator housing  41  responsive to the coils  44 ,  45 . More particularly, the flexure bearings  60   a ,  60   b  move or flex in the direction of the field member  50  and return it to the equilibrium position. Overall flexure or movement of each flexure bearing  60   a ,  60   b  is about 1/10 of the length of the flexure bearing. 
     The haptic actuator  40  advantageously does not include, relative to other types of haptic actuators, shafts and/or bearings to constrain the motion of the mass  57  in a desired direction. Typically, to constrain angular motions, a second shaft or relatively complex stabilization techniques, such as stabilization magnets would be used. However, stabilization magnets may make the haptic actuator more complex, more unreliable, and increasingly expensive. By using the flexure bearings  60   a ,  60   b , movement is generally constrained in every direction except the desired direction, and several relatively expensive parts may be omitted, such as shafts, precise bearings (round/slot), and springs, resulting in a more simple haptic actuator  40 . 
     A method aspect is directed to a method of making a haptic actuator  40 . The method may include positioning at least one coil  44 ,  45  to be carried by an actuator housing  41  and positioning a field member  50  having opposing first and second sides  53 ,  54  within the actuator housing  41 . The method also includes positioning a respective flexure bearing  60   a ,  60   b  to mount each of the first and second sides  53 ,  54  of the field member  50  to be reciprocally movable within the housing responsive to the at least one coil  44 ,  45 . Each flexure bearing  60   a ,  60   b  includes a first end member  61   a ,  61   b , a second end member  62   a ,  62   b  coupled to an adjacent side of the field member, a pair of parallel spaced apart flexible arms  63   a ,  63   b  coupled between the first and second end members, and an anchor member  64   a ,  64   b  coupled to the first end member and coupled to the actuator housing. 
     Referring now to  FIG. 7 , in another embodiment, the haptic actuator  40 ″″ may include a permanent magnet  47 ″″ carried by the housing  41 ″″, and the field member  50 ″″ may include one or more coils that cooperate with the permanent magnet. In other words, in contrast to the embodiment described above, the permanent magnet is stationary (i.e., carried by the actuator housing  41 ″″) and the coils  44 ″″,  45 ″″, as part of the field member  50 ″″, are moving (i.e., connected to the mass). Of course, there may be any number of coils and/or permanent magnets. 
     Referring now to  FIG. 8 , another embodiment of a haptic actuator  140  is illustrated. Similar to the haptic actuator  40  described above, the haptic actuator  140  includes an actuator housing  141  having a dimension in a length direction greater than a width direction and a coil  144  carried by the actuator housing. The coil  144  illustratively has a loop shape. A second coil, not shown, may be carried by the actuator housing  141  in spaced relation from the coil  144 . Of course, there may be any number of coils  144 , and the coil may have a different shape. 
     The haptic actuator  140  also includes a field member  150  having opposing first and second sides  153 ,  154 . The field member  150 , similarly to the actuator housing  141 , has a dimension in a length direction greater than a width direction. Thus, the field member  150  is reciprocally movable in the width direction (i.e., the y-direction). While the movement of the field member  150  is described as being moveable in one direction, i.e., a linear haptic actuator, it should be understood that in some embodiments, the field member may be movable in other directions, i.e., an angular haptic actuator, or may be a combination of both a linear and an angular haptic actuator. 
     The field member  150  includes permanent magnets  151 ,  152  under the coil  144 , or between the first and second coils. The permanent magnets  151 ,  152  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. 
     The permanent magnets  151 ,  152  also have a rectangular shape and are aligned along a length of the coil  144 . While a pair of rectangular shaped permanent magnets is illustrated, it will be appreciated that there may be any number of permanent magnets having any shape. 
     The field member  150  also includes masses  157  adjacent the permanent magnets  151 ,  152 . The masses  157  may be tungsten, for example. The masses  157  may be a different material and there may be more than one mass. 
     The haptic actuator  140  also includes a flexure bearing  160  mounting each of the first and second sides  153 ,  154  of the field member  150  to be reciprocally movable within the actuator housing  141  responsive to the coil  144 . The flexure bearing  160  includes first and second opposing end members  161   a ,  161   b , and two pairs of parallel spaced apart flexible arms  162   a - 162   b ,  163   a - 163   b  coupled between the first and second end members and spaced apart on opposing sides of the field member  150 . In other embodiments, there may be more than two pairs of parallel spaced apart flexible arms  162   a - 162   b ,  163   a - 163   b , or only one pair. 
     The haptic actuator  140  also includes first and second anchor members  164   a - 164   b ,  165   a - 165   b  each having a rectangular shape and respectively coupling one of each of the two pairs of parallel spaced apart flexible arms  162   a - 162   b ,  163   a - 163   b . The first anchor members  164   a ,  164   b  are illustratively coupled between inner ones of the two pairs of the parallel spaced apart flexible arms and the adjacent portions of the field member  150 . In particular, the first anchor members  164   a ,  164   b  are coupled to a medial portion of the field member  150  and a medial portion of the inner ones  162   b ,  163   b  of the pairs of parallel spaced apart flexible arms. In some embodiments, for example, where there is a single pair of parallel spaced apart flexible arms, there may be a single first anchor. In other embodiments, there may be more than two first anchors  164   a ,  164   b.    
     The second anchor members  165   a ,  165   b  respectively couple the outer ones  162   a - 162   b  of each pair of parallel spaced apart flexible arms to adjacent portions of the actuator housing  141 . In particular, the second anchor members  165   a ,  165   b  are coupled to a medial portion of the actuator housing  141  and a medial portion of the outer ones  163   a ,  162   a  of the pairs of the parallel spaced apart flexible arms respectively. In some embodiments, for example, where there is a single pair of parallel spaced apart flexible arms  162   a - 162   b ,  163   a - 163   b , there may be a single second anchor member. In other embodiments, there may be more than two second anchor members  165   a ,  165   b . Moreover, while the first and second anchor members  164   a - 164   b ,  165   a - 165   b  have been described as being rectangular, in some embodiments the first and second anchor members may be a different shape. 
     Each of the pairs of parallel spaced apart flexible arms  162   a - 162   b ,  163   a - 163   b  illustratively has a non-uniform height. Referring briefly to  FIG. 9 , in some embodiments, each of the pairs of parallel spaced apart flexible arms  163   a ′ may include one or more openings therein  169 ′. By having a non-uniform height or having an opening therethrough, stress areas, which may be referred to as “stress hot spots,” may be reduced by reducing the amount of material, thereby also increasing displacement. 
     A method aspect is directed to a method of making an actuator  140 . The method includes positioning at least one coil  144  to be carried by the actuator housing  141 . The method also includes positioning a field member  150  having opposing first and second sides  153 ,  154  within the housing and positioning the flexure bearing  160  to mount each of the first and second sides of the field member to be reciprocally movable within the housing responsive to the at least one coil  144 . 
     Referring now to  FIG. 10 , in another embodiment, the haptic actuator  140 ″ may include permanent magnets  151 ″,  152 ″ carried by the housing  141 ″, and the field member  150 ″ may include one or more coils  144 ″ that cooperate with the permanent magnets. In other words, in contrast to the embodiment described above, the permanent magnets  151 ″,  152 ″ are stationary (i.e., carried by the actuator housing  141 ″) and the coil  144 ″, as part of the field member  150 ″ is moving (i.e., connected to the masses  157 ″). Of course, there may be any number of coils and/or permanent magnets. For example, another set of permanent magnets may be carried on opposing sides of the coil  144 ″ than the first and second magnets  151 ″,  152 ″ 
     Referring now to  FIGS. 11 and 12 , another embodiment of a haptic actuator  240  is illustrated. The haptic actuator  240  includes an actuator housing  241  having a dimension in a length direction greater than a width direction and first and second sets of coils  244   a - 244   d ,  245   a - 245   d  are carried by the actuator housing  241  in spaced apart relation by the top and bottom of the actuator housing. The coils  244   a - 244   d ,  245   a - 245   d  each illustratively have a loop shape and each extends along a width of the actuator housing  241 . Each of the first set of coils  244   a - 244   d  is in side-by-side relation. Each of the second set of coils  245   a - 245   d , is also in side-by-side relation. While four first coils  244   a - 244   d  and four second coils  245   a - 245   d  are illustrated, it will be appreciated by those skilled in the art that there may be any number of coils  244   a - 244   d ,  245   a - 245   d , and the coils may have a different shape. 
     The haptic actuator  240  also includes a field member  250  having opposing first and second sides  253 ,  254 . The field member  250 , similarly to the actuator housing  241 , has a dimension in a length direction greater than a width direction. Thus, the field member  250  is reciprocally movable in the length direction (i.e., the x-direction). While the movement of the field member  250  is described as being moveable in one direction, i.e., a linear haptic actuator, it should be understood that in some embodiments, the field member may be movable in other directions, i.e., an angular haptic actuator, or may be a combination of both a linear and an angular haptic actuator. 
     The field member  250  includes permanent magnets  251   a - 251   e  between the first and second sets of coils  244   a - 244   d ,  245   a - 245   d . The permanent magnets  251   a - 251   e  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. 
     The permanent magnets  251   a - 251   e  also each have a rectangular shape and are spaced apart along a length of the actuator housing  241 . While rectangular shaped permanent magnets  251   a - 251   e  are illustrated, it will be appreciated that there may be any number of permanent magnets having any shape between the first and second coils  244   a - 244   d ,  245   a - 245   d.    
     The field member  250  also includes masses  257   a - 257   d  between the permanent magnets  251 ,  252 . The masses  257   a - 257   d  may be tungsten, for example. The masses  257   a - 257   d  may be a different material and there may be more or less than the three masses illustrated. The masses  257   a - 257   d  may be part of a body of the field member  250 , for example members extending across the actuator housing  241 . 
     The haptic actuator  240  also includes a respective flexure bearing  260  mounting each of the first and second sides  253 ,  254  of the field member  250  to be reciprocally movable within the actuator housing  241  responsive to the first and second sets of coils  244   a - 244   d ,  245   a - 245   d . Each flexure bearing  260  includes a first anchor member  261  coupled to an adjacent portion of the actuator housing  241 , more particularly, adjacent an end and a side (i.e., a corner) of the actuator housing. A second anchor member  262  is coupled to an adjacent side of the field member  250  and also adjacent the first side  247   a  of the actuator housing  241 . The first and second anchor members  261 ,  262  are illustratively spaced apart at an initial at-rest position. However, under compression, for example, the first and second anchor members  261 ,  262  may be in contact, as will be appreciated by those skilled in the art. 
     A first flexible arm  263  couples the first and second anchor members  261 ,  262  together. The first flexible arm  263  has a bend therein to define a V-shape, for example. The first flexible arm  263  may have more than one bend therein. 
     Each flexure bearing  260  also includes a third anchor member  264  coupled to an adjacent portion of the actuator housing  241 , illustratively in a corner opposite the first anchor member  261 . A fourth anchor member  265  is coupled to an adjacent side of the field member  250  opposite the second anchor member  262  and also adjacent the second side of the actuator housing  241 . A second flexible arm  266  couples the third and fourth anchor members  264 ,  265  together and has a bend therein, for example, to also define a V-shape. The second flexible arm  266  may have more than one bend therein. 
     A method aspect is directed to a method of making a haptic actuator  240 . The method includes positioning at least one coil  244   a - 244   d  to be carried by an actuator housing  241  and positioning a field member  250  having opposing first and second sides  253 ,  254  within the actuator housing. The method also includes positioning respective flexure bearings  260  to mount each of the first and second sides  253 ,  254  of the field member  250  to be reciprocally movable within the actuator housing responsive to the at least one coil. 
     Referring now to  FIG. 13 , in another embodiment, the haptic actuator  240 ′ may include permanent magnets  251   a ′- 251   d ′ carried by the housing  241 ′, and the field member  250 ′ may include coils  244   a ′- 244   d ′ that cooperate with the permanent magnets. In other words, in contrast to the embodiment described above, the permanent magnets are stationary (i.e., carried by the actuator housing  241 ′) and the coils  244   a ′- 244   d ′ as part of the field member  250 ′ are moving (i.e., connected to the masses  257   a ′- 257   d ′). Of course, there may be any number of coils and/or permanent magnets. For example, there may be a second set of permanent magnets carried on an opposing side of the coils  244   a ′- 244   d′.    
     Referring now to  FIGS. 14 and 15 , another embodiment of a haptic actuator  340  is illustrated. The haptic actuator  340  includes an actuator housing  341  having a dimension in a length direction greater than a width direction and first and second sets of coils  344   a - 344   d ,  345   a - 345   d  are carried by the actuator housing in spaced apart relation by the top and bottom of the actuator housing. The coils  344   a - 344   d ,  345   a - 345   d  each illustratively has a loop shape and each extends along a width of the actuator housing  341 . Each of the first set of coils  344   a - 344   d  is in side-by-side relation. Each of the second set of coils  345   a - 345   d , is also in side-by-side relation. While four first coils  344   a - 344   d  and four second coils  345   a - 345   d  are illustrated, it will be appreciated by those skilled in the art that there may be any number of coils, and the coils may have a different shape. 
     The haptic actuator  340  also includes a field member  350  having opposing first and second sides  353 ,  354 . The field member  350 , similarly to the actuator housing  341 , has a dimension in a length direction greater than a width direction. Thus, the field member  350  is reciprocally movable in the length direction (i.e., the x-direction). While the movement of the field member  350  is described as being moveable in one direction, i.e., a linear haptic actuator, it should be understood that in some embodiments, the field member may be movable in other directions, i.e., an angular haptic actuator, or may be a combination of both a linear and an angular haptic actuator. 
     The field member  350  includes permanent magnets  351   a - 351   e  between the first and second sets of coils  344   a - 344   d ,  345   a - 345   d . The permanent magnets  351   a - 351   e  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. 
     The permanent magnets  351   a - 351   e  also each have a rectangular shape and are spaced apart along a length of the actuator housing  341 . While rectangular shaped permanent magnets  351   a - 351   e  are illustrated, it will be appreciated that there may be any number of permanent magnets having any shape. 
     The field member  350  also includes a body  356  that includes masses  357   a - 357   d  between the permanent magnets  351   a - 351   e . The masses  357   a - 357   d  may be tungsten, for example. The masses  357   a - 357   d  may be a different material and there may be any number of masses. The field member  350  also includes shafts  358   a ,  358   b  extending outwardly from the body  357  adjacent the first and second ends  353 ,  354 . 
     The haptic actuator  340  also illustratively includes a frame member  370  extending along a first side of the actuator housing  341 . A respective flexure bearing  360  is carried by the frame member  370  and mounts each of the first and second ends  353 ,  354  of the field member  350  to be reciprocally movable within the actuator housing  341  responsive to the first and second coils  344   a - 344   d ,  345   a - 345   d.    
     Each flexure bearing  360  includes a base member  361  coupled to an end of the frame member  370 , and spaced apart flexible arms  362   a ,  362   b  extending outwardly from the base member to a second side of the actuator housing  341 . The spaced apart flexible arms  362   a ,  362   b  are spaced apart at distal ends thereof at an initial at-rest position, and may be parallel at the initial at-rest position. When the flexure bearing  360  is under compression, the spaced apart flexible arms  362   a ,  362   b  may contact one another at the distal ends thereof. The spaced apart flexible arms  362   a ,  362   b  also illustratively include an opening  364   a ,  364   b  therein for receiving respective ones of the shafts  358   a ,  358   b  therein. 
     The haptic actuator  340  also includes a respective guide member  371   a ,  371   b  coupled between a respective end of the actuator housing  341  and a respective flexure bearing  360 . Each guide member  371   a ,  371   b  has an opening  372   a ,  372   b  therein for receiving a respective one of the shafts  358   a ,  358   b . Each guide member  371   a ,  371   b  also has a tapered shape, and more particularly, a width that is decreasing along the width thereof. A thinner or smaller end of each guide member is adjacent the base member of each flexure bearing  360 , for example, to permit the field member  350  to have a larger displacement along the movement or travel path (i.e., the x-axis). As will be appreciated by those skilled in the art, the distal ends of the spaced apart flexible arms slide on the shafts  358   a ,  358   b . In some embodiments, there may be no shafts and openings. 
     A method aspect is directed to a method of making a haptic actuator  340 . The method includes positioning at least one coil  344   a - 344   d ,  345   a - 345   d  to be carried by an actuator housing  341  and positioning a field member  350  having opposing first and second sides  353 ,  354  within the actuator housing. The method also includes positioning the respective flexure bearing  360  to mount each of the first and second sides  353 ,  354  of the field member  350  to be reciprocally movable within the housing responsive to the at least one coil  344   a - 344   d ,  345   a - 345   d.    
     Referring to  FIG. 16 , in another embodiment, the haptic actuator  340 ′ may include first and second sets of permanent magnets  351   a ′- 351   e ′,  352   a ′- 352   e ′ carried by the housing, and the field member  350 ′ may include coils  344   a ′- 344   d ′ that cooperate with the permanent magnets, and more particularly, that are between the first and second sets of permanent magnets. In other words, in contrast to the embodiment described above, the permanent magnets  351   a ′- 351   e ′,  352   a ′- 352   e ′ are stationary (i.e., carried by the actuator housing  341 ′) and the coils  344   a ′- 344   d ′ as part of the field member  350 ′ are moving (i.e., connected to the masses). Of course, there may be any number of coils and/or permanent magnets. 
     Referring now to  FIGS. 17 and 18 , another embodiment of a haptic actuator  440  is illustrated. The haptic actuator  440  may include an actuator housing having a dimension in a length direction greater than a width direction and first and second sets of coils carried by the actuator housing in spaced apart relation, for example, as described above. 
     The haptic actuator  440  also includes a field member  450  having opposing first and second sides  453 ,  454 . The field member  450 , similarly to the actuator housing, has a dimension in a length direction greater than a width direction. Thus, the field member  450  is reciprocally movable in the length direction (i.e., the x-direction). While the movement of the field member  450  is described as being moveable in one direction, i.e., a linear haptic actuator, it should be understood that in some embodiments, the field member may be movable in other directions, i.e., an angular haptic actuator, or may be a combination of both a linear and an angular haptic actuator. 
     The field member  450  includes permanent magnets  451   a - 451   f  that are positioned between the first and second sets of coils. The permanent magnets  451   a - 451   f  may be neodymium, for example, and may be positioned in opposing directions with respect to their respective poles. 
     The permanent magnets  451   a - 451   f  also each have a rectangular shape and are spaced apart along a length of the field member  450 , and more particularly, spaced within openings  455   a - 455   f  in the field member  450 . While rectangular shaped permanent magnets  451   a - 451   f  are illustrated, it will be appreciated that there may be any number of permanent magnets having any shape between and the openings  455   a - 455   f  may also have any shape. 
     The field member  450  also includes masses  457   a - 457   e  between the permanent magnets  451   a - 451   f . The masses  457   a - 457   e  are illustratively part of the body of the field member  450 , for example, members extending across the field member and defining the openings  455   a - 455   f . Of course, the masses  457   a - 457   e  can be arranged as described above with respect to the other embodiments. 
     The haptic actuator  440  also includes a respective flexure bearing  460  mounting each of the first and second sides  453 ,  454  of the field member  450  to be reciprocally movable within the actuator housing responsive to the first and second sets of coils. Each flexure bearing  460  includes a flexible member  463  having a wishbone or Y-shape, with two diverging arms  462   a ,  462   b  joined together at proximal ends  475   a ,  475   b . The two diverging arms  462   a ,  462   b  have spaced distal ends  476   a ,  476   b  operatively coupled between adjacent portions of the field member  450  and the housing. 
     The flexible member  463  has a bend  478  therein joining together the two diverging arms  462   a ,  462   b  at the proximal ends  475   a ,  475   b . The bend  478  causes the two diverging arms  462   a ,  462   b  to be spaced apart at the distal ends  476   a ,  476   b . Illustratively, the two diverging arms  462   a ,  462   b  include a parallel portion  477   a ,  477   b  at the distal ends  476   a ,  476   b . In some embodiments, the distal ends  476   a ,  476   b  of the two diverging arms  462   a ,  462   b  may continue to diverge instead of turning or becoming parallel. 
     Referring briefly to  FIG. 19  in another embodiment, the two diverging arms  462   a ′,  462   b ′ are parallel at the proximal ends  475   a ′,  475   b ′ and are coupled together, for example, via a weld joint  479 ′. 
     Referring now to  FIG. 20 , in another embodiment, each flexure bearing  460 ″ may include first and second flexible members  463   a ″,  463   b ″. A respective anchor member  461 ″ is coupled to an adjacent portion of the housing and spaced from an adjacent portion of the field member  450 ″. The anchor member  461 ″ is illustratively L-shaped, having a length aligned along the adjacent portion of the housing. The first and second flexible members  463   a ″,  463   b ″ are coupled between the respective anchor member  461 ″ and the adjacent portions of the field member  450 ″. The first and second flexible members  463   a ″,  463   b ″ are arranged so that the proximal end of the first flexible member  463   a ″ is adjacent the distal end of the second flexible member  463   b″.    
     The table below illustrates exemplary mode shapes and frequencies versus design. Indeed, as will be appreciated by those skilled in the art, the wishbone or Y-shaped design of the flexible member  463  may provide increased stability versus a U or V-shaped flexible member, for example. 
     
       
         
           
               
               
               
            
               
                   
                   
               
               
                   
                 Mode 
                   
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                 Rocking Z 
                   
                   
               
               
                   
                 X Mode 
                 Mode 
                 Z Mode 
                 Y Mode 
               
               
                   
                   
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 U/V Shaped 
                 100 Hz 
                 285 Hz 
                 316 Hz 
                 329 Hz 
               
               
                   
                 w/o 
               
               
                   
                 magnetic 
               
               
                   
                 anti-spring 
               
               
                   
                 Wishbone 
                 100 Hz 
                 381 Hz 
                 382 Hz 
                 405 Hz 
               
               
                   
                 Shaped w/o 
               
               
                   
                 magnetic 
               
               
                   
                 anti-spring 
               
               
                   
                 U/V Shaped 
                 100 Hz 
                 Unstable 
                 128 Hz 
                 329 Hz 
               
               
                   
                 w/ magnetic 
               
               
                   
                 anti-spring 
               
               
                   
                 Wishbone 
                 100 Hz 
                 250 Hz 
                 251 Hz 
                 405 Hz 
               
               
                   
                 Shaped w/ 
               
               
                   
                 magnetic 
               
               
                   
                 anti-spring 
               
               
                   
                   
               
            
           
         
       
     
     A method aspect is directed to a method of making a haptic actuator  440 . The method includes positioning at least one coil to be carried by an actuator housing and positioning a field member  450  having opposing first and second sides  453 ,  454  within the actuator housing. The method also includes positioning respective flexure bearings  460  to mount each of the first and second sides  453 ,  454  of the field member  450  to be reciprocally movable within the actuator housing responsive to the at least one coil. 
     Referring now to  FIG. 21 , another embodiment of a flexure bearing  560  is illustrated for use with a field member in a haptic actuator as described above. As will be appreciated by those skilled in the art and along the lines as described above, two flexure bearings  560  are typically used in the haptic actuator. 
     Each flexure bearing  560  includes a first anchor member  561  coupled to an adjacent portion of the actuator housing, and more particularly, adjacent an end and a side (i.e., a corner) of the actuator housing. A second anchor member  562  is coupled to an adjacent side of the field member and also adjacent the first side of the actuator housing. The first and second anchor members  561 ,  562  are illustratively spaced apart at an initial at-rest position. However, under compression, for example, the first and second anchor members  561 ,  562  may be in contact, as will be appreciated by those skilled in the art. 
     First and second parallel, spaced apart flexible arms  563   a ,  563   b  each couple the first and second anchor members  561 ,  562  together. The first and second flexible arms  563   a ,  563   b  each has a bend  578   a ,  578   b  therein to define a V-shape, for example. The first and second parallel and spaced apart flexible arms  563   a ,  563   b  may each have more than one bend therein. The first and second parallel, spaced apart flexible arms  563   a ,  563   b  may each have a varying thickness along a length thereof (e.g., from the first anchor member  561  through the bend  578   a ,  578   b  to the second anchor member  562 ). While two parallel, spaced apart flexible arms are illustrated, it will be appreciated that any number of parallel, spaced apart flexible arms  563   a ,  563   b  may couple the first and second anchor members  561 ,  562 . 
     A method aspect is directed to a method of making a haptic actuator. The method includes positioning at least one coil to be carried by an actuator housing and positioning a field member having opposing first and second sides within the actuator housing. The method also includes positioning respective flexure bearings  560  to mount each of the first and second sides of the field member to be reciprocally movable within the actuator housing responsive to the at least one coil. 
     Indeed, while various embodiments have been described with respect to various flexure bearing configurations and coil and permanent magnet configurations, it should be understood that elements from any of the embodiments may be used with any of the other embodiments. For example, a given haptic actuator may include more than one type of flexure bearing as described herein, for example, to not only allow movement of the field member, but return it to an equilibrium position. 
     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: 20160728
Publication Date: 20180731
Grant Date: 20180731
Priority Date: 20150918
Inventors: HAJATI, ARMAN
HOTELLING, STEVEN P.
PRAGADA, ANURANJINI
Assignee: APPLE INC
CPC Classifications: [{"code": "G06F1/163", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2215/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02K33/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02K33/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F3/016", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F3/016", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/163", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2231/028", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2215/00", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02K33/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "G06F3/016", "inventive": true, "first": false, "tree": "[]"}, {"code": "H02K33/16", "inventive": false, "first": false, "tree": "[]"}, {"code": "H02K33/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2231/028", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 58283240