PATENT DOCUMENT

Publication Number: US-9420074-B2
Application Number: US-201414271374-A
Country: US
Kind Code: B2

Title: Light guided alignment for semi-automated seal application

Abstract:
In one embodiment, a method of installing a component in an electronic device is described. A light source shines a light through an aperture of on one end of the electronic device. A light sensor positioned on the opposite end moves with a fixture having the component. When the light sensor determines a central portion of the light, the fixture and the component may be aligned with the aperture of the electronic device, and the fixture installs the component. In another embodiment, a method of detecting proper installment of the component is described. A microphone may be used to detect sound transmission from a speaker which transmits sound through the aperture. If the microphone detects sounds from an interface region between the component and the housing, the component is not properly installed.

Claims:
What is claimed is: 
     
       1. A method for aligning and installing a component with an electronic device having a housing that includes a housing aperture, the method comprising:
 securing the component with a fixture, the component comprising a component aperture; 
 providing, from a light source, light having a maximum intensity that passes through the housing aperture and the component aperture to a light sensor carried by the fixture, the maximum intensity associated with a central portion of the light; 
 actuating the fixture perpendicular with respect to the light such that the light sensor detects the maximum intensity; and 
 actuating the fixture toward the housing to secure the component with the housing. 
 
     
     
       2. The method as recited in  claim 1 , wherein the light source is external with respect to the housing. 
     
     
       3. The method as recited in  claim 1 , further comprising:
 detecting, with the light sensor, a first intensity of the light less than the maximum intensity at a first portion of the light, the first portion different from the central portion; 
 detecting, with the light sensor, a second intensity of the light less than the maximum intensity at a second portion of the light with the light sensor, the second portion different from the central portion; and 
 determining the maximum intensity based on the first intensity and the second intensity. 
 
     
     
       4. The method as recited in  claim 1 , wherein providing, from the light source, the light comprises providing the light that passes through a mesh portion of the component. 
     
     
       5. The method as recited in  claim 1 , wherein the fixture includes a chamber defining an opening of the fixture. 
     
     
       6. The method as recited in  claim 5 , wherein the light sensor is positioned within the chamber. 
     
     
       7. The method as recited in  claim 5 , wherein the opening of the fixture is similar to the component aperture. 
     
     
       8. The method as recited in  claim 1 , wherein securing the component with the housing comprises:
 adhesively attaching the component to an interior region of the housing such that the housing aperture is aligned with the component aperture. 
 
     
     
       9. The method as recited in  claim 8 , further comprising, subsequent to the adhesively attaching the component, performing a test to determine an alignment of the component on the housing. 
     
     
       10. The method as recited in  claim 1 , wherein actuating the fixture comprises:
 actuating the fixture in accordance with a first direction to determine a first plurality of light intensities; 
 actuating the fixture in accordance with a second direction to determine a second plurality of light intensities different from the first plurality of light intensities; and 
 determining the maximum intensities based on the first plurality of intensities and the second plurality of intensities. 
 
     
     
       11. The method as recited in  claim 10 , wherein the first direction is perpendicular with respect to the second direction. 
     
     
       12. The method as recited in  claim 10 , wherein securing the component with the housing comprises acoustically sealing the component with the housing.

Description:
FIELD 
     The described embodiments relate generally to installing a component to a device. In particular, the present embodiments relate to aligning the component with an inner portion of an electronic device for installation of the component, and testing to ensure proper installation of the component once installed. 
     BACKGROUND 
     Proper installment of components in an electronic device generally leads to better overall performance of the electronic device. In order to properly install components in several electronic devices on an assembly line, it may be necessary to automate the process. One automation process includes a camera system having a charge-coupled device (“CCD”) camera or a complementary metal-oxide semiconductor (“CMOS”) camera used in conjunction with a software package configured to detect placement of components on the electronic device. The camera system may, for example, capture an image of the component on the electronic device and use the software package to compare the image with an image of a properly installed component. 
     However, camera systems are relatively expensive. In addition, several manual hours may be required to operate the camera system. For example, an operator must be properly trained on how the camera system works. Also, the camera systems may require proper alignment at all times which may be difficult in an assembly line. Realignment may also cost several manual hours. Also, variations in lighting within the assembly line may reduce the ability for the camera system to function in the desired manner. 
     SUMMARY 
     In one aspect, a method for aligning a component for installation in a housing of an electronic device is described. The method may include shining a light from a light source through an aperture of the housing, the light having a central portion. The method may also include actuating a fixture, the fixture having the component and a light sensor, along a first direction such that the light sensor detects the light. The method may also include aligning the light sensor with the central portion of the light. 
     In another aspect, a method for testing for proper installation of a component to a housing of an electronic device is described. The method may include transmitting a sound through an aperture of the housing, the sound originating from an outer portion of the housing. The method may also include transmitting the sound through an aperture of the component and a chamber of a fixture. The fixture is sealed to the component. The method may also include determining whether a portion of the sound is detected in an area proximate to an interface region of the housing and the component. 
     In another aspect, a fixture on an assembly line for manufacturing an electronic device is described. The fixture may include a first portion having a first cavity; the first cavity extending to a first opening on a surface of the first portion. The fixture may also include a second portion having a second cavity extending from a second opening on a second surface of the fixture to a third opening on a third surface of the fixture; the second cavity is substantially perpendicular to the first cavity and configured to receive a protrusion. The first cavity may include a cross sectional area substantially similar to a cross sectional area of an aperture of a component to be installed on the electronic device, and the fixture may be capable of rotating around a longitudinal axis of the protrusion. 
     A fixture on an assembly line for manufacturing an electronic device is described. The fixture may include a first cavity extending to a first opening on a first surface of the fixture. The fixture may also include a second cavity extending from a second opening on a second surface of the fixture to a third opening on a third surface of the fixture. The second cavity is capable of receiving a protrusion that actuates the fixture. The first cavity is smaller than an aperture of a component, the component configured to be installed on the electronic device. The fixture is capable of rotating about a longitudinal axis of the protrusion when the second cavity receives the protrusion. 
     Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which: 
         FIG. 1  shows an isometric view of an embodiment of a system used to align a component in an electronic device; 
         FIG. 2  shows an exploded view of an embodiment of a component near an embodiment of a housing of the electronic device; 
         FIG. 3  shows a dimensional comparison of an aperture in the embodiment of the component and an aperture in the embodiment of the housing, both of which are shown in  FIG. 2 ; 
         FIG. 4  shows a cross sectional view of the embodiment of the system shown in  FIG. 1  with a light source shining light into the housing; 
         FIG. 5  shows a cross sectional cutaway along the  5 - 5  line in  FIG. 4  showing an embodiment of a light gradient created by the light source; 
         FIGS. 6-9  show an embodiment of the light sensor, fixture, and component traversing in the y-direction to find the central portion (or local maximum) of the light source; 
         FIG. 10  shows a flow chart of an alignment process in accordance with the described embodiments; 
         FIG. 11  shows a top view of an embodiment of a fixture; 
         FIG. 12  shows an isometric view of an embodiment of a system used to test for proper installment of a component in an electronic device; 
         FIG. 13  shows a cross sectional view of the embodiment of the system shown in  FIG. 12  with an audio speaker emitting sound into a chamber of a fixture; 
         FIGS. 14 and 15  show cross sectional views of improper alignment of a component on an electronic device; 
         FIG. 16  shows an alternate embodiment of a system used to test for proper installment of a component in an electronic device; and 
         FIG. 17  shows a flow chart of a testing process in accordance with the described embodiments. 
     
    
    
     Those skilled in the art will appreciate and understand that, according to common practice, various features of the drawings discussed below are not necessarily drawn to scale, and that dimensions of various features and elements of the drawings may be expanded or reduced to more clearly illustrate the embodiments of the present invention described herein. 
     DETAILED DESCRIPTION 
     Reference will now be made in detail to representative embodiments illustrated in the accompanying drawings. It should be understood that the following descriptions are not intended to limit the embodiments to one preferred embodiment. To the contrary, it is intended to cover alternatives, modifications, and equivalents as can be included within the spirit and scope of the described embodiments as defined by the appended claims. 
     In the following detailed description, references are made to the accompanying drawings, which form a part of the description and in which are shown, by way of illustration, specific embodiments in accordance with the described embodiments. Although these embodiments are described in sufficient detail to enable one skilled in the art to practice the described embodiments, it is understood that these examples are not limiting; such that other embodiments may be used, and changes may be made without departing from the spirit and scope of the described embodiments. 
     The following disclosure relates to aligning a component within a device (e.g., a tablet computer, portable electronic device) during an assembly process, as well as testing to ensure the component is properly installed. The component may include an acoustic seal. In one embodiment, the assembly process may include a fixture attached to a movable table, both of which are proximate to an inner portion of a housing of the device. The fixture may be configured to rotate at least partially around an axis. A light sensor may also be positioned within a chamber of the fixture. The component and a release layer may also be positioned on an outer surface of the fixture. Light from a light source passes through an aperture of the housing of the device to the light sensor. The movable table may move the fixture in multiple directions allowing the light sensor to determine the area of highest light intensity (“local maximum”) of the light source. The light source is positioned such that the local maximum extends through a central portion of the aperture of the housing. Using information from the light sensor, the movable table may move the fixture, and accordingly, the component, to the local maximum. The fixture may then move in a direction toward the inner surface to install the component. 
     In another embodiment, an acoustical test ensures a component is properly installed. The component is attached to an inner surface of a housing of a device, and configured to extend around an aperture of the housing. A pressure sensitive adhesive (“PSA”) may be used to attach the component to the housing. An audio speaker is placed on an outer portion of the housing. A microphone may be attached to a fixture substantially similar to the fixture previously described. The acoustical test may be performed by emitting sound from the audio speaker and through the aperture of the housing, an aperture of the component, and into a chamber of the fixture. If the microphone does not detect the emitted sound, the component is properly installed. If the microphone detects the emitted sound, the component is not properly installed. The acoustical test is generally performed during early stages of the assembly. Thus, if improper installation is detected, the housing may be discarded from the assembly process with minimal assembly rather discarding a fully assembled device. Also, this combined test and assembly step is at least one less step used to assemble the device which may contribute to lower manufacturing time and cost. 
     For purposes of clarity, the term “longitudinal” as used throughout this detailed description and in the claims refers to a direction extending a length or major axis of a component. Also, the phrase “acoustically sealed” as used throughout this detailed description and in the claims refers to two structures engaged with one another such that sound cannot pass through a portion where the two structures are engaged. 
       FIGS. 1-4  illustrate a portion of an assembly station for assembling device  100 . The device  100  may be a device such as a tablet computer, mobile telecommunications device (for example, smartphone), or portable laptop computer.  FIG. 1  shows an isometric view of the assembly station having fixture  110  configured to attach a component to housing  101  of the device. The component may be an acoustic seal configured to prohibit dust or other contaminants from entering an aperture of device  100 . Generally, fixture  110  may be any structure used in an assembly process capable of affixing small components to a device  100 . In some embodiments, the component may be a button. In the embodiment shown in  FIG. 1 , fixture  110  is configured to install a component, or microphone seal (discussed later). Also, in some embodiments, fixture  110  may be made of plastic, metal, or a combination thereof. In the embodiment shown in  FIG. 1 , fixture  110  is made of aluminum. Also, fixture  110  is generally “L-shaped” but could be any shape in order to achieve a desired result, such align and install a component and/or provide an installation test (discussed later). In this case, fixture  110  is designed to traverse on the assembly station such that first aperture  122  of fixture  110  engages an aperture (shown later) of housing  101 . 
       FIG. 1  further shows an enlarged view of fixture  110  having chamber  120 . For purposes of clarity, some structures in the enlarged view are removed. Chamber  120  is a cavity within fixture  110  extending from one end inside fixture  110  to first aperture  122  located on lateral surface  114  of fixture  110 . In some embodiments, first aperture  122  is a cylindrical shape. In the embodiment shown in  FIG. 1 , first aperture  122  is generally rectangular. Generally, first aperture  122  is designed to have an area larger than that of an aperture of housing  101 . This will be discussed later in detail. Chamber  120  is generally of a dimension similar to that of first aperture  122  throughout chamber  120 . Also, chamber  120  is configured to receive light sensor  130  used to align fixture  110  (and ultimately, the component) with the aperture of housing  101 . Light sensor  130  may be a photoelectric sensor, or any other device configured to detect light from a light source external to housing  101  and determine the light intensity from the light source. As shown in  FIG. 1 , light sensor  130  is attached to a top portion of chamber  120 . Fixture  110  further includes second aperture  124  on top surface  116  of fixture, and cavity  126  extending from top surface  116  of fixture  110  to an opening of chamber  120 . Cavity  126  and second aperture  124  allow light sensor  130  to electrically connect to a power source and/or an input module of a controller or programmable unit (not shown) via conductive element  132 . In other embodiments, conductive element  132  may extend through a cavity (not shown) to electrically connect with the power source, controller, and/or programmable unit. 
     Also, fixture  110  includes pinhole  112  configured to receive column  170 . Column  170  passes through fixture  110  and support member  171 , and is attached to a movable table (not shown) configured to move in both a horizontal (“x”) direction and vertical (“y”) direction. Column  170  and support member  171  may also be rotated by the movable table around longitudinal axis  180  of column  170 . Accordingly, fixture  110  may also move in the same directions as column  170  and support member  171 . Advances in drilling techniques allow for high precision in forming pinhole  112  such that when column  170  engages fixture  110 , fixture  110  is configured to have relatively low tolerances. In other words, there is little unwanted movement of fixture  110  with respect to column  170 . 
     Release layer  146  is configured to detach from lateral surface  114  once the component is installed on housing  101 . A first surface of release layer  146  is attached to lateral surface  114  of fixture  110 . A second surface (shown later) of release layer  146  may be attached to the component to be installed on housing  101 . Also, when the component is installed, release layer  146  is further configured to detach from the component. 
       FIGS. 2 and 3  illustrate the relationship of housing  101  and component  140 .  FIG. 2  shows an exploded view of component  140  having first portion  141 , mesh portion  143 , and second portion  144 . First portion  141  includes recessed portion  142  and second portion  144  includes a recessed portion (not shown), both of which are configured to receive mesh portion  143 . Accordingly, some of the dimensions of mesh portion  143  are less than that of first portion  141  and second portion  144 . Also, first portion  141  further includes aperture  151 , second portion  144  includes aperture  154 , and release layer  146  includes aperture  156 . Also, as shown in  FIG. 2 , aperture  151 , aperture  154 , and aperture  156  are generally of the same dimensions. Also, although aperture  151 , aperture  154 , and aperture  156  are generally rectangular, these apertures could embody a different shape such that the apertures maintain dimensions larger than that of aperture  103 . Referring to  FIG. 3 , aperture  151  includes length  157  and width  158 . Aperture  103  of housing  101 , on the other hand, is smaller than that of aperture  151 . In particular, aperture  103  includes length  105  and width  106  that are less than length  157  and width  158 , respectively. This allows aperture  103  to be positioned within aperture  151 , or conversely, for aperture  151  to extend around aperture  103  without directly contacting aperture  103 . The smaller cross sectional area of aperture  103  as compared to the cross sectional area of aperture  151  allows a pressure sensitive adhesive (“PSA”) (not shown) to be applied to a surface of first portion  141  that faces housing  101  such that first portion  141  adhesively attaches to housing  101  without first portion  141  contacting any portion of aperture  103 . It should be noted this alignment is preferred in the assembly of the device. 
     Referring again to  FIG. 2 , mesh portion  143  made of a generally porous material. This allows light and/or sound waves to pass through mesh portion  143 . Despite the porous material, mesh portion  143  is configured to prevent certain contaminants (such as dust or liquid) from entering the device. Also, mesh portion  143  may also contribute to the acoustic performance of the device. 
       FIGS. 4-10  illustrate the alignment process for component  140  onto housing  101 . In  FIG. 4 , light source  190  directing light toward aperture  103 . In some embodiments, light source  190  is a laser. In other embodiments, light source  190  could be an infrared light source. Still, in other embodiments, light source  190  could be of a particular color (such as visible red). These embodiments may be useful in order to allow light sensor  130  to accurately detect light from light source  190 . In the embodiment shown in  FIG. 4 , light source  190  is a collimated white light. In other words, the white light emits several light rays, some of which are generally parallel to each other. As shown in  FIG. 4 , only a portion of the light from light source  190  may reach light sensor  130 . The alignment process is configured such that aperture  103  trims or clips some of the light while allowing some of the light to pass through aperture  103 . For example, light ray  191  contacting housing  101  may be reflected by, or absorbed by, housing  101  but does not pass through aperture  103 . Light ray  192 , however, passes through aperture  103 . Light passing through aperture  103  may also pass through the aperture of component  140  (that is, the apertures of the portions of component  140  as well as mesh portion  143 ) and through the aperture of release layer  146 . This light may be detected by light sensor  130 . 
     Light passing through aperture  103  may be having a higher intensity in some portion as compared others. In other words, the light may be brighter in some areas than in other areas. For example,  FIG. 5  shows light gradient  210  taken along the line  5 - 5  in  FIG. 4 . In some embodiments, the light source and the aperture are configured to form light gradient  210  of several intensities. For example, light gradient  210  may include first intensity  211 , second intensity  212 , third intensity  213 , fourth intensity  214 , and fifth intensity  215 . The light intensity of light gradient  210  is highest in the center of light gradient  210  than the outermost region. In other words, first intensity  211  has a higher light intensity than that of second intensity  212 , and so on. Also, first intensity  211  may also be referred to as a local maximum of the light from light source  190 . Generally, first intensity  211  is at the center of the light and also corresponds to the brightest component of the light. 
     Light sensor  130  (shown in  FIG. 4 ) is configured to detect all intensities of light gradient  210 . Also, light source  190  (shown in  FIG. 4 ) is aligned with aperture  103  such that first intensity  211  having light ray  195  extending through a central portion of aperture  103 . Accordingly, when light sensor  130  detects first intensity  211 , light sensor  130  and fixture  110  may be properly aligned with housing  101  and/or aperture  103 . Also, fixture  110  generally has low tolerance requirements not only in a rotational direction, but also a vertical direction. For example,  FIG. 4  shows component having lip portion  10 . Component  140  must be installed without contacting lip portion  10 . As such, it is critical to avoid unwanted movement in the y-direction. Therefore, aligning fixture  110  with the local maximum of light gradient is important to ensure that component  140  and/or fixture  110  do not contact lip portion  10  of housing  101 . 
       FIGS. 6-9  illustrate fixture  110  traversing in a first direction relative to light gradient  210  in order to align component  140  with the aperture of the housing. In some embodiments, the first direction is in the x-direction. In the embodiment shown in  FIGS. 6-9 , the first direction is the y-direction. Light sensor  130  may be configured as an input device to a controller (not shown), such as a programmable logic controller (“PLC”). Also, light sensor  130  may transmit current (on the order of milliamps) to signal the light intensity read by light sensor  130 . For example, a low current transmitted by light sensor  130  corresponds to a low light intensity, and a relatively higher current transmitted corresponds to a higher light intensity. The controller may be configured to read the light intensity readings from light sensor  130  (for example, by converting current into a light intensity) and signal a motor to drive a movable table (not shown), such as an X-Y table. The controller may be proximate to fixture  110  or may be located in another portion of the assembly process. Fixture  110 , connected to the movable table, may move fixture  110  in the x-direction and/or the y-direction in order to properly align component  140  with an aperture of the housing as previously described. In other embodiments, light sensor  130  is coupled directly to a motor configured to move a movable in response to current readings by light sensor  130 . 
       FIG. 6  shows light sensor  130  reading a light intensity corresponding fourth intensity  214  of light gradient  210  (shown in  FIG. 5 ). In order to determine whether the portion of light gradient  210  read by light sensor  130  is the highest intensity of light gradient  210 , the movable table actuates fixture  110  to traverse along the y-direction to take further readings. As shown in  FIG. 7 , light sensor  130  reads a light intensity corresponding first intensity  211  of light gradient  210 . While the controller may determine first intensity  211  has a greater intensity than that of fourth intensity  214 , the movable table may further actuate fixture  110  to traverse along the y-direction to take further readings. As shown in  FIG. 8 , light sensor  130  reads a light intensity corresponding fourth intensity  214  of light gradient  210 . At this point, the controller may determine that fixture  110  is traversing along the y-direction in a direction of decreasing light intensity, and signal for the movable table to retract (or travel in the opposite direction) to a position along the y-direction to the position corresponding to the position in which light sensor  130  previously detected first intensity  211 , as shown in  FIG. 9 . At this point, the component  140  is aligned with the local maximum of light intensity, and therefore, the aperture of the housing. A similar process may be repeated in the x-direction in order to further align component  140  with the local maximum. In other embodiments, the alignment process may be programmed to run for a predetermined period of time (for example, 1-5 seconds) and then actuate fixture  110  to a position corresponding to the local maximum, or highest light intensity, during the predetermined period. 
       FIG. 10  is a flow chart  300  which details an alignment process. In a first step  302 , the light sensor takes an initial light intensity reading to determine the light intensity of the light gradient at a given location. The initial reading may be transmitted to a device such as a controller. Then in step  304 , the light source and the fixture traverse along a first direction to take an additional reading of the light gradient. The first direction could be the x-direction or the y-direction. Then in step  306 , the light sensor takes another reading. In step  308 , the controller may compare the initial reading to the subsequent reading. If the subsequent reading is higher than the initial reading, as shown in step  310 , the alignment process may be repeated beginning at step  306 . If, on the other hand, at step  308  it is determined that the subsequent reading is less than the initial reading, then in step  312 , the light sensor and the fixture traverse in the opposite direction of the first direction to a position corresponding the highest intensity reading as determined by the light sensor. It should be understood that the alignment process could include traversing in a second direction that is substantially perpendicular to the first direction. For example, the alignment process could traverse in the x-direction if the process has traversed in the y-direction. 
     Contrary to the white light previously described, laser light is generally a focused light source of a single light intensity. Referring again to  FIG. 4 , in embodiments where light source  190  is a laser light, light sensor  130  may generally act as a switch. In other words, rather than detecting various light intensities, light sensor  130  may switch to an “on” state when the laser light is detected and switch to an “off” at all other light intensities (for example, ambient light). As such, when laser light passes through the central portion of aperture  103 , the controller may signal for fixture  110  to stop when light sensor  130  detects the laser light. It should be understood that the cross section of the laser light also generally represents the “local maximum” of the laser light due to the characteristics of the laser light. 
       FIG. 11  illustrates a top view of showing release layer  146  attached to component  140  on a first surface of release layer  146 , and release layer  146  attached to fixture  110  on a second surface of release layer. Also, fixture  110  includes length  118 . Length  118  may be approximately in the range of 10 mm to 420 mm. Generally, length  118  is such that when fixture  110  is rotated around column  170  in a direction toward housing  101 , component  140  is substantially parallel to housing  101  when component  140  is proximate to housing  101 . Also, as shown in  FIG. 11 , PSA  161  is applied a surface first portion  141  of component  140 . When component  140  is properly aligned with aperture  103 , the amount of PSA  161  used to attach component  140  with housing  101  is such that PSA  161  sufficient holds component  140  to housing  101  but does not intrude into any portion of aperture  103 . 
     Also, in some embodiments, several light sensors may be positioned around the fixture. Each light sensor could transmit a light intensity to a controller. The controller may use the readings from the light sensors to calculate a local maximum of the light, and actuate the fixture and component accordingly. Also, although not shown, some embodiments may include a light sensor external with respect to the housing of the device and a light within the housing of the device. This may be advantageous where the light sensor readings are critical and any movement of the light sensor is undesirable. 
     Some embodiments may include a test in order to confirm the component is properly attached to the housing.  FIG. 12  illustrates an acoustical test to determine whether the component is proper installed on the housing. The acoustical test includes a microphone  410  on top surface  116  of fixture  110 , generally above chamber  120 . The acoustical test also includes a speaker (shown later) configured to emit sound into chamber  120  through an aperture of housing  1001 . In some embodiments, the acoustical test is performed after the alignment process (previously described) and subsequent installation of the acoustical seal. 
       FIG. 12  further shows housing  1001  including first alignment block  102  and second alignment block  104 , both of which are configured to guide fixture  110  such that the component is properly aligned with housing  1001 . Fixture  110  may slide along a surface of first alignment block  102  and second alignment block  104 . In some embodiments, housing  1001  includes only a first alignment block  102 . In other embodiments, housing  1001  includes three or more alignment blocks. Still, in other embodiments, housing  1001  may not have an alignment block (similar to housing  101  shown in  FIG. 1 ). First alignment block  102  and second alignment block  104  may serve as a substitute to the alignment process previously described. However, it should be understood that in some embodiments alignment blocks may be used in conjunction with the alignment process. Also, the acoustical test may be initiated by switch  422  on fixture  110 . Switch  422  may be electrically connected to microphone  410  and/or the speaker. In some embodiments, switch  422  is electrically connected to a controller (not shown). Also, switch  422  may be further configured to set the PSA so the component may be installed. 
       FIG. 13  illustrates a cross sectional view of a system for the acoustical test which includes microphone  410  on fixture  110 , audio speaker  420  attached to an outer portion of housing  1001 , and switch  422 . Housing  1001  includes first alignment block  102  to ensure component  140  is aligned with aperture  103  before installing component  140 . Audio speaker  420  is attached to housing  1001  such that audio speaker  420  transmits a test sound (shown as sound wave  425 ) in a direction through aperture  103 , component  140 , release layer  146 , and ultimately into chamber  120 . As stated previously, mesh portion  143  is made of material(s) which allow sound transmission to permeate through mesh portion  143 . Audio speaker  420  may be configured to transmit any sound from an audio transmission device (not shown). Also, microphone  410  generally detects sound transmissions from any source that emits sound. This may include, for example, ambient noise in a device assembly plant. Also, both microphone  410  and audio speaker  420  may be attached to a controller (not shown) previously described. 
     It will be appreciated that release layer  146  is acoustically sealed with fixture  110  a surface of release layer, and acoustically sealed to component  140  on another surface of release layer  146 . In some embodiments (not shown), component  140  may be directly attached to fixture  110  (that is, no release layer  146 ). When component  140  is directly attached to fixture  110 , component  140  is acoustically sealed with fixture  110 . 
       FIG. 13  also shows interface region  430 . Interface region  430  is a portion in which component  140  engages housing  101 , and extends around an outer perimeter of component  140 . Generally, interface region  430  is a region most likely to emit sound transmission from audio speaker  420  when component is not acoustically sealed with housing  1001 . To determine whether component  140  was properly installed, audio speaker  420  emits a sound transmission (“test sound”). If microphone  410  does not detect sound transmission from audio speaker  420  through an interface region  430 , component  140  is acoustically sealed with housing  1001 , and therefore properly installed. However, if microphone  410  detects sound transmission from audio speaker  420  through interface region  430 , acoustical seal  140  is not acoustically sealed with housing  101 , and therefore improperly installed on housing  101 . In the latter event, the controller may subsequently signal to another member of the assembly line to remove housing  1001  having an improperly installed component  140 . As previously noted, this combined assembly and test step occurs relatively early in the assembly process. Accordingly, when a misaligned component  140  is detected, no further assembly to housing  1001  is performed. This not only lowers cost associated with installing additional components on a device that will ultimately not be sold, but also allows another device to be assembled in place of the device having a misaligned component  140 . 
     In some embodiments, the controller may signal the audio transmission device to transmit a sound through audio speaker  420  in a predetermined frequency range in which microphone  410  is configured to receive. Accordingly, microphone  410  may ignore other ambient noises not within the predetermined range. In other embodiments, the acoustical test may include a second microphone (not shown) configured to receive sound transmission from, for example, ambient noise, allowing the acoustical test to “ignore” ambient noise. For example, the controller may receive transmission from microphone  410  and the second microphone, reduce each transmission into a mathematical computation, and subtract sound transmission of the second microphone from sound transmission from microphone  410 . The controller may then analyze the resultant sound transmission to determine whether microphone  410  received sound transmission from audio speaker  420 . 
     For the acoustical test to perform properly, microphone  410  should be capable of detecting sound transmission from audio speaker  420 , if at all, only through portions such as interface region  430 . It is essential, therefore, that audio speaker  420  be properly secured to housing  101  such that sound transmission from audio speaker  420  passes only through aperture  103 . Alternatively, it may be necessary to acoustically block sound transmission from audio speaker  420  passing over top portion  109  (shown in  FIG. 13 ) of housing  101 . Also, although sounds wave  425  extend through chamber  120 , sound wave  425  do not extend through cavity  126  in a manner such that they may be detected by microphone  410 . Further, fixture  110  is made of material(s) such that sound wave  425  generally do not pass through fixture  110 . 
     Installation issues (corresponding to a failure event) of component  140  may happen for several reasons. For example,  FIG. 14  illustrates component  140  having a slanted surface  145 . In other words, slanted surface  145  is not substantially parallel with the inner portion of housing  1001  where component  140  is generally installed. This may be due to, for example, a manufacturing flaw of component  140 . Installation issues also include misalignment of a properly manufactured component  140 . In  FIG. 15 , for example, component  140  is installed on housing  101  (shown also in  FIG. 1 ) at a portion lower than that of a properly aligned component  140 . In particular, a lower edge of component  140  is lower than aperture  103  of housing  101 . In both cases, sound wave  425  may be permitted to extend through interface region  430  and be detected by microphone  410 . Also, installation issue may also derive from improperly setting PSA on, for example, the component  140 . This may create gaps between the PSA and component  140  thereby allowing sound wave  425  to pass through interface region  430 . 
     Other tests may be performed to ensure component  140  is properly installed. For example,  FIG. 16  illustrates a test system using valve  450  connected to air line  460 , and seal  470  configured to plug aperture  103 . In some embodiments, valve  450  is a pneumatic valve. Also, in some embodiments, air line  460  may receive air through an air compressor, or an air pump. In this test, air is supplied to chamber  120  of fixture  110  through air line  460  and valve  450 . If air does not escape through interface region  430 , component  140  has been properly installed. However, if air escapes through interface region  430 , component  140  has been improperly installed. Determining air escape may be performed by monitoring pressure loss in chamber  120  or placing a structure near interface region  430  configured to move when air from interface region  430  contacts the structure. Manual means for determine determining proper installation of component  140  may also be performed. For example, air passing through interface region  430  may make a sound audible to an operator thereby indicating to the operator that component  140  is improperly installed. These air tests described herein may also be a combined assembly and test step performed relatively early in the manufacturing process. 
       FIG. 17  illustrates a flow chart  600  for assembling and testing installment of a component. In step  602 , the component is aligned with the aperture of the housing. Of course, this step is performed before installing the component. Alignment may be performed by the alignment process previously described (using at least a light and at least a light sensor), and/or using alignment blocks on the housing of the device. Then, in step  604 , the component is installed to the housing. This may performed, for example, by rotating or swiveling a fixture (lever) around a longitudinal axis of a column extending through the fixture. Then, in step  606 , a test is performed to determine if the component is properly installed on the housing. Testing may include any test for installment previously described (for example, the acoustical test). If the test indicates the component is not properly installed, in step  610 , the housing is removed from the assembly line. Then, in step  612 , the discarded housing is replaced by a new housing on the assembly line and the process is repeated at step  602 . If, however, the test indicates the component is properly installed, then in step  614 , the housing is moved to the next step of the assembly process. In step  616 , the assembly process is completed by installing the remaining components necessary to make the device. 
     The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the described embodiments. Thus, the foregoing descriptions of the specific embodiments described herein are presented for purposes of illustration and description. They are not target to be exhaustive or to limit the embodiments to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Metadata:
Filing Date: 20140506
Publication Date: 20160816
Grant Date: 20160816
Priority Date: 20140506
Inventors: ELY COLIN M.
HAVSKJOLD DAVID GLENN
SANFORD EMERY A.
MANULLANG TYSON BENNER
Assignee: APPLE INC
CPC Classifications: [{"code": "H05K13/0015", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/53265", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49897", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "H04M2250/12", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/24", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K13/0015", "inventive": true, "first": false, "tree": "[]"}, {"code": "Y10T29/49897", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "Y10T29/53265", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 54369136