PATENT DOCUMENT

Publication Number: US-9779894-B2
Application Number: US-201414553985-A
Country: US
Kind Code: B2

Title: Button features of an electronic device

Abstract:
Systems and methods for forming button assemblies for electronic devices are disclosed. According to some embodiments, the button assemblies include one or more sound improvement features to improve the sound that the button assemblies make when pressed by users of the electronic devices. According to some embodiments, the button assemblies include shims that provide proper alignment of the various components of the button assemblies and to accommodate any tolerance stack up of the various components of the button assemblies. The shims can include alignment features to prevent the shims from shifting within the button assemblies. According to some embodiments, thicknesses of the shims are customized to accommodate varying tolerance stack ups of the components of the button assemblies. In some embodiments, the button assemblies include a combination of sound improvement features and shims.

Claims:
What is claimed is: 
     
       1. A button assembly for an electronic device having a housing with an opening, the button assembly comprising:
 a switch module; 
 a bracket configured to support the switch module, the bracket positioned within the housing at the opening, the bracket including a trim and a through hole formed through the trim, the through hole having an undercut; and 
 a dampener positioned on the trim such that actuation of the switch module causes the dampener to engage the housing and the trim is prevented from directly contacting the housing, wherein the dampener is disposed in the through hole such that the dampener interlocks with the bracket via the undercut. 
 
     
     
       2. The button assembly of  claim 1 , wherein the through hole comprises:
 a first diameter at a first surface on which the dampener is positioned, and 
 a second diameter at a second surface opposite the first surface, the second diameter greater than the first diameter. 
 
     
     
       3. The button assembly of  claim 1 , wherein the trim includes four sides, wherein the dampener has two sections with each section formed on opposing sides of the trim. 
     
     
       4. The button assembly of  claim 1 , wherein the trim includes four corners, wherein the dampener has four sections with each section formed proximate a corner of the trim. 
     
     
       5. The button assembly of  claim 1 , wherein the dampener is comprised of a material configured to reduce a noise associated with pressing the switch module. 
     
     
       6. The button assembly of  claim 1 , wherein the dampener is adhered onto a surface of the trim with an adhesive. 
     
     
       7. The button assembly of  claim 1 , wherein the dampener comprises a stiffening agent. 
     
     
       8. The button assembly of  claim 7 , wherein the stiffening agent comprises glass filler. 
     
     
       9. A button assembly for an electronic device, the button assembly comprising:
 a button having a flange; 
 a switch configured to provide an electrical connection for the electronic device when actuated by the button; 
 a bracket that carries the switch at least partially in a housing of the electronic device; and 
 a shim positioned on the bracket, the shim carrying the switch, wherein the shim includes a thickness that biases the flange against the housing, and wherein the shim prevents shifting of at least one of the bracket and the button during operation of the switch. 
 
     
     
       10. The button assembly of  claim 9 , wherein the shim has a round shape corresponding to a recess of the bracket. 
     
     
       11. The button assembly of  claim 9 , further comprising an alignment feature that has a shape such that the shim is maintained at least partially within a recess of the bracket at a predetermined orientation with respect to the bracket. 
     
     
       12. The button assembly of  claim 9 , wherein the shim has one of a square, rectangular, elliptical, or triangular shape. 
     
     
       13. The button assembly of  claim 9 , wherein a surface of the shim has an electrophoretic coating. 
     
     
       14. The button assembly of  claim 9 , wherein the shim includes a shape corresponding to a square, a rectangle, an oval, or a triangle. 
     
     
       15. The button assembly of  claim 9 , wherein the shim rests on the bracket. 
     
     
       16. The button assembly of  claim 9 , wherein the button comprises a pocket that at least partially receives the shim. 
     
     
       17. A method for assembling a button assembly for an electronic device, the method comprising:
 securing a button in the electronic device, the button having a flange; 
 securing a switch in the electronic device, the switch configured to provide an electrical connection for the electronic device when actuated by the button; 
 providing a bracket that carries the switch at least partially in a housing of the electronic device; and 
 positioning a shim on the bracket, the shim carrying the switch, wherein the shim includes a thickness that biases the flange against the housing, and wherein the shim prevents shifting of at least one of the bracket and the button during operation of the switch. 
 
     
     
       18. The method of  claim 17 , further comprising providing an alignment feature that has a shape such that the shim is maintained at least partially within a recess of the bracket and at a predetermined orientation with respect to the bracket. 
     
     
       19. The method of  claim 17 , wherein positioning the shim on the bracket comprises one of a square shim, a rectangular shim, an elliptical shim, or a triangular shim. 
     
     
       20. The method of  claim 17 , wherein the button comprises a pocket that at least partially receives the shim.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of International Application PCT/US14/67452, with an international filing date of Nov. 25, 2014, entitled “Button Features Of An Electronic Device”, and claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application No. 62/046,822, filed Sep. 5, 2014, entitled “Button Features Of An Electronic Device”, each of which is incorporated herein by reference in its entirety. 
    
    
     FIELD 
     The present disclosure relates generally to devices, assemblies and methods related to button assemblies of electronic devices. More specifically, the present embodiments relate to providing a robust button assembly that has an aesthetically appealing feel and sound when actuated. 
     BACKGROUND 
     Modern electronic devices generally have a number of user interfaces such that users can interact with the internal components of the electric devices. Examples of such user interfaces include touch screens, keypads, microphones, and buttons. Buttons are typically made of an assembly of multiple mechanical pieces that work together when a user presses on the button, causing one or more switches to actuate. These mechanical pieces work in intricate concert with each other to reliably actuate a switch when a user simply presses on a button. For consumer electronic devices such as portable phones, it is important that all the mechanical features of the button assemblies work together robustly in order to withstand the numerous press events from a user. Portable electronic devices can also undergo numerous drop events. Therefore, the button assemblies must be designed to be robust enough to withstand such drop events and prevent false press events. 
     In addition, with the advent of smaller electronic devices it is important that the button assemblies take as little room within electronic devices in order to leave room for other components of the electronic devices. Furthermore, consumers demand that the button assemblies have a consistent and good “feel” when a button is pressed. That is, the button assembly should not feel loose or have play when a user presses a button. Therefore, what are needed are better button assemblies and methods for forming button assemblies to meet the complex demands of modern electronic devices. 
     SUMMARY 
     This paper describes various embodiments that relate to button assemblies of electronic devices. 
     According to one embodiment, a button assembly for an electronic device is described. The button assembly includes a bracket configured to support a switch module and is configured to be positioned within an opening of a housing of the electronic device. The bracket including a trim with a surface that nears an impact surface of the housing when the switch module is pressed. The button assembly also includes a dampener positioned between the surface of the trim and the impact surface of the housing such that the surface of the trim is prevented from directly contacting the impact surface of the housing when the switch module is pressed. The dampener is made of a sufficiently compliant material to reduce a noise associated with the surface of the trim contacting the impact surface of the housing. 
     According to another embodiment, a button assembly for an electronic device is described. The button assembly includes a switch configured to provide an electrical connection for the electronic device. The button assembly also includes a bracket configured to support the switch with respect to a housing of the electronic device, the bracket including a recess. The button assembly additionally includes a shim positioned between the bracket and the switch. The shim has an alignment feature that protrudes from a base of the shim. The alignment feature is positioned within the recess of the bracket so as to prevent shifting of the shim with respect to the bracket and the switch during operation of the button assembly. 
     According to a further embodiment, a method of forming a customized shim of a button assembly for an electronic device to give the button assembly a predetermined feel is described. The button assembly includes a switch, a button and a bracket. The method includes measuring a number of dimensions of the button assembly. The measuring includes determining a dimension of the switch while a predetermined preload force is applied to the switch. The predetermined preload force is associated with an amount of depression of button assembly when pressed by a user of the button assembly. The method further includes forming the shim such that a thickness of the shim is chosen based on the plurality of dimensions. 
     Other aspects and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The described embodiments may be better understood by reference to the following description and the accompanying drawings. Additionally, advantages of the described embodiments may be better understood by reference to the following description and accompanying drawings in which: 
         FIGS. 1A and 1B  show a perspective view and front view of an electronic device, in accordance with some embodiments. 
         FIGS. 2A and 2B  shows section views of button assemblies, in accordance with some embodiments. 
         FIGS. 3A-3C  show perspective views of different brackets as part of button assemblies, in accordance with some embodiments. 
         FIGS. 4A and 4B  show perspective views of a bracket being assembled with a noise dampening coverlay, in accordance with some embodiments. 
         FIGS. 5A-5C and 6A-6C  show perspective views of brackets being assembled with noise dampening overmolds using two different manufacturing processes, in accordance with some embodiments. 
         FIG. 7  shows perspective and section views of a bracket trim with interlocking features, in accordance with some embodiments. 
         FIGS. 8A-8D  show four different brackets having noise dampening overmolds formed thereon, in accordance with some embodiments. 
         FIG. 9  shows a flowchart illustrating a process for forming a button assembly that includes a noise dampener, in accordance with some embodiments. 
         FIGS. 10A and 10B  show a button assembly that includes a shim, in accordance with some embodiments. 
         FIGS. 11A and 11B  show a button assembly that includes a shim with an alignment feature, in accordance with some embodiments. 
         FIG. 11C  show section views of alignment features of shims, in accordance with some embodiments. 
         FIG. 12A  shows a section view of a button assembly that includes customized shim, in accordance with some embodiments. 
         FIGS. 12B-12D  show section views of a switch as part of the button assembly of  FIG. 12A . 
         FIG. 13  shows a flowchart illustrating a process for forming a customized shim of a button assembly, in accordance with some embodiments. 
         FIG. 14  shows a flowchart illustrating a process for forming a button assembly that includes a customized shim, in accordance with some embodiments. 
     
    
    
     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, they are 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. 
     Described herein are button assemblies and methods for manufacturing button assemblies as part of electronic devices. According to some embodiments, the button assemblies include one or more sound improvement features to improve the sound that the button assemblies make when pressed by a user. According to other embodiments, the button assemblies include one or more shims that provide proper alignment of the various components of the button assemblies and/or to accommodate any tolerance stack up of the various components of the button assemblies. According to some embodiments, the button assemblies include a combination of sound improvement features and shims. 
     The methods described herein are well suited for providing robust and aesthetically appealing button assemblies for consumer electronic products, such as those manufactured by Apple Inc., based in Cupertino, Calif. In particular embodiments, the methods are used to form button assemblies for exterior portions of computers, portable electronic devices and/or accessories for electronic devices. 
     These and other embodiments are discussed below with reference to  FIGS. 1-13 ; however, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. 
       FIGS. 1A and 1B  show a perspective view and front view, respectively, of an electronic device  100  having one or more button assemblies in accordance with some embodiments. Electronic device  100  includes housing  102  that is configured to house multiple internal electronic components. In some embodiments, electronic device  100  is a portable phone capable of providing telephonic communication for a user of electronic device  100 . In some embodiments, electronic device  100  includes one or more wireless communication antenna(s) within housing  102  for providing wireless communication to and/or from electronic device  100 . Display  104  is configured to display output from electronic device  100  to a user. In some embodiments, display  104  includes a touch screen assembly configured to accept touch input from a user. 
     Electronic device  100  can include a menu button or home button  106 , power button  112 , mute button  108 , and volume buttons  110 . In some embodiments, the exterior surface of display  104  corresponds to a glass or plastic cover that covers all or a majority of a front side of electronic device  100 . In this way, home button  106  can be positioned within an opening of the glass or plastic cover. In some embodiments, portions of the glass or plastic cover are transparent or translucent to allow viewing of an underlying display assembly. Power button  112 , mute button  108 , and volume buttons  110  can be positioned within side portions of electronic device  100 . In some embodiments, these side portions of electronic device  100  are made of a metal, plastic and/or ceramic material. 
     Although embodiments herein make reference to electronic device  100 , which can be in the form of a mobile phone, this is for illustrative purposes only and it should be appreciated that the button assemblies provided herein can be used in any suitable electronic device such as a tablet computing device, a laptop computing device, a user interface device, a media player, a wearable computing device, and/or any suitable electronic device having one or more button assemblies. 
     As described above, some embodiments described herein involve forming sound improvement features in the button assemblies in order to improve the sound that the button assemblies make when pressed by a user. These embodiments are described in detail below with respect to  FIGS. 2-9 . In some embodiments, the button assemblies include one or more shims that can be used to align various components of the button assemblies. The shims can have alignment features to prevent shifting of the shims. These embodiments are described in detail below with respect to  FIGS. 10 and 11 . In some embodiments, methods for providing customized shims to accommodate varying tolerance stack ups of the components of the button assemblies are described. These embodiments are described in detail below with respect to  FIGS. 12 and 13 . Note that one or more of the sound improvement features and shim features described below can be combined within a single button assembly. 
       FIGS. 2A and 2B  show section views a button assembly  200  in accordance with described embodiments. In some embodiments, button assembly  200  corresponds to a home button, such as home button  106  described above with reference to in  FIGS. 1A and 1B . It should be understood, however, that the noise dampening features described below with reference to  FIGS. 2A and 2B  can be implemented with any suitable button assembly and it not limited to a home button as shown in  FIGS. 1A and 1B . 
       FIG. 2A  shows button assembly  200 , which includes switch module  202  assembled within an opening  208  of housing  204 . Housing  204  can correspond to an exterior surface of the electronic device. In some embodiments, housing  204  corresponds to a cover, such as a transparent glass or plastic cover, as part of a display portion of an electronic device. Switch module  202  includes can include a stack up of different components that assure proper functionality of button assembly  200 . For example, switch module  202  includes a switch such that when a user presses button  206 , the switch is activated. In some embodiments, switch module  202  is designed to give a user a distinctive “click” feel when button  206  is pressed. 
     Bracket  210  supports switch module  202  within opening  208  and is coupled to housing  204 . Bracket  210  includes trim  212  that define a perimeter of bracket  210 . When button  206  is pressed, trim  212  of bracket  210  moves away from impact surface  216 . When button  206  is released, trim  212  moves back in direction  214  toward housing  204 . As a result, trim  212  contacts housing  204  at impact surface  216 . In some cases, the impact of trim  212  to impact surface  216  can cause an audible sound for a user of the device. The sound will depend on a number of factors, including the material of trim  212  and housing  204 . In a particular embodiment, trim  212  is made of a metal material, such as stainless steel or an aluminum alloy, and housing  204  is made of a glass material, resulting in a high-pitched tinging sound. In some cases, this high-pitched tinging sound can be undesirable. 
     In order to reduce the amount of audible sound of button assembly  200 , such as a high-pitched tinging sound, one or more noise dampening features can be implemented. FIG.  2 B shows button assembly  200  after noise dampener  218  is implemented in accordance with described embodiments. Dampener  218  is positioned between trim  212  of bracket  210  and impact surface  216  of housing  204 . Dampener  218  can be made of a compliant material such that when trim  212  moves in direction  214  toward housing  204 , dampener  218  reduces or eliminates noise associated with trim  212  contacting impact surface  216 . In some cases, this can provide a more pleasing sound to a user when button  206  is pressed. In some embodiments, dampener  218  is made of a plastic, silicone and/or rubber material. In some embodiments, dampener  218  is coupled to trim  212 . In other embodiments, dampener  218  is coupled to impact surface  216  of housing  204 . In other embodiments, multiple dampeners  218  are coupled to both trim  212  and impact surface  216 . Dampener  218  can be adhered onto trim  212  and/or impact surface  216  using any suitable mechanism, including molding or use of an adhesive. 
       FIGS. 3A-3C  show perspective views of different brackets  300 ,  310  and  320 , respectively, in accordance with described embodiments. Note that the shapes of brackets  300 ,  310  and  320  can vary depending on application requirement and are not limited to having the rounded rectangular perimeter shown in  FIGS. 3A-3C . For example, the brackets can have a round, elliptical, square, triangular, or irregular shaped perimeter. Brackets  300 ,  310  and  320  can each be configured to support a switch module when a user applies a pressing force to the switch module. As such, brackets  300 ,  310  and  320  can each be made of a sufficiently rigid material for withstanding such pressing force without too much give, such as a metal material like stainless steel or rigid aluminum alloy. 
       FIG. 3A  shows bracket  300 , which includes trim  302  that defines a perimeter of bracket  300 . Trim  302  can be also referred to as a lip or flange of bracket  300 . Bracket  300  includes bezel  306  that protrudes above surface  304  of trim  302  and that includes opening  308  configured to accommodate a switch module or a portion of a switch module. Bezel  306  and opening  308  can have any suitable shape and are not limited to the round shapes shown in  FIG. 3A . Surface  304  of trim  302  is uncovered and can contact a housing portion, such as impact surface  216  of housing  204  if impact surface  216  is not covered with a dampener. As such, a button assembly having bracket  300  can provide an audible noise when a user presses on the button assembly. 
       FIG. 3B  shows bracket  310 , which has similar features as bracket  300 . In particular, bracket  310  includes trim  312  and bezel  316 , which includes opening  318  for accommodating a switch module. Bracket  310  additionally includes coverlay  319  that covers at least a portion of surface  314  of trim  312 . As shown in  FIG. 3B , coverlay  319  can be formed in two sections  319   a  and  319   b , each covering opposing sides of trim  312 . It should be noted that coverlay  319  can have any suitable number of sections. For example, coverlay can be formed in four sections that cover each corner  315   a ,  315   b ,  315   c  and  315   d  of trim  312 . In one embodiment, coverlay  319  is a single piece that covers substantially all of surface  314 . Coverlay  319  acts as a noise dampening feature that is positioned between trim  312  and a corresponding impact surface of a housing to dampen the noise associated with the trim  312  coming in contact with the impact surface of the housing. 
     Coverlay  319  can be made of any suitable material including plastic, silicone, rubber, fabric, or combination thereof, and can be coupled to surface  314  using any suitable method. In some embodiments, coverlay  319  is made of a material that is flexible, capable of remaining flat when adhered onto surface  314 , and remains chemically stable when exposed to thermal processes. In a particular embodiment, coverlay  319  is made of a polyimide material that is adhered onto surface  314  using an epoxy adhesive. In some embodiments, coverlay  319  is adhered onto surface  314  using a vacuum lamination operation to assure that coverlay  319  is conformally and securely applied to surface  314 . Examples of suitable methods for manufacturing coverlay  319  and assembling coverlay  319  onto bracket  310  are described in detail below with respect to  FIGS. 4A and 4B . 
       FIG. 3C  shows bracket  320 , which has similar features as bracket  300 . In particular, bracket  320  includes trim  322  and bezel  326 , which includes opening  328  for accommodating a switch module. Bracket  320  additionally includes overmold  329  that covers at least a portion of surface  324  of trim  322 . As shown in  FIG. 3C , overmold  329  can be formed in four sections  329   a ,  329   b ,  329   c  and  329   d , each covering corners  325   a ,  325   b ,  325   c  and  325   d  of trim  322 , respectively. However, overmold  329  can have any suitable number of sections. In one embodiment, overmold  329  is a single piece that covers substantially all of surface  324 . Like coverlay  319 , overmold  329  can act as a noise dampening feature that is positioned between trim  322  and a corresponding impact surface of a housing to dampen the noise associated with the trim  322  coming in contact with the impact surface of the housing. 
     Overmold  329  can be made of any suitable overmold material, including plastic materials. In some embodiments, overmold  329  is made of polyether ether ketone (PEEK), polyphenylsulfone (PPSU), a combination of PEEK/PPSU, or polyphthalamide (PPA). In some embodiments, overmold  329  is formed of a plastic material that includes a stiffening agent, such as glass filler. In a particular embodiment, overmold  329  is made of a PEEK/PPSU mix with about 30% glass filler. In another particular embodiment, overmold  329  is made of a PPA material with glass filler. The choice of material will depend on application requirements. 
     The shape of overmold  329  can be accomplished using any suitable method, including an injection molding process. During the injection molding process, overmold  329  is deposited onto surface  324  in molten form and allowed to harden. In some embodiments, overmold  329  is shaped by injecting the molten material in a mold with a cavity that has a shape that gives overmold  329  a desired shape. In other embodiments, overmold  329  is shape after hardened onto surface  324 . In some embodiments, one or more engagement features  317  are formed on surface  324  for overmold  329  to engage with and secure overmold  329  to trim  322 . Overmold can be made of any suitable material including plastic, silicone, rubber, fabric, or combination thereof. Examples of suitable methods for manufacturing overmold  329  and assembling overmold  329  onto bracket  320  are described in detail below with respect to  FIGS. 5-7 . 
       FIGS. 4A and 4B  show perspective views of bracket  400  being assembled with noise dampening coverlay  404  in accordance with some embodiments. At  FIG. 4A , coverlay  404  is shaped to match the shape of trim  406 . In some embodiments, the thickness of coverlay  404  is selected to match trim  406  dimensions of binned brackets  400  having a defined trim  406  thickness in order to achieve tight tolerances in the final button assembly. In some embodiments, the shape of coverlay  404  is achieved using a punching process where coverlay  404  is cut with a punching tool in punch direction  414  such that any burrs that may form do not stick upwards to create a non-flat datum surface. 
     At  FIG. 4B , coverlay  404  is adhered onto surface  408  of trim  406  using adhesive  410 . If coverlay  404  is formed using a punch process, coverlay  404  is oriented such that any burrs formed during the punch process are positioned proximate surface  408 . In some embodiments, a vacuum lamination process is used in order to assure conformal adherence of coverlay  404  to surface  408 . As shown in inset  416 , coverlay  404  can be cut to be offset a distance  418  from an edge of trim  406  to assure that there is no overhang of coverlay  404 . 
     In embodiments involving an overmold, a number of manufacturing processes can be used in order to form a suitable noise dampening overmold.  FIGS. 5A-5C and 6A-6C  shows two different brackets formed using different overmolding processes. In particular,  FIGS. 5A-5C  show bracket  500  formed using an overmolding process without the use of a co-machining operation.  FIGS. 6A-6C  show bracket  600  formed using an overmolding process involving a co-machining process. 
       FIG. 5A  shows bracket  500  after a pre-machining process is performed. During the pre-machining process engagements features  504   a ,  504   b ,  504   c  and  504   d  are formed at corners  502   a ,  502   b ,  502   c  and  502   d  of bracket  500 . Bezel  512 , which protrudes above surface  506  can be formed prior to or during the pre-machining process for forming engagements features  504   a - 504   d . Engagements features  504   a - 504   d  can be recessed or protruding portions on surface  506  of trim  508  that are configured to accommodate and engage with portions of an overmold. In some embodiments, engagement holes  510  are additionally formed within surface  506  to also accommodate and engage with portions of an overmold. In some embodiments, engagement holes  510  are formed all the way through trim  508  and have undercut geometries. These embodiments will be described in detail below with reference to  FIG. 7 . Note that any suitable number of engagement features  504   a - 504   d  and engagement holes  510  can be used. In addition, the location and shapes of engagement features  504   a - 504   d  and engagement holes  510  can vary depending on design choice. 
       FIG. 5B  shows bracket  500  after overmold  514  is molded onto bracket  500 , including on surface  506  and bezel  512 . In some embodiments, a perimeter of overmold  514  is offset with respect to a perimeter of trim  508  leaving a portion  516  of trim  508  exposed. This offset can be provided to assure that overmold  514  does not overhang over surface  506 . At  FIG. 5C , overmold  514  is cut to such that sections  514   a ,  514   b ,  514   c  and  514   d  positioned at corners  504   a - 504   d  remain. Overmold  514  can be cut using any suitable mechanism, including suitable CNC machining procedures. 
       FIGS. 6A-6C  shows an alternative method for forming an overmold on bracket compared to as described above with reference to  FIGS. 5A-5C .  FIG. 6A  shows bracket  600  after a pre-machining process where engagements features  604   a  and  604   b  are formed within surface  606  of trim  608 . Bezel  610 , which protrudes above surface  606  can be formed prior to or during the pre-machining process for forming engagements features  604   a  and  604   b . Bracket  600  can be oversized compared to a final shape such that portions of bracket  600  can be removed during a subsequent co-machining process. 
     Engagement features  604   a  and  604   b  can be recessed or protruding portions on surface  606  of trim  608  that are configured to accommodate and engage with portions of an overmold. In some embodiments, engagement holes  602  are provided within surface  606  to accommodate and engage with portions of an overmold. In some embodiments, engagement holes  602  are formed all the way through trim  608  and have undercut geometries. The number, size and shapes of engagement features  604   a  and  604   b  and engagements holes  602  can vary depending on design requirements. Note that bracket  600  has a roughly round perimeter and does not yet have corners of a final shape. In some embodiments, flat portion  612  is formed as a reference for subsequent machining processes. 
     At  FIG. 6B , overmold  612  is molded over at least a portion of surface  606 . Overmold  612  can be oversized such that portions of overmold  612  can be removed during a subsequent co-machining process. Any suitable molding technique can be used, including an injection molding process. At  FIG. 6C , bracket  600  and overmold  614  are co-machined forming corners  616   a ,  616   b ,  616   c  and  616   d  into bracket  600 . In addition, overmold  614  is cut into sections  614   a ,  614   b ,  614   c  and  614   d  positioned at respective corners  616   a - 616   d . Bracket  600  and overmold  614  can be shaped using any suitable mechanism, including suitable CNC machining procedures. Since bracket  600  and overmold  614  are co-machined, overmold  614  need not be offset with respect to trim  608 , thereby achieving a tight tolerance. Thus, in some cases, the manufacturing methods described with reference to  FIGS. 6A-6C  may be preferred over the methods described with reference to  FIGS. 5A-5C . 
     As described above, in some embodiments, an overmold is formed within engagement holes formed within a trim of a bracket. To illustrate,  FIG. 7  shows a perspective view and section view of bracket trim  700  showing engagement holes  702  formed therein. Overmold material  704  molds into and engages with the sidewalls  706  of holes  702 , thereby securing overmold  704  to trim  700 . In some embodiments, sidewalls  706  of engagement holes  702  have an undercut geometry to withstand forces separating overmold  704  from within engagement holes  702 , thereby locking overmold  704  to trim  700 . In this way, engagement holes  702  can be referred to as interlocking features. 
     As described above, overmolds can have any number of sections and have any shape suitable for acting as a noise dampener. To illustrate,  FIGS. 8A-8D  show brackets having different patterns of noise dampening overmolds formed thereon in accordance with some embodiments.  FIG. 8A  shows bracket  800 , which includes trim  806  with engagement features  802  and engagement holes  804 . Overmold  808  is formed in four sections along corners of trim  806 . Overmold  808  is secured to trim  806  by engagement features  802  and engagement holes  804 .  FIG. 8B  shows bracket  810 , which includes trim  816  with engagement features  812  and engagement holes  814 . Overmold  818  is formed in four sections along corners of trim  816  and is secured to trim  816  by engagement features  802  and engagement holes  804 . As shown, overmold  818  and engagement features  812  have different shapes and are in different locations compared to overmold  808  and engagement features  802  of bracket  800 . 
       FIG. 8C  shows bracket  820 , which includes trim  826  with engagement features  822  and engagement holes  824 . Overmold  828  is formed in four sections along corners of trim  826  and is secured to trim  826  by engagement features  822  and engagement holes  824 . As shown, engagement features  822  have different shapes compared to the engagement features of brackets  800  and  810 .  FIG. 8D  shows bracket  830 , which includes trim  836  with engagement features  832  and engagement holes  834 . Overmold  838  is formed in two sections along opposing sides of trim  836  and is secured to trim  836  by engagement features  832  and engagement holes  834 . Note that the number and pattern of overmolds, engagement features, and engagement holes shown in  FIGS. 8A-8D  are illustrative of a few embodiments and are not meant to limit the scope of possible combinations and configurations. 
       FIG. 9  shows flowchart  900  illustrating a process for forming a button assembly that includes a noise dampener, in accordance with described embodiments. At  902 , a bracket for supporting a switch module of a button assembly for an electronic is formed. The bracket can be positioned within an opening of a housing for the electronic device. The bracket includes a trim with a surface that contacts the housing when a user of the electronic device presses the switch module. The bracket and housing can each be made of hard material such that when the trim contacts the housing an audible noise is created. 
     At  904 , a dampener is positioned between the surface of the bracket and an impact surface of the housing. The dampener can be in the form a thin layer of material made of a sufficiently compliant material to reduce the audible noise. In some embodiments, the dampener is made of a plastic material. The dampener can be in the form of a coverlay that is adhered to the surface of the trim using an adhesive or can be in the form of an overmold that is molded onto the surface of the trim. 
     As described above, the button assemblies described herein can include one or more shims used to align various components of the button assemblies.  FIGS. 10A and 10B  show section views of a portion of button assembly  1000 , which includes shim  1002  positioned between bracket  1004  and switch  1006 . Switch  1006  is configured to provide an electrical connection button assembly  1000  and an electrical component of the electrical device that is associated with button assembly  1000 . In particular, shim  1002  is positioned within recess  1008  if bracket  1004 . The sidewalls of recess  1008  constrain shim  1002  with respect to bracket  1004  when button assembly  1000  is fully assembled. Bracket  1004  can be configured to support a switch module of button assembly  1000 . In some embodiments, thickness  1010  of bracket  1004  is minimized so as to minimize a stack up thickness of button assembly  1000 . Shim  1002  is generally a thin piece of material used to align or accommodate for dimensional tolerance differences between different components of a button assembly. In some cases, shim  1002  can reduce play of the button assembly and improve reliability of the button assembly. Shim  1002  of button assembly  1000  can be made of any suitable material having sufficient rigidity for retaining its general shape when a pressing force is applied to switch  1006 . In some embodiments, shim  1002  is made of a metal material, such as stainless steel or hard aluminum alloys. 
     One problem associated with the configuration of button assembly  1000  is that although shim  1002  is positioned within recess  1008 , the sidewalls of recess  1008  may not be enough to constrain shim  1002  with respect to bracket  1004  and shim  1002  can shift within recess. In some embodiments, an adhesive applied between bracket  1004  and shim  1002  to help stabilize shim  1002 . Another disadvantage of the configuration of button assembly  1000  relates to assembly of button assembly  1000 . To illustrate,  FIG. 10B  shows button assembly  1000  during an assembly operation, with shim  1002  being positioned within recess  1008  of bracket  1004 . Since in some embodiments thickness  1010  of bracket  1004  is minimized, recess  1008  recesses a small distance  1012  within bracket  1004 . In a particular embodiment distance  1012  is about 0.1 mm. Thus, during assembly, it may be difficult to detect when shim  1002  is positioned askew relative to recess  1008 , as shown in  FIG. 10B . If shim  1002  is not properly seated within recess  1008  during subsequent assembly procedures, this could have detrimental consequences including scrapping of the button assembly  1000 . 
     To address the limitation of a button assembly configuration described above with reference to  FIGS. 10A and 10B , some embodiments include a shim that has an alignment feature.  FIGS. 11A and 11B  show button assembly  1100  that includes shim  1102  with an alignment feature  1112 , in accordance with some embodiments. Shim  1102  is configured to be positioned between bracket  1104  and switch  1106 . In some cases, shim  1102  can reduce play of the button assembly  1100  and improve reliability of the button assembly  1100 . Switch  1106  is configured to provide an electrical connection button assembly  1100  and the electrical device that is associated with button assembly  1100 . Bracket  1104  is configured to support switch  1106  with respect to a housing of the electronic device. Alignment feature  1112  corresponds to a protruding portion or pin that protrudes from a base of shim  1102  and is configured to fit within recess  1108  of bracket  1104 . Since shim  1102  is positioned within recess  1108 , this prevents shim  1102  from shifting during the manufacture and/or operation of button assembly  1100 . In some embodiments, recess  1108  corresponds to a hole that is formed through the thickness  1110  of bracket  1104 . Shim  1102  can be made using any suitable manufacturing process, including a turning process (similar to the way screws are made) or a forging process. 
     Since alignment feature  1112  constrains the position of shim  1102  with respect to bracket  1104 , no sidewalls, or very small sidewall, are needed. This can reduce the thickness  1110  of bracket  1104  compared to thickness  1010  of bracket  1004  shown in  FIGS. 10A and 10B . In addition, the configuration of button assembly  1100  can provide more reliable assembly compared to button assembly  1000 . To illustrate,  FIG. 11B  shows button assembly  1100  during an assembly operation, with shim  1012  being positioned within recess  1108  of bracket  1104 . When shim  1102  is positioned askew relative to recess  1108  and bracket  1104 , as shown in  FIG. 11B , shim  1102  will be positioned at a more extreme angle compared to shim  1002  of  FIG. 10B . Thus, misalignment of shim  1102  will be more easily detected during the manufacturing process, reducing the potential of scraping of parts. 
       FIG. 11C  shows different possible shapes of alignment feature  1112  of shim  1102  as viewed from section line A-A. As shown, alignment feature  1112  can have any suitable shape, including a round  1114 , square  1116 , rectangular  1118 , elliptical  1120 , or triangular  1122  shape. The shape of recess  1108  would have a corresponding shape. For example, a shim  1112  having a round  1114  shape will have a correspondingly round shaped recess. In some embodiments it is preferable for alignment feature  1112  to have a round  1114  shape. This round  1114  shape can give shim  1102  a mushroom shaped appearance. The round  1114  shape can prevent interaction of shim  1102  with switch  1106  during operation that can damage switch  1106 . The round  1114  shape can also allow easy location and fit of shim  1102  within recess  1108  since the orientation of shim  1102  would not matter. In other embodiments, shim  1102  has a square  1116 , rectangular  1118 , elliptical  1120 , or triangular  1122  shape to assure the shim  1112  is positioned within recess  1108  at a predetermined orientation with respect to bracket  1104 . 
     In some embodiments, the surface quality of shim  1102  is important. For example, in some cases it may be preferable for shim  1102  to have a very smooth surface where shim  1102  contacts bracket  1104  allowing for less frictional force between shim  1102  and bracket  1104 . This can be achieved, for example, by buffing or plating surfaces of shim  1102  with a smooth coating. In a particular embodiment, an electrophoresis method is used to electrolytically deposit an electrophoretic coating on surfaces of shim  1102 . The electrophoretic coating can be made of an electrophoretic paint or ink. In a particular embodiment, multiple shims  1102  are formed using a forging process such that the multiple shims  1102  are attached to a sheet of material. The sheet having the multiple shims  1102  then undergoes an electrophoresis process to coat the multiple shims  1102  at once. The individual shims  1102  can then be broken out into separated shims  1102  with the electrophoretic coatings intact. In other embodiments, it is preferable for shim  1102  to have a matt or blasted surface to provide good engagement with the bracket  1104 . The different textures, i.e., smooth or matt, can provide different feels to the switching mechanism of button assembly  1100 . 
     As described above, in some embodiments the shims are customized to accommodate varying tolerance stack ups of the components of button assemblies. Tolerance stack up refers to the cumulative effect of variations in dimensions of individual components of a button assembly that cause an overall variation in the button assembly compared to other button assemblies within a product line. A particular problem associated with button assemblies is that tolerance stack ups can cause each button assembly to have a different “feel”. The feel of a button assembly can refer to, among other things, an amount of applied pressure necessary to cause activation of the button assembly, an amount of depression of the button assembly when pressed, and a return force of the button assembly after being pressed. Providing a shim that is customized for each button assembly can compensate for variations due tolerance stack up and provide a product line of button assemblies where each button assembly has substantially the same feel. 
       FIG. 12A  shows a section view of a button assembly  1200  that includes a customized shim in accordance with some embodiments. Button assembly  1200  includes shim  1202 , switch  1204 , bracket  1206  and button  1208 , which are positioned within housing  1210 . Housing  1210  includes bore holes  1212  which align with holes  1214  of bracket  1206  to accommodate fasteners that fasten bracket  1206  to housing  1210 . Housing  1210  also includes an indented region, which includes an opening for accommodating button  1208 . Button  1208  corresponds to an exterior user interface of button assembly  1200  and is configured for a user to press. Switch  1204  is configured to provide an electrical connection between button assembly  1200  and an electrical component of the electrical device that is associated with button assembly  1200 . For example, switch  1204  can control a volume or a power (on/off switch), or correspond to a menu or home button of the device. Shim  1202  is positioned between switch  1204  and button  1208  and within pocket  1209  of button  1208 . 
     Switch  1204 , bracket  1206 , and button  1208  each have tolerances associated with them during the manufacturing process such that when assembled together could lead to an unacceptable amount of tolerance stack up. In a particular embodiment, the tolerances in switch  1204 , bracket  1206 , and button  1208  can lead to a combined stack up tolerance of about 0.2 mm. If shim  1202  is too thin, one or more of switch  1204 , bracket  1206 , button  1208 , and shim  1202  can shift during operation of button assembly  1200  causing button assembly  1200  to have a loose feel and/or to malfunction. If shim  1202  is too thick, this can detrimentally affect the amount of preload for button assembly  1200 , which can detrimentally affect the feel of button assembly  1200 . In addition, different button assemblies will have varying amount of combined stack up tolerances, leading to inconsistent button assembly functionality. 
     To address this problem, shim  1202  is configured to accommodate varying thicknesses of one or more of switch  1204 , bracket  1206 , and button  1208 . In particular, a customized thickness  1216  of shim  1202  is chosen to accommodate the stack up tolerance variations. Choosing thickness  1216  prevents shifting of one or more of switch  1204 , bracket  1206 , button  1208 , and/or shim  1202  during operation of button assembly  1200 . In addition, providing a shim  1202  that is customized for each button assembly  1200  will result in a product line of button assemblies  1200  that have a consistent feel and performance. 
     In order choose thickness  1216  of shim  1202 , multiple measurements are taken with respect to datum surfaces of housing  1210 , bracket  1206 , switch  1204 , and button  1208 . According to some embodiments, three measurements are taken: first distance  1219 , second distance  1221  and third distance  1223 . In particular, a first distance  1219  between datum surface  1218  of bracket  1206  and first datum surface  1220  of button  1208  is measured. In some embodiments, first distance  1219  is determined by measuring a distance between a surface of housing  1210  that engages with button  1208  (corresponding to datum surface  1220 ) and a surface of housing  1210  that engages with bracket  1206  (corresponding to datum surface  1218 ). In one embodiment datum surface  1218  is defined by a surface on bracket proximate hole  1214 , and first datum surface  1220  is defined by a surface of flange  1222  of button  1208 . Flange  1222  can be configured to engage with housing  1210  when button assembly  1200  is fully assembled. A second distance  1221  between datum surface  1218  of bracket  1206  and datum surface  1224  of switch  1204  is measured. In one embodiment, datum surface  1224  is defined by a top surface of switch  1204 . Second distance  1221  can correspond to a height of switch  1204 . A third distance  1223  between first datum surface  1220  of button  1208  and second datum surface  1226  of button  1208  is measured. In one embodiment, second datum surface  1226  is defined by a surface within pocket  1209  of button  1208 . 
     Once first distance  1219 , second distance  1221 , and third distance  1223  are measured, a customized thickness  1216  of shim  1202  can be calculated so as to be thick enough to provide an optimal amount of preload for button assembly  1200  yet thin enough to prevent shifting of one or more of switch  1204 , bracket  1206 , button  1208 , and shim  1202 . In one embodiment, thickness  1216  of shim  1202  can be calculated to provide a predetermined amount of preload force to provide a particular feel for button assembly  1200 . In some embodiments, it is preferable to apply pressure on button assembly  1200  while the measurements are performed. For example, switch  1204  can have gaps related to air can get trapped inside the mechanism of switch  1204  when pressure is not applied. 
       FIGS. 12B-12D  show section views of switch  1204  before and after applying a preload force. In the embodiments shown in  FIGS. 12B-12D , switch  1204  has a dome-type switch mechanism. Note that other types of switches with different mechanisms may also be used. Switch  1204  includes base  1230 , dome  1232 , nub  1234  and membrane  1236 . Base  1230  can correspond to a rigid support that supports dome  1232 . Dome  1232  can correspond to a flexible and resilient material or combination of materials. Nub  1234  can be a rigid body that adds height to switch  1234 . Membrane  1236  can correspond to a flexible film or membrane that positions nub  1234  with respect to dome  1234 . Membrane  1236  can seal internal regions of switch  1236  such that a sealed cavity  1231  is formed. 
       FIG. 12B  shows switch  1204  without an applied preload force. As shown, gap  1238  can form between dome  1232  and nub  1234 . Gap  1238  can be caused by air or other gas that gets trapped within cavity  1231  of switch  1204  during assembly. In some cases, gap is formed when the air or gas expands due to exposure of switch  1204  to a higher temperature than surroundings where switch  1204  was assembled. As a result of gap  1238 , switch  1204  has a first height  1221   a . At  FIG. 12C , a first amount of preload force F 1  is applied to switch  1204 , which reduces gap  1238 . In  FIG. 12C , first amount of preload force F 1  is sufficient to close gap  1238  such that nub  1234  contacts dome  1232 . Applying first amount of preload force F 1  reduces the height of switch  1204  to a first reduced height  1221   b . At  FIG. 12D , a second amount of preload force F 2  is applied to switch  1204 . Second amount of preload force F 1  is larger than preload force F 1  and not only closes gap  1238  but also compresses dome  1232  to a certain amount. Applying second amount of preload force F 2  further reduces the height of switch  1204  to a second reduced height  1221   c . Note that once the first amount or the second amount of preload forces F 1  and F 2  are removed, dome  1232  can spring back into its original dome shape, thereby providing the backpressure for returning switch  1204  to its original position (e.g.,  FIG. 12B ). 
     Thus, the amount of force applied to switch  1204  can result in switch  1204  having different heights. In addition, different amounts of preload force can be associated with giving a different feel of switch  1204  when assembled within button assembly  1200 . In order to provide a consistent feel to the button assembly  1200 , a predetermined amount of preload force can be applied prior to measurement. That is, the same amount of preload is applied to each switch  1204  to provide a consistent feel to the switch  1204  and to the button assembly  1200 . For example, the predetermined amount of preload can correspond to F 1  or F 2 , described above. In some embodiments, the amount of preload force is small, on the order of 5 to 10 grams. Thus, pressing on switch  1204  with a predefined small load (e.g., 5-10 grams) can provide more consistent measurement results. Any suitable mechanism can be used to apply the preload load, including applying a mass of predetermined weight, using an actuator to press onto switch  1204 , or using a non-contact air blast to apply the pressure. 
       FIG. 13  shows flowchart  1300  illustrating a high-level process for forming a customized shim of a button assembly, in accordance with some embodiments. At  1302 , a number of dimensions of the button assembly associated with a feel of the button assembly are measured. As described above, dimensions of the button assembly associated with a feel of the button assembly can include a dimension of the switch while a predetermined preload force is applied to the switch. In some embodiments, the predetermined preload force can be associated with an amount of depression of button assembly when pressed, for example, by a user of the button assembly. In some embodiments, the predetermined preload force can be associated with an amount of applied pressure necessary to cause activation of the switch. In some embodiments, the predetermined preload force can be associated with a return force of the button assembly after being pressed. In some embodiments, the predetermined preload force is associated with two or more of the amount of depression, the amount of applied pressure necessary to cause switch activation, and the return force. 
     Other dimensions of the button assembly that can be measured include a dimension of an indented region of a housing for the electronic device. As described above, the indented region can be configured to accommodate the button assembly. Another dimension that can be measured includes one or more dimensions related to a pocket of the button assembly. As described above, the pocket can be configured to accommodate and position the shim with respect to the switch. At  1304 , a customized shim having a thickness based on the measured dimensions is formed. As described above, using a customized shim for each button assembly can provide for a product line of button assemblies that have substantially the same feel when pressed by a user of the electronic devices. 
       FIG. 14  shows flowchart  1400  illustrating a process for forming a button assembly that includes a customized shim, in accordance with some embodiments. At  1402 , a first distance between a datum surface of the bracket and a first datum surface of the button is measured. In some embodiments, the first distance is determined by measuring a distance between a two surfaces of an indented region of a housing where the button assembly is to be positioned. In one embodiment, the button includes a flange configured to engage with a housing of the electronic device and a surface of the flange defines the first datum surface of the button. At  1404 , a second distance between the datum surface of the bracket and a datum surface of the switch is measured. At  1406 , a third distance between the first datum surface of the button and a second datum surface of the button is measured. In one embodiment, the button includes a pocket configured to position the shim therein and a surface of the pocket defines the second datum surface of the button. 
     In some embodiments, the first, second, and third distances are measured using a computer measurement device, such as a computer that is coupled to a vision or imaging system that can detect surfaces and other visual markers. At  1408  a thickness of the shim is chosen based on the first distance, the second distance and the third distance. For example, a computer can calculate an optimal thickness for the shim so as to provide a predetermined amount of preload and minimum shifting of the button assembly. The shim can then be formed to have the chosen distance and positioned between the switch and the button during manufacture of the button assembly. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling manufacturing and/or assembly operations or as computer readable code on a computer readable medium for controlling a manufacturing/assembly line. The computer readable storage medium is any data storage device that can store data, which can thereafter be read by a computer system. Examples of the computer readable storage medium include read-only memory, random-access memory, CD-ROMs, HDDs, DVDs, magnetic tape, and optical data storage devices. The computer readable storage medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     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 specific embodiments are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the described 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: 20141125
Publication Date: 20171003
Grant Date: 20171003
Priority Date: 20140905
Inventors: COHEN SAWYER I.
CATER TYLER B.
RAMMAH MARWAN
ZHANG YAOCHENG
HUO EDWARD S.
SHAH DHAVAL N.
MYERS SCOTT A.
KATIYAR VIVEK
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H2221/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/062", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/064", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/52", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2221/08", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/064", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/062", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/52", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/705", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 55438139