PATENT DOCUMENT

Publication Number: US-9891100-B2
Application Number: US-201314051207-A
Country: US
Kind Code: B2

Title: Electronic device having light sensor package with diffuser for reduced light sensor directionality

Abstract:
An electronic device display may have a display cover layer. The cover layer may have a border that has an opaque masking material with an opening defining a light window for an ambient light sensor. The ambient light sensor may have a photodetector mounted in a light sensor housing. A molded clear plastic light diffuser may be used to diffuse light for the ambient light sensor that is passing through the light window. The light diffuser may reduce directionality in the ambient light sensor. The light diffuser may have an array of molded protrusions such as flat-topped cones. Alignment features may be formed in the light sensor housing and the light diffuser. Clips and other molded structures for attaching the light sensor to a mounting bracket or other structures may be molded into the light diffuser and light sensor housing.

Claims:
What is claimed is: 
     
       1. Apparatus, comprising:
 a light sensor housing; 
 a photodetector in the light sensor housing; 
 a plastic light diffuser that diffuses light entering the light sensor housing and that has first and second opposing surfaces, wherein the plastic light diffuser comprises an array of light scattering features formed on the first surface and mounting clips that extend from the second surface, and wherein the array of light scattering features and the mounting clips are integrally formed as a single plastic member; and 
 a support structure, wherein the plastic diffuser is interposed between the light sensor housing and the support structure, and wherein the support structure comprises openings through which the mounting clips extend to attach the plastic light diffuser to the support structure. 
 
     
     
       2. The apparatus defined in  claim 1  wherein the array of light scattering features comprises flat-topped protrusions. 
     
     
       3. The apparatus defined in  claim 2  wherein the flat-topped protrusions include flat-topped cones. 
     
     
       4. The apparatus defined in  claim 1  wherein the array of light scattering features includes depressions in the plastic light diffuser. 
     
     
       5. The apparatus defined in  claim 1  wherein the plastic light diffuser comprises a compression-molded clear polymer film. 
     
     
       6. The apparatus defined in  claim 1  wherein the plastic light diffuser comprises injection-molded clear plastic. 
     
     
       7. The apparatus defined in  claim 1  wherein the light sensor housing comprises a first shot of injection molded plastic and wherein the plastic light diffuser comprises a second shot of injection molded plastic that is overmolded over the first shot of injection molded plastic. 
     
     
       8. The apparatus defined in  claim 1  wherein the plastic light diffuser has alignment features selected from the group consisting of: alignment protrusions and alignment recesses. 
     
     
       9. The apparatus defined in  claim 1  wherein the light sensor housing has a first set of alignment features and wherein the plastic light diffuser has a mating second set of alignment features to align the light diffuser to the light sensor housing. 
     
     
       10. The apparatus defined in  claim 1  wherein the support structure comprises a metal bracket and wherein the mounting clips are received in the openings to attach the plastic light diffuser to the metal bracket. 
     
     
       11. An electronic device, comprising:
 a display having a display cover layer coated with an opaque masking layer that has a light window; 
 an ambient light sensor aligned with the light window; and 
 a molded light diffuser for the ambient light sensor that diffuses light passing to the ambient light sensor through the light window, wherein the molded light diffuser has a planar surface through which the light enters the molded light diffuser and a second surface opposite the planar surface that has an array of molded protrusions comprising flat-topped cones with circular bases through which the light exits the molded light diffuser, wherein each flat-topped cone with a circular base has an angled surface and a flat surface, wherein a first portion of the light that enters the molded light diffuser along an axis exits the molded light diffuser along the axis through the flat surface, and wherein a second portion of the light that enters the molded light diffuser at an angle to the axis is redirected towards the ambient light sensor by the angled surface as the second portion exits the molded light diffuser. 
 
     
     
       12. The electronic device defined in  claim 11 , wherein a first angled surface of a first flat-topped cone with a circular base in the array meets a second angled surface of a second flat-topped cone with a circular base in the array at a point on the second surface. 
     
     
       13. The electronic device defined in  claim 11 , wherein the molded light diffuser comprises mounting clips that extend from the planar surface, and wherein the array of molded protrusions and the mounting clips are integrally formed as a single plastic member. 
     
     
       14. A light sensor, comprising:
 a light sensor housing; 
 a photodetector in the light sensor housing, wherein the light sensor housing comprises a rear portion on which the photodetector is mounted and housing walls that extend from the rear portion to surround the photodetector; and 
 a molded light diffuser that diffuses light passing to the photodetector, wherein the molded light diffuser has a first surface with molded flat-topped protrusions through which the light exits the molded light diffuser and a second surface opposite the first surface that defines a first plane through which the light enters the molded light diffuser, wherein each molded flat-topped protrusion has an angled surface and a flat surface, wherein a first portion of the light that enters the molded light diffuser along an axis exits the molded light diffuser along the axis through the flat surface, and wherein a second portion of the light that enters the molded light diffuser at an angle to the axis is redirected towards the photodetector by the angled surface as the second portion exits the molded light diffuser. 
 
     
     
       15. The light sensor defined in  claim 14  wherein the molded flat-topped protrusions comprise flat-topped cones. 
     
     
       16. The light sensor defined in  claim 15  wherein the light diffuser includes molded clips. 
     
     
       17. The light sensor defined in  claim 14 , wherein the molded light diffuser comprises alignment holes in the first surface and the light sensor housing comprises alignment protrusions that extend into the alignment holes to mount the molded light diffuser to the light sensor housing.

Description:
BACKGROUND 
     This relates generally to light sensors and, more particularly, to structures for diffusing light for light sensors in electronic devices. 
     Electronic devices often include light sensors. For example, light sensors can be used to make ambient light measurements. An electronic device may use ambient light data to control display brightness under a variety of ambient lighting conditions. 
     If care is not taken, ambient light sensors may exhibit different sensitivities for incoming light from different directions. This directionality is generally not desired in an ambient light sensor, as it can make a device overly sensitive to its orientation relative to concentrated light sources rather than being responsive to the overall level of ambient light in the vicinity of the sensor. 
     To reduce directionality, an ambient light sensor may be provided with a diffuser. The diffuser is typically formed from a polymer film that is coated with acrylic beads. The film is attached to the ambient light sensor using pressure sensitive adhesive, which can lead to assembly challenges due to potential misalignment during attachment, difficulty in removing backing material from the pressure sensitive adhesive, and other handling issues. 
     It would therefore be desirable to be able to provide improved ways to diffuse light for a light sensor within an electronic device. 
     SUMMARY 
     An electronic device may be provided with a display having a display cover layer. The display may have a central rectangular active area surrounded by a ring-shaped inactive border area. The underside of the display cover layer in the inactive border area may be coated with an opaque masking material such as black ink. An opening may be formed in the opaque masking material to define a light window for incoming ambient light. 
     An ambient light sensor may be mounted within the electronic device in alignment with the light window to receive and measure the incoming ambient light. The light sensor may have a photodetector mounted in a light sensor housing. A molded clear plastic light diffuser may be used to diffuse light that is entering the light sensor housing through the light window and that is passing to the photodetector. The light diffuser may reduce the directionality of the ambient light sensor. 
     The light diffuser may be formed using compression molding techniques or injection molding techniques. During molding, light scattering features such as bumps, pits, ribs, and channels may be molded into the plastic of the light diffuser. For example, an array of light scattering features such as an array of flat-topped protrusions or an array of flat-bottomed depressions may be formed. The light scattering features may by rotationally symmetric features such as flat-topped cones to help minimize directionality. 
     The light diffuser may be overmolded over the light sensor housing. Alignment features may be formed in the light sensor housing and the diffuser and clips and other molded structures for attaching the light sensor to a mounting bracket or other support structures may be molded into the light diffuser and light sensor housing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of an illustrative electronic device such as a handheld computing device of the type that may be provided with one or more light sensors in accordance with an embodiment. 
         FIG. 2  is a cross-sectional side view of an illustrative electronic device of the type shown in  FIG. 1  showing how the electronic device may be provided with an ambient light sensor in accordance with an embodiment. 
         FIG. 3  is a cross-sectional side view of a portion of an electronic device that has a light sensor such as an ambient light sensor in which light is being diffused into the light sensor in accordance with an embodiment. 
         FIG. 4  is graph showing how the presence of a light diffuser such as a molded light diffuser in a light sensor such as an ambient light sensor reduces light sensor directionality in accordance with an embodiment. 
         FIG. 5  is a perspective view of an illustrative molded diffuser having an array of protrusions such as flat-topped cones that may be used to diffuse light in a light sensor such as an ambient light sensor in accordance with an embodiment. 
         FIG. 6  is a cross-sectional side view of a diffuser of the type shown in  FIG. 5  showing how angled light may be diffused so as to strike a photodetector in accordance with an embodiment. 
         FIG. 7  is a cross-sectional side view of an illustrative diffuser with pointed protrusions that may be used to diffuse light in a light sensor such as an ambient light sensor in accordance with an embodiment. 
         FIG. 8  is a cross-sectional side view of an illustrative diffuser with flat-topped diffuser protrusions that may be used to diffuse light in a light sensor such as an ambient light sensor in accordance with an embodiment. 
         FIG. 9  is a cross-sectional side view of an illustrative diffuser with flat-topped diffuser protrusions that are separated from each other by flat areas on the surface of the diffuser in accordance with an embodiment. 
         FIG. 10  is a cross-sectional side view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with rounded protrusions in accordance with an embodiment. 
         FIG. 11  is a cross-sectional side view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with protrusions that have rough surfaces in accordance with an embodiment. 
         FIG. 12  is a top view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with flat-topped circular cone shaped diffuser protrusions in accordance with an embodiment. 
         FIG. 13  is a top view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with flat-topped elliptical cone shaped diffuser protrusions in accordance with an embodiment. 
         FIG. 14  is a top view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with flat-topped square pyramidal shaped diffuser protrusions in accordance with an embodiment. 
         FIG. 15  is a top view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with flat-topped hexagonal pyramidal shaped diffuser protrusions in accordance with an embodiment. 
         FIG. 16  is a perspective view of an illustrative diffuser of the type that may be formed from a molded clear plastic structure with an array of depressions in accordance with an embodiment. 
         FIG. 17  is a perspective view of an illustrative diffuser structure for a light diffuser of the type that may be formed from a molded clear plastic structure with raised ribs in accordance with an embodiment. 
         FIG. 18  is a perspective view of an illustrative diffuser structure for a light diffuser of the type that may be formed from a molded clear plastic structure with channels in accordance with an embodiment. 
         FIG. 19  is a top view of an illustrative light diffuser for a light sensor such as an ambient light sensor having light diffuser structures such as rib and channel structures of the types shown in  FIGS. 17 and 18  arranged in a random pattern of orientations to diffuse light in accordance with an embodiment. 
         FIG. 20A  is a cross-sectional side view of a compression molding system with rollers for embossing a polymer film to create a diffuser in accordance with an embodiment. 
         FIG. 20B  is a cross-sectional side view of a portion of the rollers and polymer film of  FIG. 20A  showing how the polymer film may be provided with protrusions using depressions in the rollers in accordance with an embodiment. 
         FIG. 20C  is a system diagram of illustrative equipment for forming a light diffuser for an ambient light sensor such as an injection molding tool of the type that may be used to create a molded diffuser structure in accordance with an embodiment. 
         FIG. 21  is a flow chart of illustrative steps involved in forming structures for an ambient lights sensor such as diffuser structures and light sensor housing structures in accordance with an embodiment. 
         FIG. 22  is a diagram showing equipment and operations that may be used in forming an ambient light sensor with an integral molded diffuser in accordance with an embodiment. 
         FIG. 23  is a cross-sectional side view of an illustrative light diffuser that has been formed from clear plastic overmolded onto a metal frame or other structure in accordance with an embodiment. 
         FIG. 24  is a perspective view of an illustrative light sensor such as an ambient light sensor that has an opaque light sensor housing with alignment features such as posts that mate with corresponding alignment features such as alignment holes in a molded diffuser in accordance with an embodiment. 
         FIG. 25  is a cross-sectional side view of an illustrative light sensor housing with standoff posts that create a gap between an associated molded diffuser and the upper surface of the light sensor housing in accordance with an embodiment. 
         FIG. 26  is a cross-sectional side view of an illustrative light sensor in which a molded diffuser has alignment features for aligning the diffuser with respect to a light sensor housing and has engagement features for attaching the diffuser to a mounting bracket in accordance with an embodiment. 
         FIG. 27  is a perspective view of an illustrative light sensor such as an ambient light sensor having an opaque housing and an overmolded clear diffuser with integrated alignment ribs of the type that may be used to align the light sensor with respect to a mounting bracket in accordance with an embodiment. 
         FIG. 28  is a cross-sectional side view of an illustrative light sensor housing having features that interlock with overmolded light diffuser plastic to secure a molded light diffuser to the light sensor housing during plastic molding operations in accordance with an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Electronic devices may be provided with light sensors. Light sensors may be used in proximity sensors, as stand-alone ambient light sensors, as optical input devices, as part of multi-sensor arrays, or in other portions of an electronic device. Configurations in which a light sensor is used as an ambient light sensor in an electronic device are sometimes described herein as an example. This is, however, merely illustrative. Light sensors may be used for any suitable application in an electronic device. 
     An illustrative electronic device of the type that may be provided with a light sensor is shown in  FIG. 1 . An electronic device such as electronic device  10  of  FIG. 1  may be computing device such as a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a smaller device such as a wrist-watch device, a pendant device, a headphone or earpiece device, or other wearable or miniature device, a television, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system such as a system in which electronic equipment with a display is mounted in a kiosk or automobile, equipment that implements the functionality of two or more of these devices, or other electronic equipment. In the illustrative configuration of  FIG. 1 , device  10  is a portable device such as a cellular telephone, media player, tablet computer, or other portable computing device. Other configurations may be used for device  10  if desired. The example of  FIG. 1  is merely illustrative. 
     Device  10  may have one or more displays such as display  14  mounted in housing structures such as housing  12 . Housing  12  of device  10 , which is sometimes referred to as a case, may be formed of materials such as plastic, glass, ceramics, carbon-fiber composites and other fiber-based composites, metal (e.g., machined aluminum, stainless steel, or other metals), other materials, or a combination of these materials. Device  10  may be formed using a unibody construction in which most or all of housing  12  is formed from a single structural element (e.g., a piece of machined metal or a piece of molded plastic) or may be formed from multiple housing structures (e.g., outer housing structures that have been mounted to internal frame elements or other internal housing structures). 
     Display  14  may be a touch sensitive display that includes a touch sensor or may be insensitive to touch. Touch sensors for display  14  may be formed from an array of capacitive touch sensor electrodes, a resistive touch array, touch sensor structures based on acoustic touch, optical touch, or force-based touch technologies, or other suitable touch sensor components. 
     Display  14  for device  10  includes display pixels formed from liquid crystal display (LCD) components or other suitable display pixel structures such as organic light-emitting diode display pixels, electrophoretic display pixels, plasma display pixels, etc. The display pixels may be arranged in an array having numerous rows and columns to form rectangular active area AA of  FIG. 1 . Rectangular active area AA may be located in the center of device  10  and may be surrounded by inactive border regions such as inactive area IA. 
     A display cover layer may cover the surface of display  14  or a display layer such as a color filter layer (e.g., a layer formed from a clear substrate covered with patterned color filter elements) or other portion of a display may be used as the outermost (or nearly outermost) layer in display  14 . The outermost display layer may be formed from a transparent glass sheet, a clear plastic layer, or other transparent member. To hide internal components from view, the underside of the outermost display layer or other display layer surface in inactive area IA may be coated with an opaque masking layer such as a layer of black ink. If desired, openings may be formed in the outermost layer of display  14  (e.g., in inactive area IA) to accommodate components such as button  16  and speaker port  18  of  FIG. 1  (as examples). Buttons, connector ports, and other structures may also be accommodated using openings in housing  12 . 
     One or more light sensors may be incorporated into device  10 . For example, light sensors may be mounted behind openings in the sidewalls or rear wall of housing  12 . As shown in  FIG. 1 , display  14  may have a region within inactive area IA such as area  20  under which one or more light sensors may be mounted. The opaque masking layer in area  20  may, if desired, be provided with a light window (e.g., an opening in the black ink layer or other light-transmitting window structure). The light window may allow light to pass through display  14  to reach a light sensor that is mounted within housing  12  in alignment with the light window. If desired, a light window for a light sensor may be formed from a laser-drilled hole or other opening in housing  12  or other portions of device  10 . 
     A cross-sectional side view of electronic device  10  of  FIG. 1  is shown in  FIG. 2 . The cross-section of  FIG. 2  is taken through a portion of inactive area IA containing window region  20  of  FIG. 1 . As shown in  FIG. 2 , the underside of display cover layer  22  may be provided with a layer of opaque masking material  26  such as black ink. Black ink  26  may be patterned to form a rectangular opening to permit light from the array of display pixels in active area AA to escape outwards from the front face of device  10 . Black ink  26  may also be patterned to form light window  24 . Light sensor  30  may be aligned with light window  24 , so that light  28  that passes through light window  24  can be measured. 
     Light sensor  30  may have a housing. The housing may be formed from plastic, metal, or other materials. A light sensitive electrical component such as photodetector  32  may be mounted within the bottom portion of the light sensor housing. Photodetector  32  is a semiconductor device (e.g., a silicon device) that senses light and produces a corresponding electrical signal that can be processed by control circuitry within device  10 . 
     Electrical contacts associated with photodetector  32  and light sensor  30  may be soldered to a printed circuit such as flexible printed circuit  34 . Flexible printed circuit  34  may be attached to printed circuit board connector  36 . Printed circuit board connector  36  may be coupled to metal signal line traces within printed circuit  40 . Printed circuit  40  may be a rigid printed circuit board (e.g., a printed circuit formed from fiberglass-filled epoxy) or may be a flexible printed circuit (e.g., a flex circuit formed from a sheet of polyimide or other flexible polymer layer). 
     Electrical components  38  may be mounted on printed circuit board  40 . Components  38  may include integrated circuits, connectors, sensors, light-emitting components, audio components, discrete devices such as inductors, capacitors, and resistors, switches, and other electrical devices. If desired, light sensor  30  may be mounted on other substrates (e.g., a rigid printed circuit board, an injection molded plastic substrate with conductive traces, a layer of ceramic or glass, or other substrate). The configuration of  FIG. 2  in which light sensor  30  has been mounted to flexible printed circuit  34  is merely illustrative. 
     As shown in  FIG. 3 , light sensor  30  may be used to gather and measure off-axis ambient light  28 . Off-axis light is light such as light ray  28  that is directed towards device  10  at a non-zero angle A with respect to device front face surface normal  50 . Surface normal  50  is perpendicular to the plane of the front and rear surfaces of display cover layer  22  and is perpendicular to the plane of the front and rear faces of light diffuser  46  (i.e., light diffuser  46  may line in a plane parallel to the plane of display cover layer  22 ). 
     Light diffuser  46  diffuses incoming light and thereby reduces the directionality of sensor  30 . Diffuser  46  helps enhance off-axis sensitivity, so that ambient light measurements accurately reflect the overall amount of ambient light surrounding electronic device  10 , rather than measuring incoming light mainly from a particular direction. 
     Diffuser  46  may be mounted on the top of light sensor housing  44  (and may therefore be considered to form the upper surface of the light sensor housing). Diffuser  46  may be attached to light sensor housing  44  using adhesive, using fasteners such as screws, using clips or other engagement features, or other attachment mechanisms. If desired, diffuser  46  may be overmolded onto light sensor housing  44 . For example, diffuser  46  and light sensor housing  44  may be formed from separate shots of plastic in a plastic injection molding process. Light sensor housing  44  may be formed from an opaque material such as black plastic to prevent stray light from entering the sidewalls or rear (lower) wall of housing  44 . Diffuser  46  may be formed from clear plastic or other material that is transparent to light  28 . Photodetector  32  may be light sensitive component for measuring the intensity of incoming light  28  and may be mounted at the bottom of light sensor housing  44  or elsewhere in the structures that form light sensor  30 . 
     Electronic device housing  12  may contain internal housing structures such as mounting brackets, midplate structures, rails, frames, and other support structures. For example, housing  12  may contain a support structure such as support structures  42  to help support and mount components such as light sensor  30  within device  10 . Support structures  42  may be formed from a metal member (e.g., a metal bracket structure) or other structures. 
     Support structures  42 , which may sometimes be referred to as a bracket or support member, may have one or more openings such as opening  48 . Opening  48  may be aligned with light window  24  in opaque masking layer  26  to ensure that light  28  can reach diffuser  46 . Once incoming ambient light  28  strikes diffuser  46 , the incoming light is diffused. Some of the diffused light reaches photodetector  32  and is converted into a light detector signal for processing by control circuitry within device  10  (e.g., control circuitry in one or more integrated circuits among electronic devices  38  on printed circuit  40  of  FIG. 2 ). If desired, other mounting arrangements may be used for light sensor  30  (e.g., arrangements in which light sensor  30  is aligned with an opening in housing  12 , etc.). The use of bracket  42  to help secure light sensor  30  and/or other structures within device housing  12  in alignment with light window  24  on display cover layer  22  is merely illustrative. 
       FIG. 4  is a graph showing how the electrical sensor output signal from light sensor  30  varies as a function of incoming light angle A for light passing through light window  24 . Angle A represents the angular deviation for the incoming light from surface normal  50  of  FIG. 3 . 
     Line  52  of  FIG. 4  corresponds to the expected response of a light sensor without a light diffuser. In this situation, on-axis light is efficiently collected and measured by the light detector, but off-axis light (i.e., light at an angle greater than angle L or less than angle −L) is not efficiently collected and therefore cannot contribute to an ambient light measurement. The narrow acceptance angle of the sensor associated with solid line  52  (i.e., the relatively high directionality of this type of sensor) may create inaccuracies when attempting to make ambient light measurements for the environment surrounding an electronic device. 
     Line  54  of  FIG. 4  corresponds to the response of a light sensor that includes light diffuser  46 . In this situation, on-axis light is collected slightly less efficiently than the on-axis light collected by the sensor associated with line  52  because some of the on-axis light is diffused away from photodetector  32 . However, off-axis light collection efficiency is significantly improved due to the ability of light diffuser  46  to diffuse some of the off-axis light towards photodetector  32 . The improved off-axis performance of a light sensor with light diffuser  46  is indicated by the significantly larger sensor output associated with incoming light angles between L and M and between −L and −M. The use of light diffuser  46  therefore helps reduce directionality and makes light sensor  30  less sensitive to orientation when making ambient light measurements. 
     A perspective view of an illustrative configuration for light diffuser  46  of light sensor  30  is shown in  FIG. 5 . As shown in  FIG. 5 , diffuser  46  may have a planar substrate portion  46 F from which protrusions  46 P in an array of protrusions  46 P protrude outwardly. When light diffuser  46  is installed in device  10 , protrusions  46 P may protrude downwardly towards photodetector  32  (as an example). 
     Protrusions  46 P may have the shape of flat-topped cones as shown in  FIG. 5  or may have other shapes suitable for directing incoming off-axis light rays such as ray  28  at angle. A downwards in vertical direction −Z towards photodetector  32  in light sensor housing  44 . Cones are rotationally symmetric, which helps ensure that light diffuser  46  will exhibit low directionality. The flat tops in flat-topped cones  46 P of  FIG. 5  help ensure that on-axis light can be sensed and will not be unnecessarily scattered. 
     Protrusions  46 P may be arranged in a two dimensional array having multiple rows and columns (e.g., tens or hundreds of rows and columns or more) or may be arranged in other patterns on the surface of substrate portion  46 F. The material that is used in forming protrusions  46 P and substrate portion  46 F may be a clear polymer such as polyethyleneterephthalate (PET) or polycarbonate (PC) or other transparent material. Compression molding techniques, injection molding techniques, or other techniques may be used in forming diffuser  46 . Substrate portion  46 F and molded light scattering features such as protrusions  46 P or other arrays of molded light scattering features may be formed as parts of a single integral plastic member or may, if desired, be formed using two or more separate plastic structures. Configurations in which diffuser  46  is formed from a molded plastic member are sometimes described herein as an example. In general, any suitable structures may be used in forming a structure that diffuses light for light sensor  30 . 
       FIG. 6  is a cross-sectional side view of diffuser  46  of  FIG. 5  showing how incoming light rays may be directed towards photodetector  32  of light sensor  30 . As shown in  FIG. 6 , the presence of protrusions  46 P on substrate portion  46 F of diffuser  46  give rise to angled protrusion surfaces  54  (e.g., the sides of the flat-topped cones in configurations in which protrusions  46 P are flat-topped cones). Diffuser  46  also has flat protrusion surfaces  56  on protrusions  46 P and has flat substrate areas  52  on substrate portion  46 F that are formed from the spaces between respective protrusions  46 P. The flat regions on substrate portion  46 F such as flat areas  52  allow incoming light rays such as vertical light ray  28 - 1  and similar nearly vertical rays to pass through diffuser  46  and reach photodetector  32 . Likewise, the flat regions on protrusions  46 P such as flat areas  56  allow incoming light rays such as vertical light ray  28 - 2  and similar nearly vertical light rays to reach photodetector  32 . Angled protrusion surfaces such as the angled surfaces in areas  54  are angled at non-zero angles with respect to surface normal  50  and therefore tend to direct light rays such as angled light ray  28 - 4  downwards towards photodetector  32 . Some angled light rays such as angled light ray  28 - 3  strike flat areas such as areas  52  and  56  and tend to pass through detector  30  without being deflected towards photodetector  32 . Nevertheless, the presence of protrusions  46 F and angled protrusion surfaces  54  can help increase the amount of off-axis light reaching photodetector  32 , as illustrated by off-axis light ray  28 - 4 . 
     In the illustrative example of  FIG. 5 , diffuser  46  was provided with protrusions  46 P that have the shape of flat-topped cones. If desired, diffuser  46  may have other shapes.  FIG. 7  is a cross-sectional side view of diffuser  46  showing how protrusions  46  may have sharp tips  58 . In the illustrative configuration of  FIG. 8 , protrusions  46 P have been provided with flat tops and are spaced relatively close to each other. As shown in  FIG. 9 , protrusions  46 P with flat tops may be spaced apart from each other to create flat areas  52  between the protrusions on substrate portion  46 F. As described in connection with  FIG. 6 , the inclusion of flat diffuser areas such as areas  56  and  52  helps ensure that on-axis light rays reach photodetector  32 . 
     If desired, protrusions  46 P may have rounded profiles, as shown in  FIG. 10 .  FIG. 11  shows how protrusions  46 P may be provided with surface roughness features  60  (i.e., undulations, pits, bumps, and other surface features with dimensions that can be significantly smaller than the dimensions of protrusions  46 P or other primary light scattering features in light diffuser  46 ). 
     Other types of protrusions  46 P may be used in diffuser  46  if desired. Moreover, protrusions  46 P may be formed on the upper surface of diffuser  46 , on the lower surface of diffuser  46 , or on both the upper and lower surfaces of diffuser  46 . Protrusions  46  may have circular footprints (i.e., circular outlines when viewed from above along vertical dimension −Z ( FIG. 5 ) or may have footprints of other suitable shapes. In the illustrative top view of  FIG. 12 , diffuser  46  has been formed from an array of flat-topped cones having circular footprints.  FIG. 13  is a top view of an illustrative diffuser in which protrusions  46 P have elliptical footprints. In the  FIG. 14  example, protrusions  46 P have been formed from flat-topped pyramidal structures having square footprints. Pyramidal-type structures may also be formed using footprints with other shapes (see, e.g., the flat-topped hexagonal pyramidal protrusions  46 P of  FIG. 15 ). 
     If desired, depressions (e.g., pits, channels, or other recesses) may be formed in substrate  46 F to serve as light scattering features for diffuser  46 . As shown in  FIG. 16 , for example, diffuser  46  may have an array of molded light scattering features such as an array of circular depressions  46 D with flat bottoms  56  and angled sidewall surfaces  54 . Depressions  46 D may have other shapes (e.g., flat-bottomed cones with elliptical footprints, flat-bottomed pyramidal depressions with footprints that are square, rectangular, hexagonal, or other shapes, depressions with roughened surfaces, depressions with curved sidewalls, etc.). 
     Some or all of the surface(s) of diffuser  46  may be provided with laterally elongated protrusions such as ribs  46 R of  FIG. 17  or laterally elongated depressions such as channels  46 C of  FIG. 18 . To ensure that diffuser  46  exhibits minimal directionality, the surface of diffuser  46  may be provided with a randomly oriented patchwork of channels and/or grooves as shown in the top view of illustrative diffuser  46  of  FIG. 19 . In the example of  FIG. 19 , a combination of ribs and grooves form diffuser  46 . If desired, diffuser  46  can contain only ribs or only grooves (e.g., ribs or grooves arranged in random orientations as shown in  FIG. 19 ). 
       FIG. 20A  shows how diffuser material can be formed using molding techniques. In the example of  FIG. 20A , compression molding equipment is formed from a pair of rollers  62 . Polymer film  60  is fed through rollers  62  in direction  70 . Rollers  62  rotate about rotational axes  64  in directions  66 . Polymer film  60  is initially featureless. Rollers  62  preferably contain pits, bumps, grooves, channels, or other protrusions and/or depressions for creating corresponding surface features on one or both of the opposing surfaces of polymer film  60 . During compression molding operations, film  60  is received between rollers  62  and corresponding compression molded polymer film  68  exits rollers  62  in direction  70 . 
       FIG. 20B  is a detailed view of the surfaces of rollers  62  in an illustrative configuration in which rollers  62  contain depressions  72 . With this type of arrangement, compression molded polymer film  68  contains corresponding diffuser protrusions  46 P (e.g., flat-topped conical protrusions or protrusions of other shapes). If desired, protrusions  46 P may be formed on only one side of film  68 . The configuration of  FIG. 20B  in which protrusions  46 P have been formed on opposing upper and lower surfaces of film  68  is shown as an example. After forming compression-molded film  68 , film  68  may be divided into individual diffuser pieces. Diffusers such as diffuser  46  may, for example, be formed from die cut portions of molded film  68 . If desired, compression molding operations may be used to form surface features in molded polymer material  68  with other shapes. The example of  FIG. 20B  is merely illustrative. 
       FIG. 20C  shows how injection molding techniques may be used to form diffuser  46 . Initially, polymer beads  78  may be stored in hopper  74 . When it is desired to form diffuser  46 , the polymer beads may be heated to form molten polymer material that is injected into the interior (mold cavity) of injection molding die  76 . Die  76  may have flat-bottomed depressions for forming a diffuser with flat-topped protrusions  46 P or may have other suitable shapes for forming a desired injection-molded diffuser. 
     Illustrative steps involved in forming diffusers using a molding process such as an injection molding process are shown in  FIG. 21 . 
     At step  80 , molten plastic may be injection molded into a mold die such as die  76  of  FIG. 20C . The cavity in the mold die has the shape of a desired diffuser  46 . After cooling the molten plastic at step  82  and removing the cooled part from the mold die at step  84 , one or more additional optional shots of molten plastic may be injection molded (e.g., to form additional portions of light sensor  30 ), as shown by line  88 . As an example, all or part of sensor housing walls  44  may be injection molded (overmolded) onto molded diffuser  46  or molded diffuser  46  may be formed by injection molding clear plastic material onto sensor housing walls  44 . If desired, a photodetector device, sensor leads, and other structures may be incorporated into molded parts during molding (i.e., sensor components can be partly covered with molten plastic during insert molding operations). Injection molded light sensor structures may be assembled with other structures to form electronic device  10  during the operations of step  86 . If desired, a combination of injection molded parts and compression molded parts may be used in forming light sensor  30 . For example, sensor housing  44  may have injection molded walls and diffuser  46  may be formed using compression molding techniques, etc. In this type of situation, the plastic of sensor housing  44  may be molded to diffuser  46 . Molding operations that include three or more molded light sensor structures and/or material that is machined or otherwise patterned to form diffuser and housing structures may also be used. Adhesive, interlocking engagement features such as clips, fasteners, plastic welds, and other attachment techniques may be used in addition to or instead of using multiple shots of plastic to attach portions of light sensor  30  together. Injection molding techniques that involve heating plastic sufficiently to melt the plastic are preferably formed from thermoplastic materials (i.e., materials that can be placed in a molten state by application of heat). If desired, plastic structures for diffuser  46  and/or light sensor housing  44  may be formed using a mold die to define a desired shape for a thermoset material (e.g., a liquid polymer that is cured to form solid diffuser and/or housing structures using heat or ultraviolet light curing). The molding operations of  FIG. 21  are merely illustrative. 
       FIG. 22  is a system diagram showing how light sensor  30  may be formed using molding techniques. In the example of  FIG. 22 , molding tool  90  (e.g., an injection molding tool) may be used to form light sensor housing  44 . Light sensor housing  44  may, for example, be formed from an opaque plastic such as injection molded black plastic. Light sensor housing  44  may have the shape of an opened-top box or other suitable shape. The U-shaped walls of housing  44  in  FIG. 22  correspond to an illustrative light sensor housing cross section for an open-topped cube-shaped box. In the example of  FIG. 22 , housing walls  44  are formed before mounting photodetector  32  within housing walls  44  using sensor mounting tool  92  (e.g., a computer-controlled positioner or other mounting tool). If desired, molding tool  90  may be used to injection mold plastic for housing structures  44  around the sides of photodetector  32  (i.e., around a semiconductor die or a semiconductor package with protruding leads on which a semiconductor die can be mounted). For example, molding techniques may be used to allow the leads for the package to protrude through the rear of housing wall  44 . Openings may also be formed in housing wall  44  when molding housing wall with tool  90  to accommodate photodetector terminals. After forming light sensor housing structure  44  and mounting photodetector  32  within housing wall  44 , molding tool  94  may be used to mold clear plastic for diffuser  46  onto sensor  30 . For example, molding tool  94  may overmold clear plastic for diffuser  46  onto housing walls  44  to create an internal cavity  98  that includes photodetector  32 , as show in  FIG. 22 . A molded light diffuser may also be attached to housing walls  44  using adhesive, clips or other engagement features, fasteners, welds, etc. 
     If desired, plastic overmolding operations for light sensor structures such as light sensor housing  44  and diffuser  46  may involve molding plastic material over one or more preformed structures such as metal structures, carbon fiber composite structures or other fiber composites, glass structures, ceramic structures, or other structures. As shown in  FIG. 23 , for example, diffuser  46  may be formed from clear plastic that is overmolded over structures  96 . Structures  96  may be support structures such as one or more metal brackets or other metal members (see, e.g., support structures  42  of  FIG. 3 ), may be internal frame members, metal midplate structures or other structural housing members (e.g., parts of housing  12  of device  10 ), other internal structures in device  10 , or other structures. If desired, light sensor housing structures  44  may be overmolded over structures  96 . To facilitate mounting of structures  96  in device  10 , structures  96  may include screw holes, engagement features such as prongs and openings for clips, springs, and other engagement structures. Structures  96  may be formed by machining, stamping (e.g., using a die press), laser processing techniques, or other techniques. 
       FIG. 24  is a perspective view of an illustrative configuration for light sensor structures such as light sensor housing  44  and diffuser  46 . In the illustrative arrangement of  FIG. 24 , light sensor housing  44  has an open-topped box shape that defines an internal cavity such as cavity  98 . Photodetector  32  may be located at the bottom of cavity  98 . 
     Diffuser  46  may be attached to the top of light sensor housing  44  to form light sensor  30 . Adhesive, plastic welds, interlocking engagement features, screws or other fasteners, injection molding, or other attachment mechanisms may be used to attach diffuser  46  to light sensor housing  44 . In the example of  FIG. 24 , light sensor  44  and diffuser  46  have mating alignment features. Light sensor housing  44  has protrusions such as alignment posts  44 P and diffuser  46  has corresponding alignment holes  100 . There are four alignment posts  44 P and four associated alignment holes  100  in the example of  FIG. 24 . This is merely illustrative. Light sensor housing  44  may have one or more alignment posts, two or more alignment posts, three or more alignment posts, or other suitable number of alignment posts. Diffuser  46  may have one or more alignment holes, two or more alignment holes, three or more alignment holes, or other suitable number of alignment holes. Configurations for light sensor housing  44  and diffuser  46  in which diffuser  46  is provided with one or more alignment protrusions such as one or more alignment posts and in which light sensor housing  44  is provided with one or more mating alignment holes may also be used. If desired, light sensor housing  44  may have both alignment protrusions (e.g., cylindrical alignment posts or other alignment posts) and alignment recesses (e.g., cylindrical alignment holes or other alignment holes) and diffuser  46  may have a corresponding set of alignment recesses and alignment protrusions. For example, if light sensor housing  44  contains M alignment posts and N alignment holes, diffuser  46  may contain M mating alignment holes and N mating alignment posts. Alignment features based on ribs, channels, and other features may also be used. Interlocking alignment features (sometimes referred to as engagement features) may be used both to align housing  44  and diffuser  46  with respect to each other and to attach housing  44  and  46  together. 
       FIG. 25  is a cross-sectional side view of an illustrative configuration for light sensor  30  in which alignment protrusions  44 P have been configured to serve as standoffs that create a separation such as gap G between lower surface  102  of diffuser  46  and upper surface  104  of light sensor housing  44 . Alignment protrusions  44 P of  FIG. 25  may be alignment posts with a cylindrical cross-sectional shape, a square cross-sectional shape, or other suitable cross-sectional shape. Alignment posts  44 P of  FIG. 25  may be received within mating alignment recesses such as alignment holes  100  in diffuser  46 . 
     Features may be formed in diffuser  46  and/or housing  44  of light sensor  30  to facilitate alignment and attachment to other device structures. Consider, as an example, the arrangement of  FIG. 26 . In the example of  FIG. 26 , diffuser  46  has been provided with engagement features (mounting and alignment features) such as integral alignment ridges  46 L and integral alignment and mounting clips  46 G. 
     Light sensor housing  44  may have a box shape. Ridges  46 L may be formed on the lower surface of diffuser  46  in a configuration that receives the upper portion of light sensor housing  44  (as an example). Other alignment features may be formed as part of diffuser  46  and/or light sensor housing  44  if desired (e.g., alignment recesses and/or alignment protrusions of the type described in connection with  FIG. 25 ). 
     Clips  46 G may extend upward from diffuser  46  in alignment with mating openings in structures  42 . Structures  42  may be a metal structure such as a metal mounting bracket or other metal member or may be formed from other materials (e.g., plastic support structure material, glass, ceramic, fiber composite material, etc.). Clips  46 G may include wedge-shaped tips  108 . Tips  108  may have lower surfaces  106 . The main body of diffuser  46  may have opposing upper surfaces  110 . When clips  46 G are inserted upwards through the holes in bracket  42 , the angled surfaces of wedges  108  bear against the sides of the holes in structures  42 , thereby bending clips  46 G outwards in directions  116 . Diffuser  46  may be formed from a plastic material that is resilient (i.e., a material that springs back into its original shape after being bent). Once the wedge-shaped tips  108  of clips  46 G have passed through the holes in bracket  42  sufficiently that the angled surfaces of clips  46 G no longer bear against structures  42 , clips  46 G will spring back in directions  118 , thereby locking bracket  42  in place between opposing downwards-facing diffuser alignment surfaces such as clip surfaces  106  and upwards-facing diffuser alignment surfaces  110 . The use of these alignment surfaces and resilient (elastic) clip structures  46 G mounts diffuser  46  to bracket  46  with a desired alignment. If desired, clip structures of this type may be used in attaching diffuser  46  to housing  44 . Diffuser  46  may be attached to light sensor housing  44  using adhesive, fasteners such as screws, additional clips such as clips  46 G, or other attachment mechanisms or may be joined with light sensor housing  44  by molding diffuser  46  to light sensor housing  44  or by molding light sensor housing  44  to diffuser  46 . These techniques may also be used in attaching diffuser  46  to structures  42 . 
     Light sensor housing  44  may be electrically connected to a substrate such as substrate  200 . Electrical connections between light sensor  30  and substrate  200  may be formed from welds, conductive adhesive, solder, fasteners, connectors, or other conductive connections. Substrate  200  may be dielectric substrate formed from glass, ceramic, molded plastic, or other dielectric material. For example, substrate  200  may be a rigid printed circuit board formed from a rigid printed circuit board material such as fiberglass-filled epoxy or may be a flexible printed circuit such as a flex circuit formed from a sheet of polyimide or a layer of other flexible polymer. In the illustrative example shown in  FIG. 26 , light sensor  30  has been soldered to flexible printed circuit  200  (e.g., a flex circuit such as flex circuit  34  of  FIG. 2 ) so that light sensor  30  may move in upwards direction Z to bear against structures  42 . Biasing structure  202  may be interposed between the lower surface of flexible printed circuit  200  and an opposing inner surface of housing  12  or other housing structure. Biasing structure  202  may include compressed springs, compressed foam, other structures that press flexible printed circuit  200  and light sensor  30  upwards in direction Z. The biasing force provided by optional biasing structure  202  may help ensure that light sensor  30  is accurately seated in position relative to structures  42  and is properly aligned with respect to light window opening  24  in opaque masking layer  26  and the corresponding opening in structures  42  (i.e., opening  48 ) 
     Downwardly extending alignment protrusions  46 L of  FIG. 26  may have the shape of posts (e.g., four posts at four respective corners of light sensor housing  44 ), may have the shape of alignment rails that run across opposing edges of light sensor housing  44 , or may have other shape for receiving light sensor housing  44  (e.g., interlocking alignment posts and holes or other engagement features, etc.). 
       FIG. 27  is a perspective view of light sensor  30  showing how diffuser  46  may be provided with a pair of alignment ribs  122  that run along opposing sides of diffuser  46 . The spacing between ribs  122  creates recess  120 . Recess  120  and alignment ribs  122  may be sized to engage with a mating portion in structures  42 . For example, structures  42  may have the shape of a metal bracket with a rectangular section that is received within recess  120 . In general, light sensor  30  (i.e., diffuser  46  and/or light sensor housing  44 ) may have alignment protrusions, alignment recesses, clips and other mounting structures for clipping or otherwise attaching light sensor  30  to housing  12 , to other housing structures, to structures  42 , etc. 
     To ensure that diffuser  46  is securely attached to light sensor housing  44  in configurations in which diffuser  46  and light sensor housing  44  are attached by plastic molding techniques, housing and/or diffuser  46  may be provided with engagement features that help engage overmolded plastic structures. As an example, light sensor housing  44  may be provided with engagement structures such as hooks  124  of  FIG. 28  (e.g., hooks  124  may be formed as part of the process of injection molding housing  44 ). During subsequent injection molding operations, diffuser  46  may be overmolded over light sensor housing  44  so that some diffuser material is formed within regions  126  under hooks  124 . This locks diffuser  46  to light sensor housing  44 , so that diffuser  46  and light sensor housing  44  cannot be easily dislodged. If desired, diffuser  46  may be provided with hooks or other molding engagement structures and light sensor housing  44  may be overmolded on top of the molding engagement structures on diffuser  46 . 
     The example of  FIG. 28  in which diffuser  46  has been overmolded on top of light sensor housing  44  is merely illustrative. 
     The foregoing is merely illustrative and various modifications can be made by those skilled in the art without departing from the scope and spirit of the described embodiments. The foregoing embodiments may be implemented individually or in any combination.

Metadata:
Filing Date: 20131010
Publication Date: 20180213
Grant Date: 20180213
Priority Date: 20131010
Inventors: RUH RICHARD
Assignee: APPLE INC
CPC Classifications: [{"code": "G01J1/0403", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L31/02327", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01L31/0203", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/0231", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/4204", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0474", "inventive": true, "first": true, "tree": "[]"}, {"code": "H10F77/413", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/0231", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/4204", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0403", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/413", "inventive": true, "first": false, "tree": "[]"}, {"code": "H10F77/50", "inventive": true, "first": false, "tree": "[]"}, {"code": "G02B5/0231", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/4204", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0403", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01J1/0474", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01J1/0474", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 52808867