PATENT DOCUMENT

Publication Number: US-9058941-B2
Application Number: US-201213589236-A
Country: US
Kind Code: B2

Title: Floating switch assemblies and methods for making the same

Abstract:
Switch assemblies that mitigate stack up variations and methods of making the same are provided. The stack up variations are mitigated by embodiments that use a floating switch design. The floating switch design may eliminate height variations in the stack up by directly mounting an activation assembly to a support bracket. This ensures that the stack up height of the activation assembly and support bracket remain fixed, independent of a flexible printed circuit board (PCB) that may also be secured to the activation assembly. This way, regardless of the thickness of the flexible PCB and any height variations in solder used to secure the flexible PCB to the activation assembly, the stack up height of the activation assembly and support bracket remains fixed.

Claims:
What is claimed is: 
     
       1. An electronic device, comprising:
 a bracket; 
 an activation assembly comprising:
 a structural member fixed to the bracket; 
 a dome switch disposed on the structural member; 
 at least one terminal that extends away from an outer surface of the structural member; and 
 
 a flexible printed circuit board that relays an electrical signal received from the at least one terminal when a switch event occurs, the flexible printed circuit board having a first side coupled to the bracket and to the at least one terminal. 
 
     
     
       2. The electronic device of  claim 1 , wherein the circuit board comprises a cutout to accommodate the structural member, such that the circuit board surrounds at least a portion of the structural member. 
     
     
       3. The electronic device of  claim 1 , wherein a first of the at least one terminal is electrically coupled to the dome switch. 
     
     
       4. The electronic device of  claim 1 , wherein the structural member further comprises at least one alignment post that engages the bracket. 
     
     
       5. The electronic device of  claim 4 , wherein a vent hole exists in one of the at least one alignment post. 
     
     
       6. The electronic device of  claim 5 , further comprising a sealing member disposed over the activation assembly and the flexible printed circuit board. 
     
     
       7. The electronic device of  claim 1 , further comprising a support member that couples the first side of the circuit board to the bracket. 
     
     
       8. The electronic device of  claim 7 , wherein the support member comprises a compliant material and adhesive. 
     
     
       9. The electronic device of  claim 1 , wherein a vent hole exists in the structural member. 
     
     
       10. An electronic device, comprising:
 a housing forming an exterior surface of the electronic device, the housing comprising an aperture; 
 an actuator that protrudes through the aperture and extends beyond the exterior surface; 
 a bracket secured to an interior surface of the housing; 
 an activation assembly fixed to the bracket and the actuator, the activation assembly comprising a dome switch and at least two terminals; and 
 a flexible printed circuit board that relays an electrical signal received from one of the at least two terminals when a dome switch event occurs, the flexible printed circuit board having a first side coupled to the bracket and the at least two terminals. 
 
     
     
       11. The electronic device of  claim 10 , further comprising a shim between the actuator and the activation assembly. 
     
     
       12. The electronic device of  claim 10 , further comprising a support member that couples the first side of the circuit board to the bracket. 
     
     
       13. The electronic device of  claim 12 , wherein the support member comprises a compliant material and adhesive. 
     
     
       14. The electronic device of  claim 10 , wherein the activation assembly further comprises at least one alignment post that engages the bracket. 
     
     
       15. A floating switch assembly, comprising:
 a bracket; an activation assembly mounted directly on the bracket, the activation assembly comprising at least two terminals; and 
 a flexible printed circuit board that relays an electrical signal received from one of the at least two terminals when an activation assembly event occurs, the flexible printed circuit board being coupled to the at least two terminals, wherein the flexible printed circuit board is operative to float relative to the activation assembly. 
 
     
     
       16. The floating switch assembly of  claim 15 , further comprising a support member fixed to the bracket and operative to support the flexible printed circuit board. 
     
     
       17. The floating switch assembly of  claim 16 , wherein the support member comprises a compliant material and adhesive. 
     
     
       18. The floating switch assembly of  claim 15 , wherein the activation assembly further comprises at least one alignment post that extends into the bracket. 
     
     
       19. The floating switch assembly of  claim 15 , further comprising a sealing member disposed over the activation assembly and the flexible printed circuit board. 
     
     
       20. The floating switch assembly of  claim 15 , wherein the flexible printed circuit board comprises a cutout to accommodate the switch assembly, such that the circuit board surrounds at least a portion of the activation assembly. 
     
     
       21. A method for creating a floating switch assembly, the method comprising:
 mounting an activation assembly to a bracket; 
 coupling a flexible printed circuit board that relays an electrical signal received from the activation assembly when an activation assembly event occurs to the activation assembly by positioning a cutout of the flexible printed circuit board around at least a portion of the activation assembly; 
 coupling a support member to the flexible printed circuit board; and 
 coupling the support member to the support bracket. 
 
     
     
       22. The method of  claim 21 , wherein mounting the activation assembly to the bracket comprises aligning an alignment post of the activation assembly with a corresponding feature of the bracket. 
     
     
       23. The method of  claim 21 , wherein the support member comprises a compliant material and adhesive.

Description:
BACKGROUND 
     This disclosure is directed to switch assemblies, and more particularly is directed to floating switch assemblies and methods for making the same. 
     Users can provide inputs to electronic devices (e.g., portable media players and cellular telephones) using many different approaches. Some known input components are conventional switch assemblies, which may include a stack up having a switch (e.g., a dome switch). As used herein, the term “stack up” is intended to refer to the layered components that form a switch assembly. Depending on design, a switch assembly stack up may contain several components. A conventional stack up of a switch assembly includes a dome switch having two leads that are soldered to a circuit board, and the circuit board is attached to a bracket. When the switch is pressed, an inner conductive surface of the switch contacts a contact pad on the circuit board to complete a circuit. The pressing of the switch can provide a tactile ‘click’ that enhances the user&#39;s interaction with the switch. In some cases, a cosmetic piece may be placed over the switch to form a button. In response to the user pressing the cosmetic piece, the switch is in turn depressed and contacts the contact pad thereby generating an input. 
     Conventional switch assemblies can suffer from a number of drawbacks that affect performance, assembly, and incorporation into an electronic device. These drawbacks can stem from variations in the stack up of the switch assembly. In particular, the stack up is susceptible to solder height variance, which can result in various height differences between the dome and the circuit board. In addition, height differences can also be realized in the circuit board/bracket interface (e.g., the thickness of the circuit board may vary). If the stack up height exceeds predetermined tolerances, then the switch assembly may not be able to fit within an electronic device it is designed to be used with, or the switch assembly may not function in its intended manner if it does not fit properly. 
     Accordingly, there is a need for improved switch assemblies that mitigate stack up variations. 
     SUMMARY 
     Switch assemblies that mitigate stack up variations and methods of making the same are provided. The stack up variations are mitigated by embodiments that use a floating switch design. The floating switch design may eliminate height variations in the stack up by directly mounting an activation assembly to a support bracket. This ensures that the stack up height of the activation assembly and support bracket remain fixed, independent of a flexible printed circuit board (PCB) that may also be secured to the activation assembly. This way, regardless of the thickness of the flexible PCB and any height variations in solder used to secure the flexible PCB to the activation assembly, the stack up height of the activation assembly and support bracket remains fixed. Thus, the flexible PCB floats relative to the activation assembly, and any variations in solder height will vary the height of the flexible PCB relative to the activation assembly, but have no effect on the overall height of the switch stack up. 
     According to a particular embodiment, a floating switch assembly includes a bracket, an activation assembly, and a flexible printed circuit board. The activation assembly is mounted on the bracket. The flexible printed circuit board is coupled to the activation assembly, and is operative to move, or float, relative to the activation assembly. 
     According to another particular embodiment a floating switch assembly includes a bracket, an activation assembly, a flexible printed circuit board, and a support member. The activation is fixed to the bracket. The flexible printed circuit board is coupled to the activation assembly, and is operative to float relative to the activation assembly. The support member is operative to support the flexible printed circuit board without interfering with the flotation of the flexible printed circuit board. 
     According to yet another embodiment, a method of forming a floating switch assembly having a bracket, an activation assembly, and a flexible printed circuit board is disclosed. The method includes placing the activation assembly on a surface of the bracket and coupling the flexible printed circuit board to the activation assembly such that the flexible printed circuit board is operative to float relative to the activation assembly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will be more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings in which: 
         FIG. 1A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 1B  shows a top view of the illustrative floating switch assembly of  FIG. 1A  in accordance with an embodiment of the invention; 
         FIG. 2A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 2B  shows a cross-sectional view of another illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 3A  shows a partial outside perspective view of an exemplary electronic device including an illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 3B  shows a cross-sectional view of the electronic device of  FIG. 3A , taken from line B-B of  FIG. 3A , showing the floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 4A  shows an exploded view of the electronic device of  FIG. 3A  in accordance with an embodiment of the invention; 
         FIG. 4B  shows a partial inside perspective view of the electronic device of  FIG. 3A  in accordance with an embodiment of the invention; 
         FIG. 5  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 6  shows a cross-sectional view of another illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 7A  shows a cross-sectional view of yet another illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 7B  shows a partial top cross-sectional view of the floating switch assembly of  FIG. 7A  in accordance with an embodiment of the invention; 
         FIG. 8A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention; 
         FIG. 8B  shows a partial cross-sectional view of the floating switch assembly of  FIG. 8A , showing a magnified view of section B from  FIG. 8A  in accordance with an embodiment of the invention; and 
         FIG. 9  shows an illustrative method for constructing a floating switch assembly in accordance with some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     Floating switch assemblies and methods for making the same are described below with reference to  FIGS. 1-9 . 
       FIGS. 1A and 1B  show a cross-sectional and a top view, respectively, of floating switch assembly  100  in accordance with an embodiment of the invention. Floating switch assembly  100  may be included in an electronic device for providing user input to the electronic device. A user (not shown) can activate floating switch assembly  100  by exerting an activation force on activation assembly  110  in the direction of arrow A. This user activation force can depress or deform activation assembly  110  from an original position to an actuated position to change a functional state of the electronic device (e.g., whether the device should power up or turn off). 
     Floating switch assembly  100  may include activation assembly  110 , bracket  120 , flexible printed circuit board (PCB)  130 , and support members  140 . Activation assembly  110  may further include terminals  111  and actuator  112 . Flexible PCB  130  may also include cutout  131 . Activation assembly  110  is mounted directly to bracket  120  using any suitable approach (e.g., using an adhesive). Flexible PCB  130  is mounted directly to activation assembly  110  via terminals  111  and may be mounted to bracket  120  via support members  140 . 
     Activation assembly  110  may be designed to house a suitable switch (e.g., actuator  112 ), and may be constructed from any suitable material (e.g., plastic). Terminals  111  may be integrated into activation assembly  110  and may protrude from the box-like region of activation assembly  110 . Terminals  111  may be made from any suitable conductive material such as, for example, metal. Although activation assembly  110  is depicted as box shaped, it is understood that activation assembly  110  may have any suitable shape. Activation assembly  110  is operative to register switch events when a user presses down on actuator  112  in the direction of arrow A. Activation assembly  110  can convey information through terminals  111  via an electrical signal when a switch event occurs. 
     Bracket  120  serves as an anchor for activation assembly  110 . For example, bracket  120  can support activation assembly  110  when the user presses on actuator  112 . In this manner, bracket  120  may ensure that activation assembly  110  does not move or recede when force is applied to it. Bracket  120  may also provide support for other portions of floating switch assembly  100  (e.g., support members  140 ). 
     Flexible PCB  130  may include traces for relaying switch events to another component of an electronic device. For example, when switch events occur within activation assembly  110 , flexible PCB  130  may relay the switch events to a processing unit (not shown) of the electronic device. Flexible PCB  130  may also include other components (not shown) of the electronic device. Flexible PCB  130  may fit around some or all of activation assembly  110 . In order to properly fit around activation assembly  110 , flexible PCB  130  may include cutout  131 . Although cutout  131  is shown as a rectangular cutout, cutout  131  can be any shape needed to accommodate activation assembly  110 . For example, cutout  131  may have a shape similar to activation assembly  110 . More generally, one skilled in the art will appreciate that cutout  131  may have any suitable shape and dimensions to accommodate a floating switch design. Because flexible PCB  130  fits around activation assembly  110 , it does not contribute to the overall stack up height of floating switch assembly  100 . 
     Support members  140  may be positioned adjacent to activation assembly  110  and can couple flexible PCB  130  to bracket  120 . Support members  140  may be constructed from a compliant material (e.g., foam, rubber, and/or plastic) that is operative to support flexible PCB  130  without hindering movement of flexible PCB  130 . 
     The coupling interaction of activation assembly  110 , bracket  120 , and flexible PCB  130  enables PCB  130  to move, or float, relative to activation assembly  110 . As used herein, the term “float” is intended to mean that an object is able to undergo fluid movement relative to another object. The fluid movement may include translational movement, rotational movement, or a combination thereof. 
     The floating aspect of switch assembly  100  is achieved, in part, based on the design of flexible PCB  130  and how it is coupled to bracket  120  and terminals  111 . As shown in  FIG. 1B , flexible PCB  130  may include cutout  131  dimensioned to fit around activation assembly  110 , but is still able to be coupled to terminals  111 . In other words, cutout  131  may provide enough clearance between activation assembly  110  and flexible PCB  130  so that flexible PCB  130  is operative to float relative to activation assembly  110  without being obstructed. In some embodiments, as shown in  FIG. 1B , flexible PCB  130  may need to be connected as one singular element. In these embodiments, flexible PCB  130  may include bridge portion  132  to allow flexible PCB  130  to fit around activation assembly  110  as a single element. In other embodiments, two separate PCBs may be used in place of flexible PCB  130 . 
     Terminals  111  may be coupled to flexible PCB  130  using any suitable approach, for example, via solder. Flexible PCB  130  may be coupled to terminals  111  such that the ability of flexible PCB  130  to float relative to activation assembly  110  is not hindered. In some embodiments, terminals  111  may be operative to flex or rotate in order to allow for increased movement of flexible PCB  130  relative to activation assembly  110 . Flexing of terminals  111  may be about one axis of switch assembly  111  (e.g., about an axis out of the page of  FIG. 1 ) while rotation of terminals  111  may be about another axis of activation assembly  110  (e.g., about the +X axis in  FIG. 1 ). Support members  140  may be coupled to flexible PCB  130  and can support flexible PCB  130  without inhibiting its ability to float. Support members  140  can support flexible PCB  130  to prevent unnecessary stress on flexible PCB  130 , terminals  111 , and/or the coupling between them. Support members  140  are operative to support flexible PCB  130  without compromising its ability to move relative to activation assembly  110 . 
     By incorporating a floating switch design, floating switch assembly  100  can mitigate stack up variations. Floating switch assembly  100  may eliminate height variations in its stack up because the stack up height of activation assembly  110  and bracket  120  remain fixed, independent of flexible PCB  130 . This way, regardless of the thickness of flexible PCB  130  and any height variations in the coupling between flexible PCB  130  and terminals  111 , the stack up height of activation assembly  110  and bracket  120  remains fixed. Thus, flexible PCB  130  floats relative to activation assembly  110 , and any variations (e.g., in solder height) will vary the height of flexible PCB  130  relative to activation assembly  110 , but have no effect on the overall height of floating switch assembly  100 . As shown in  FIG. 1 , the stack up along the +Y axis for floating switch assembly  100  includes only activation assembly  110  and bracket  120 . Flexible PCB  130  and terminals  111  do not contribute to the height of the stack up. Therefore, variations in flexible PCB  130  (e.g., the thickness and/or uniformity of flexible PCB  130 ) and the coupling between flexible PCB  130  and terminals  111  (e.g., the amount of solder between them) are not incorporated in the stack up. Reducing the variability of floating switch assembly  100  may result in better, more consistent button feel and improved assembly control of floating switch assembly  100 . Additionally, removing flexible PCB  130  and terminals  111  from the stack up may allow for a reduced height (e.g., in +Y as shown in  FIG. 1 ) of floating switch assembly  100  as compared to conventional switch assemblies. 
     In contrast, conventional switch assemblies are formed by soldering an activation assembly on top of a circuit board. The circuit board is then fixed to a bracket. In this manner, conventional switch assemblies include a circuit board in their stack up and add height to their stack up as a result. Additionally, any variations in the uniformity of the circuit board or in the coupling of the activation assembly and the circuit board affect the orientation of the activation assembly. As a result, undesirable variations may cause conventional switch assemblies to function improperly. 
       FIG. 2A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention. Floating switch assembly  200  may be similar to floating switch assembly  100 , and elements of  FIG. 2A  may have some or all features as similarly-numbered elements of  FIG. 1 . Floating switch assembly  200  may include activation assembly  210 , bracket  220 , flexible printed circuit board  230 , and support members  240 . Activation assembly  210  may further include terminals  211 , switch  212 , structural member  213 , adhesive  214 , contact pad  215 , coupling joint  216 , and insulating member  219 . 
     Structural member  213  may be fixed to bracket  220  using adhesive  214 . Structural element  213  may be constructed from a rigid material and can provide structural support to other elements of activation assembly  210 . For example, structural element  213  may provide structural support to switch  212 , terminals  211 , or any other portion of activation assembly  210 . 
     Terminals  211  may be coupled to flexible PCB  230  using coupling joint  216 . Coupling joint  216  may electrically couple terminals  211  to flexible printed circuit board  230  using any suitable conductive material (e.g., solder). Coupling joint  216  may be constructed such that flexible printed circuit board  230  is operative to float relative to activation assembly  210 . 
     Switch  212 , depicted as a dome-shaped switch in  FIG. 2A , may be electrically connected to each of terminals  211 . Switch  212  may be operative to deform when actuated such that when the inner surface of switch  212  contacts pad  215 , an electrical circuit connection is made between terminals  211 . Although depicted as a dome-shaped switch in  FIG. 2 , in some embodiments, switch  212  may be a snap-acting pressure disc, a snap-acting force disc, a low profile tactile switch, or any other suitable type of switch. Switch  212  may be an elastically deformable switch. Switch  212  may be made of any suitable material, including, but not limited to, metal (e.g., stainless steel), plastic, or combinations thereof. 
     As shown in  FIG. 2A , floating switch assembly  200  may include a single-component switch. For example, switch  212  includes a single dome. In other embodiments, a floating switch assembly may include a multi-component switch (e.g., two or more switches coupled to one another or two or more switches placed on top of one another in a stack). For example, referring briefly to  FIG. 2B , stacked switch  212 ′ may include two domes  212 A and  212 B in a stack. In some embodiments, dome  212 A may be coupled to dome  212 B using any suitable adhesive or glue therebetween. 
     Returning to  FIG. 2A , insulating member  219  may be included in order to prevent terminals  211  from electrically shorting with another portion of floating switch assembly  200  (e.g., bracket  220 ). In addition, insulating member  219  may provide additional support to coupling joint  216 . Insulating member  219  may be constructed from any suitable insulating material, including for example, an acrylic, an epoxy, a polyurethane, a silicone, Parylene, an amorphous fluoropolymer, or any other suitable material. Although shown as a separate component in  FIG. 2A , in some embodiments, insulating member  219  may be integrated with activation assembly  210  (e.g., molded as part of structural member  213 ). 
     Support members  240  may be positioned adjacent to coupling joint  216  and can support flexible PCB  230  to prevent unnecessary strain on flexible printed circuit board  230 , terminals  211 , and/or coupling joint  216 . Support members  240  may further include compliant members  241  and support member adhesives  242 . Compliant members  241  may be fixed to bracket  220  using support member adhesives  242 . Compliant members  241  may be constructed from a compliant material (e.g., foam, rubber, or plastic) that is operative to support flexible printed circuit board  230  without compromising its ability to move relative to activation assembly  210 . 
       FIG. 3A  shows a partial perspective view of electronic device  300  having a floating switch assembly in accordance with one embodiment of the invention. From the exterior, housing  360  and actuator  350  are visible to a user.  FIG. 3B  shows a cross-sectional view of the electronic device of  FIG. 3A , taken from line B-B of  FIG. 3A .  FIG. 4A  shows an exploded view of the electronic device of  FIG. 3A  and  FIG. 4B  shows a partial perspective view from inside the electronic device of  FIG. 3A . The floating switch depicted as part of electronic device  300  may be similar to the floating switch assemblies shown in  FIGS. 1 and 2 , and as a result may share some or all features as similarly-numbered elements of  FIGS. 1 and 2 . 
     Referring to  FIGS. 3A-3B  and  4 A- 4 B collectively, electronic device  300  may include switch assembly  310 , bracket  320 , flexible printed circuit board  330 , and support member  340 . Activation assembly  310  may further include terminals  311 , switch assembly adhesive  314 , coupling joint  316 , alignment posts  317 , and insulating member  319 . A floating assembly may allow alignment pins or posts to be integrated into the switch body directly. For example,  FIG. 3B  shows floating switch assembly  300  with alignment posts  317  integrated into activation assembly  310  in accordance with one embodiment of the invention. 
     Activation assembly  310  may be fixed to bracket  320  using any suitable approach (e.g., using adhesive  314 ). In some embodiments, activation assembly  310  may include alignment posts  317  to engage bracket  320 . Alignment posts  317  may secure activation assembly  310  to bracket  320  and may prevent activation assembly  310  from moving relative to bracket  320 . Alignment posts  317  may be any suitable shape, including, but not limited to, cylindrical, spherical, ellipsoidal, hexahedral, tetrahedral, or combinations thereof. Bracket  320  may include a corresponding feature configured to receive alignment posts  317 . In some embodiments, alignment posts  317  may include at least one feature (not shown) that secures structural member  313  to bracket  320  (e.g., a snap or a hook). 
     Electronic device  300  may also include a cosmetic actuator (e.g., actuator  350 ) positioned over activation assembly  310 . Actuator  350  is secured within housing  360  and forms an outer surface of electronic device  300 . Actuator  350  may be made from any suitable material, including, but not limited to metal, rubber, plastic, or combinations thereof. Actuator  350  may provide an aesthetically pleasing outer surface of electronic device  300 , and may also protect inner components of electronic device  300  from shock or other physical damage. 
     Shim  370  may be included between actuator  350  and activation assembly  310  to support actuator  350 , adjust for a better fit between actuator  350  and activation assembly  310 , and/or provide a level surface which actuator  350  may be seated on. Shim  370  may be constructed from any suitable material. For example, shim  370  may be constructed from metal, plastic, or any other suitable material. 
     Electronic device  300  may include bracket pin  380  and bracket screw  390  which secure bracket  320  to housing  360 . Bracket pin  380  may be operative to be inserted into housing  360 . When inserted in housing  360 , bracket pin  380  may provide a hinge to which one end of bracket  320  may be attached. The other end of bracket  320  may be secured via bracket screw  390 . Bracket screw  390  may be threaded into housing  360  and tightened to hold bracket  320  in place against housing  360 . 
     As shown in  FIG. 3B , flexible PCB  330 , terminals  311 , and coupling joint  316  are not included in the stack up in +Y. Removing these elements from the stack up allows for reduced height (e.g., in +Y) of the floating assembly, and also means that variations in any of these elements are not translated into the stack up. For example, variations in the thickness of flexible PCB  330  may be compensated for by deflection of compliant member  341  and/or terminals  311 . As another example, variations in coupling joint  316  (e.g., the amount of solder between terminals  311  and flexible PCB  330 ) may be compensated for by movement of flexible PCB  330  and/or deflection of terminals  311 . Thus, the position and orientation of activation assembly  310  relative to the other elements of electronic device  300  may be more consistent as compared to conventional switch assemblies. This results in better, more predictable button feel for floating switch assembly  300 . 
       FIG. 5  shows a cross-sectional view of an illustrative floating switch assembly including a custom switch in accordance with an embodiment of the invention. As shown, vent hole  518  may be included in one of alignment posts  517 , and as such, is integrated within structural member  513 . Note that floating assembly  500  may also include other elements, such as switch assembly  510 , bracket  520 , flexible printed circuit board  530 , support member  540 , coupling joint  516 , and insulating member  519 , which may include some or all of the features disclosed in previous embodiments. 
     Switch  512  may be operative to deform when actuated such that the inner surface of switch  512  contacts contact pad  515  and provides a conductive path between terminals  511 . The pressing of switch  512  may also provide a tactile ‘click’ that enhances a user&#39;s interaction with switch  512 . When switch  512  is depressed, air from under switch  512  may travel through vent hole  518 . Vent hole  518  may be any suitable size. In some cases, vent hole  518  may have a volume smaller than the internal volume of switch  512  while in other cases vent hole  518  may have a volume substantially the same as the internal volume of switch  512 . 
     In some embodiments, vent hole  518  may be in fluid communication with an internal venting volume (not shown). In other embodiments, additional layers may be provided to further aid in forming the internal venting volume. For example, pockets may be formed with at least one film in fluid communication with the internal volume of switch  512 . 
       FIG. 6  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention. Floating switch assembly  600  may be similar to floating switch assembly  500 , and as a result may include some or all of the features disclosed with respect to  FIG. 5 . As shown in  FIG. 6 , sealing member  680  may be positioned over activation assembly  510  and extend over at least a portion of flexible PCB  530 . Sealing member  680  may create an air tight seal that prevents liquid or any other debris from contaminating floating switch assembly  600 . Sealing member  680  may be made of any suitable material (e.g., plastic). Additionally, a sealing member may be configured in a variety of ways. For example, sealing member  680  may be positioned only over structural member  513  and may not extend over flexible printed circuit board  530 . 
       FIG. 7A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention.  FIG. 7B  shows a partial top cross-sectional view of the floating switch assembly of  FIG. 7A . As shown in  FIGS. 7A and 7B , in some embodiments that do not include alignment posts, a vent may be integrated in the switch assembly rather than in the alignment posts. For example, vent hole  718  may be included in structural member  713  and switch assembly adhesive  714 . When switch  712  is depressed, air from under switch  712  may travel into vent hole  718  to relieve pressure build up on switch  712 . Vent hole  718  may be any suitable size. In some cases, vent hole  718  may have a volume smaller than the internal volume of switch  712  while in other cases vent hole  718  may have a volume substantially the same as the internal volume of switch  712 . In some embodiments, vent hole  718  may be in fluid communication with an internal venting volume (not shown). Although  FIGS. 7A and 7B  show an arbitrary positioning of vent hole  718 , those skilled in the art will appreciate that the positioning of vent hole  718  may be modified without deviating from the spirit and scope of the invention. 
       FIG. 8A  shows a cross-sectional view of an illustrative floating switch assembly in accordance with an embodiment of the invention.  FIG. 8B  shows a partial cross-sectional view of the floating switch assembly of  FIG. 8A , showing a magnified view of section B from  FIG. 8A . Those skilled in the art will appreciate that a floating switch assembly may be constructed in a variety of ways. For example, as shown in  FIG. 8A , floating switch assembly  800  may have similar elements as other disclosed embodiments; however, the elements of floating switch assembly  800  have a different configuration with respect to one another (e.g., the placement of flexible PCB  830  is different). Floating switch assembly  800  may include activation assembly  810 , bracket  820 , flexible PCB  830 , and support members  840 . Activation assembly  810  may be attached to bracket  820  as shown in  FIG. 8A . As seen in this embodiment, flexible PCB  830  may be in substantially the same plane as bracket  820  (as opposed to being positioned above bracket  820 ). Flexible PCB  830  may be coupled to terminals  811  by coupling joints  816  such that flexible PCB  830  is able to float relative to activation assembly  810 . Support members  840  may be included beneath coupling joints  816  to prevent unnecessary stress on coupling joints  816 , terminals  811 , and/or flexible PCB  830 . Support members  840  may be constructed from a compliant material (e.g., foam, rubber, or plastic) that is operative to support coupling joints  816  without compromising the ability of flexible PCB  830  to move relative to activation assembly  810 . 
       FIG. 8B  shows a magnified view of the coupling between activation assembly  810  and flexible PCB  830 . As shown in  FIG. 8B , floating switch assembly  800  may include insulating members  819  to prevent terminals  811  from electrically shorting with another portion of floating switch assembly  800 . Insulating members  819  may also provide additional support to coupling joints  816 . Floating switch assembly  800  may also include underfill  890  which may fill area under switch assembly  810  and help control the stress on coupling joints  816 . Underfill  890  may be made from any suitable material, including, but not limited to, a specially engineered epoxy. 
       FIG. 9  shows an illustrative method for constructing a floating switch assembly in accordance with some embodiments of the invention. Method  900  may begin at step  902 . At step  902 , an activation assembly may be mounted to a support bracket using any suitable process. For example, the activation assembly may be mounted to the support bracket using an adhesive. In some embodiments, the activation assembly and the support bracket may have corresponding features (e.g., alignment posts) that help fix the orientation of the activation assembly with respect to the support bracket. For illustrative purposes, the activation assembly and support bracket may be similar to activation assembly  310  and bracket  320  of  FIG. 3 . At step  904 , a flexible PCB (e.g., similar to flexible PCB  330 ) may be coupled to the activation assembly. The activation assembly may include terminals that are specially designed to allow the flexible PCB to float relative to the activation assembly. Additionally, the flexible PCB may include a cutout to accommodate a portion of the activation assembly. The cutout may provide clearance for the flexible PCB to float properly without being obstructed. At step  906 , a support member (e.g., similar to support members  340 ) may be coupled to the flexible PCB. The support member may support the flexible PCB without inhibiting its ability to float. At step  908 , the support member may be coupled to the support bracket. The resulting configuration may look similar to the floating switch assembly of  FIG. 3 . Method  900  may then conclude at step  908 . Although the method for constructing a floating switch assembly is presented using sequentially numbered steps, it is understood that the order of the steps may be altered without deviating from the scope of this disclosure. 
     As used herein, the term “electronic device” can include, but is not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, calculators, cellular telephones, other wireless communication devices, personal digital assistants, programmable remote controls, pagers, laptop computers, printers, or combinations thereof. 
     The previously described embodiments are presented for purposes of illustration and not of limitation. It is understood that one or more features of an embodiment can be combined with one or more features of another embodiment to provide systems and/or methods without deviating from the spirit and scope of the invention. It will also be understood that various directional and orientational terms are used herein only for convenience, and that no fixed or absolute directional or orientational limitations are intended by the use of these words. For example, the devices of this invention can have any desired orientation. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope and spirit of this invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20120820
Publication Date: 20150616
Grant Date: 20150616
Priority Date: 20120820
Inventors: MALEK SHAYAN
CHRISTOPHY MIGUEL C.
PLETENETSKYY ANDRIY
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H13/10", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2207/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2001/5816", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2215/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/06", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2215/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2215/006", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2001/5816", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/14", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2223/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/06", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2001/5816", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2223/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/14", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2223/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/20", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2215/006", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 50099293