PATENT DOCUMENT

Publication Number: US-8853581-B2
Application Number: US-201414188633-A
Country: US
Kind Code: B2

Title: Accessory controller for electronic devices

Abstract:
Accessories such as headsets for electronic devices are provided. A headset may be provided with a button controller assembly that has user-actuated buttons and a microphone. The microphone may be formed by mounting a microphone transducer on a printed circuit board. A housing may be mounted over the transducer to form a sealed cavity for the transducer. Circuitry may be mounted on portions of the printed circuit board that extend beyond the edges of the microphone housing. The button controller assembly may have dome switches. The dome switches may have a housing that encloses dome switch components and that forms a structural internal part for the button controller. The dome switch housing structure may have tabs or other engagement features that mate with corresponding engagement features in a button member. The button member may be pressed by a user to actuate a desired dome switch.

Claims:
What is claimed is: 
     
       1. A button controller assembly, comprising:
 a microphone housing attached to a substrate; 
 a switch housing attached to the substrate, wherein a switch is housed with the switch housing and the microphone housing protrudes into a first opening in the switch housing; and 
 a button member positioned over the switch and attached to the switch housing. 
 
     
     
       2. The button controller assembly as in  claim 1 , wherein the switch housing includes a first engagement structure and the button member a second engagement structure, wherein the button member is attached to the switch housing when the first engagement structure is coupled with the second engagement structure. 
     
     
       3. The button controller assembly as in  claim 2 , wherein the first engagement structure comprises a tab. 
     
     
       4. The button controller assembly as in  claim 3 , wherein the second engagement structure comprises an opening configured to mate with the tab. 
     
     
       5. The button controller assembly as in  claim 3 , wherein the second engagement structure comprises a groove configured to mate with the tab. 
     
     
       6. The button controller assembly as in  claim 1 , wherein the substrate comprises at least one of a rigid printed circuit board and a flex circuit. 
     
     
       7. The button controller assembly as in  claim 1 , wherein the microphone housing comprises:
 a housing attached to the substrate; 
 a transducer within the housing and attached to the substrate; and 
 an opening formed through the substrate to allow the transducer to receive sound. 
 
     
     
       8. The button controller assembly as in  claim 7 , further comprising circuitry within the housing and attached to the substrate, wherein the circuitry is electrically connected to the transducer. 
     
     
       9. The button controller assembly as in  claim 1 , further comprising circuitry attached to the substrate and protruding into a second opening in the switch housing. 
     
     
       10. The button controller assembly as in  claim 1 , wherein the microphone housing comprises:
 a housing; 
 a substrate within the housing and attached to a side of the housing; 
 a transducer within the housing and attached to the substrate; and 
 an opening formed through the housing and the substrate to allow the transducer to receive sound. 
 
     
     
       11. The button controller assembly as in  claim 10 , further comprising circuitry within the housing and attached to the substrate, wherein the circuitry is electrically connected to the transducer. 
     
     
       12. A button controller assembly, comprising:
 a microphone housing attached to a substrate; 
 a switch housing attached to the substrate, wherein a first switch and a second switch are housed with the switch housing on a first side of the switch housing and the microphone housing protrudes into a first opening in a second side of the switch housing between the first and second switches; and 
 a button member positioned over the first and second switches and attached to the switch housing, wherein the button member is configured to activate a respective switch in the switch housing when the button member is pressed. 
 
     
     
       13. The button controller assembly as in  claim 12 , further comprising a groove formed in an exterior surface of the button member between the first and second switches. 
     
     
       14. The button controller assembly as in  claim 13 , further comprising a notch formed in a sidewall of the button member between the first and second switches. 
     
     
       15. The button controller assembly as in  claim 12 , wherein the switch housing includes a first engagement structure and the button member a second engagement structure, wherein the button member is attached to the switch housing when the first engagement structure is coupled with the second engagement structure. 
     
     
       16. The button controller assembly as in  claim 15 , wherein the first engagement structure comprises a tab and the second engagement structure comprises an opening configured to mate with the tab. 
     
     
       17. The button controller assembly as in  claim 15 , wherein the first engagement structure comprises a tab and the second engagement structure comprises a groove configured to mate with the tab. 
     
     
       18. The button controller assembly as in  claim 12 , wherein the microphone housing comprises:
 a housing attached to the substrate; 
 a transducer within the housing and attached to the substrate; and 
 an opening formed through the substrate to allow the transducer to receive sound. 
 
     
     
       19. The button controller assembly as in  claim 12 , wherein the microphone housing comprises:
 a housing; 
 a substrate within the housing and attached to a side of the housing; 
 a transducer within the housing and attached to the substrate; and 
 an opening formed through the housing and the substrate to allow the transducer to receive sound. 
 
     
     
       20. The button controller assembly as in  claim 12 , wherein the button controller assembly is included in a headset.

Description:
This application is a continuation patent application of U.S. patent application Ser. No. 13/681,162, filed Nov. 19, 2012 and titled “Accessory Controller for Electronic Devices,” which is a continuation patent application of U.S. patent application Ser. No. 12/703,172, filed Feb. 9, 2010 and titled “Accessory Controller for Electronic Devices,” now U.S. Pat. No. 8,314,354, which claims the benefit of U.S. Provisional Patent Application No. 61/228,939, filed Jul. 27, 2009 and titled “Accessory Controller for Electronic Devices,” and Provisional Patent Application No. 61/230,073, filed Jul. 30, 2009 and titled “Accessory Controller for Electronic Devices,” and U.S. Provisional Patent Application No. 61/232,374, filed Aug. 7, 2009 and titled “Accessory Controller for Electronic Devices,” the disclosures of which are hereby incorporated by reference herein in their entireties. 
    
    
     BACKGROUND 
     This relates to electronic devices, and more particularly, to accessories for electronic devices with input components such as buttons and microphones. 
     Electronic devices such as computers, media players, and cellular telephones typically contain user interface components that allow these devices to be controlled by a user. It is sometimes desirable to add accessories to electronic devices. For example, a user may desire to plug a headset or adapter accessory into an electronic device to allow the user to listen to audio. 
     Headsets are sometimes provided with buttons and microphones. A headset microphone may be used to pick up a user&#39;s voice during a telephone call. Buttons may be used to control media file playback, to make volume level adjustments during a telephone call, and to issue other commands for the electronic device. Buttons and a microphone may be mounted within a button controller assembly. Microphone signals and button signals may be routed from the button controller assembly to an electronic device using wires in the headset. 
     The designers of accessories and other electronic equipment often attempt to reduce component size and part counts while retaining desired levels of functionality. Reduced component sizes and reduced part counts help to reduce device complexity and expense. 
     It would therefore be desirable to provide improved electronic device accessories such as accessories with improved buttons, microphones, and button controller assemblies. 
     SUMMARY 
     Electronic device accessories such as headsets with button controller assemblies are provided. A button controller assembly may include buttons and a microphone. 
     A microphone for the button controller assembly or other device may be formed by mounting an audio transducer to a substrate. The substrate may be a printed circuit board or other substrate that includes extending portions onto which integrated circuits and other components can be mounted. If desired, microphone components and other components can be mounted to substrates formed from parts of a housing. 
     Button functionality for the button controller assembly and other devices may be provided using switches that are actuated by button members. When a user presses a button member, the button member bears against the switch. Multiple buttons may be formed using a single flexible button structure. The switches may be implemented using dome switches. 
     The dome switches may have housings that directly mate with the button members. For example, the dome switch housings may have tabs that protrude into corresponding openings on a button structure. The housings of multiple dome switches may be formed from an integral structure. A printed circuit board may be mounted to the underside of the integral housing structure. Components such as integrated circuits, dome switch terminals, discrete circuit elements, microphone components, and other circuitry may be connected to the printed circuit board. Cavities in the dome switch housing member may receive the components that are mounted to the printed circuit board. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-22  show various structures in accordance with embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     This relates to structures such as microphone and button structures that may be used in a button controller assembly for an electronic device accessory. 
     Electronic components such as microphones and buttons may be used in a wide range of applications. For example, microphones and buttons may be used to form a button controller for a headset or other accessory. Button controller assemblies that are suitable for use in headsets are sometimes described herein as an example. In general, however, button structures and microphone structures may be used in any suitable system. 
     An illustrative system in which an accessory may be used with an electronic device is shown in  FIG. 1 . As shown in  FIG. 1 , electronic device  10  may be coupled to an accessory such as headset  12  by plugging plug  16  of accessory  12  into jack  14  of electronic device  10 . 
     Electronic device  10  may be a desktop or portable computer, a handheld electronic device such as a cellular telephone or media player, a tablet device, or any other suitable electronic device. Headset  12  may have speakers  18  and button controller assembly  22 . Button controller assembly  22  and speakers  18  may be coupled to device  10  using cable  20  (e.g., a three-wire or four-wire headset cable). Button controller assembly  22  may, if desired, include a microphone. The microphone may be used by a user of device  10  and headset  12  during a telephone call (e.g., to pick up the user&#39;s voice). 
     Button controller assembly  22  may include buttons such as buttons  24 ,  26 , and  28 . There may, in general, be any suitable number of buttons in button controller assembly (e.g., one or more buttons, two or more buttons, three or more buttons, etc.). With one suitable arrangement, which is sometimes described herein as an example, button controller assembly  22  may include three buttons. These buttons may be used to issue commands for device  10 . Examples of commands that may be issued for device  10  using the buttons of button controller assembly  22  include stop, forward, and reverse commands, volume up and down commands, telephone call control commands, etc. 
     A perspective view of an illustrative button controller is shown in  FIG. 2 . As shown in  FIG. 2 , button controller  22  may have an upper member  30  and a lower member  32 . Upper member  30  may be used to form buttons  24 ,  26 , and  28  and may therefore sometimes be referred to as a button structure or button member. Lower member  32  may be used to help enclose mechanical and electrical components in button controller  22  and may therefore sometimes be referred to as a button controller housing or enclosure. In the example of  FIG. 2 , button member  30  is used to form multiple buttons (i.e., buttons  24 ,  26 , and  28 ). This type of integral button member arrangement is, however, merely illustrative. Button members such as button member  30  may be used in forming a single button or multiple buttons. In configurations in which a single button member is used in forming multiple buttons, each portion of the button member may be flexed independently of the other portions of the button member. This allows a user to press one button (e.g., button  28 ) without activating the other buttons (e.g., buttons  26  and  24 ). 
     A cross-sectional side view of an illustrative microphone assembly of the type that may be used in button controller  22  or other equipment is shown in  FIG. 3 . As shown in  FIG. 3 , microphone assembly  34  (which may sometimes be referred to as a microphone or microphone structure) may have an audio transducer such as transducer  36 . Transducer  36  may be used to convert sound into electrical signals. Transducer  36  may be formed using microelectromechanical systems (MEMS) technology. For example, transducer  36  may have a thin MEMS diaphragm. Transducer  36  may be mounted to substrate  44  (e.g., using epoxy, solder, etc.). A vertical opening such as hole  46  may be formed through substrate  46  to allow sound to enter transducer  36 . Housing  40  may be mounted over transducer  36  to form sealed cavity  54  (e.g., using epoxy  42  or other suitable adhesives). 
     Microphone assembly  34  may include circuitry such as circuitry  38 . Circuitry  38  may include discrete electrical components, application-specific integrated circuits (ASICs) and other suitable circuits. Circuitry  38  may be mounted on substrate  44  (e.g. in cavity  54  within housing  40 ). 
     Substrate  44  may contain conductive lines (traces) such as traces  48 . Traces  48  may be used to interconnect microphone transducer  36  and circuitry  38 . Wire bonds such as wire bond  52  may also be used in interconnecting transducer  36  to circuitry  38  if desired. 
     Substrate  44  may have extending portions such as portions  56  that extend beyond the edges of housing  40 . Circuitry  50  may be mounted on the upper and lower surfaces of substrate  44  (e.g., in regions  56 ). Conductive traces  48  may be used to interconnect circuitry  50 , circuitry  38 , and transducer  36 . Circuitry  50  and  38  may include switches, capacitors, resistors, inductors, integrated circuits, etc. 
     Housing  40  may be formed from any suitable material (e.g., metal, plastic or other dielectric materials, etc.). Substrate  44  is preferably formed from a material that accommodates conductive lines  48 . As an example, substrate  44  may be formed from a dielectric such as plastic or other polymers. If desired, substrate  44  may be formed as part of a housing. Conductive traces may be formed on a plastic housing or other substrate by forming a patterned seed layer followed by electroplating (as an example). Conductive traces may also be formed by screen printing, physical vapor deposition and photolithography, insert molding (e.g., to embed metal wires, patterned metal foil, or other conductive structures within an encapsulating plastic structure), etc. With one suitable arrangement, substrate  44  is a printed circuit board. Printed circuit board materials that may be used for substrate  44  include rigid printed circuit board materials such as fiberglass filled epoxy (e.g., FR4) and flexible printed circuit board materials (e.g., flexible polymers such as polyimide). Flexible printed circuit boards are sometimes referred to as flex circuits. 
       FIG. 4  shows a cross-sectional side view of an illustrative configuration for microphone  34  in which port  46  is formed from an opening that passes through both substrate  44  and housing  40 . Housing  40  may be mounted to structure  58  (e.g., a structural component of button assembly  22  such as a portion of a housing). Transducer  36  may be mounted adjacent to acoustic port  46 . Circuitry  38  may be mounted within the sealed cavity formed by housing  40  (cavity  54 ). Substrate  44  in the configuration of  FIG. 4  may be formed from rigid or flexible printed circuit board, plastic (e.g., part of a housing structure such as housing  40 ), etc. 
     Another configuration that may be used for microphone  34  in button assembly  22  is shown in  FIG. 5 .  FIG. 5  is a cross-sectional side view showing how microphone  34  may be formed by mounting transducer  36  and circuitry  38  to the underside of substrate  44 . Substrate  44  may be, for example, a flex circuit or rigid printed circuit board. Opening  46  may be formed through substrate  44  to allow transducer  36  to receive sound. Sealed cavity  54  may be formed by attaching substrate  44  to structure  60 . 
     Structure  60  may be, for example, part of a plastic housing or other dielectric structure. Optional substrate extending regions  56  may be provided to allow circuitry  50  to be mounted to microphone assembly  34 . Conductive interconnects such as interconnect line  48  may be used to route signals between circuitry  50  and microphone components such as microphone circuitry  38  and transducer  36 . Circuitry  50  of  FIGS. 3 and 5  may be circuitry for handing microphone signals or other circuitry (e.g., button controller circuitry, general purpose audio circuitry, communications circuitry, etc.). 
     An exploded cross-sectional side view of an illustrative button controller  22  is shown in  FIG. 6 . As shown in  FIG. 6 , button controller  22  may have upper and lower portions such as button member  30  and housing member  32 . Housing member  32  and button member  30  may be formed from any suitable material (e.g., plastic, metal, etc.). In a typical configuration, button member  30  is formed form a flexible plastic that allows each button (i.e., buttons  28 ,  26 , and  24 ) to independently flex downward in direction  74 . Switches  70  are aligned with the buttons of button member  30 , so that when a given button is pressed by a user, the button will flex into contact with a corresponding switch. This actuates the switch. Control circuitry can detect that the state of the switch has changed (e.g., by detecting a closed circuit) and can take appropriate action. 
     Switches  70  may be formed using any suitable switch structures. With one illustrative configuration, which is sometimes described herein as an example, switches  70  are formed using dome switch structures. Each dome switch  70  includes a hemispherical dome member that can be pressed downward by flexing an appropriate portion of button member  30  in direction  74 . When the dome is fully compressed, the inside of the dome member will create a short circuit across the dome switches terminals. The dome may be formed from metal, metalized polymers, etc. 
     The hemispherical dome member of each dome switch  70  may be mounted to a housing. The housings may have tabs such as tabs  72  or other structures that allow switches  70  to directly mate with button member  30 . By mating switches  70  directly to button member  30 , button actuation tolerances may be improved relative to arrangements in which switches  70  and button member  30  are more indirectly coupled to each other (e.g., by using a frame or other structures in lower portion  76  of button assembly  22  to couple the dome switches to button member  30 ). 
     In the example of  FIG. 6 , switches  70  have tabs  72  that protrude into and out of the page. Each tab  72  may mate with a corresponding engagement structure in button member  30 . For example, each tab  72  may protrude into a corresponding opening  64  in one of portions  62  of button member  30  when button member  30  and lower assembly portion  76  are in an assembled (mated) state. Openings  64  may be larger than tabs  72  to allow button member  30  to travel with respect to switches  70  and the rest of lower portion  76  of button controller assembly  22 . 
     The use of tabs such as tabs  72  and interlocking features such as openings  64  is merely illustrative. Any suitable arrangement may be used to directly mate button member  30  to switches  70  and thereby couple button member  30  to lower portion  76 . For example, springs and mating openings may be used, adhesive or other rigid fastening mechanisms may be used, rails and recessed grooves may be used, other interlocking features that capture each other (e.g., using protrusions and recesses, etc.) may be used, etc. The use of dome switch housing protrusions  72  and corresponding button member openings  64  as the engagement structures that hold member  30  and portion  76  of assembly  22  together is merely illustrative. Moreover, it is not necessary for the opening portion of the engagement structures to be formed on member  30 . As an example, holes may be formed in the housings of switches  70  into which tabs on button member  30  protrude. 
     The housings of switches  70  may be connected to structure  66 . Structure  66  may be a rigid or flexible printed circuit board, a structural member such as a frame or housing piece, or any other structure. If desired, the housings of switches  70  may be formed from a single piece of material. With this type of arrangement, structure  66  need not be used to form a structural support for the dome switches and can be omitted or formed from a non-structural material (e.g., a flex circuit). 
     When dome switches such as switches  70  are interconnected to each other using a unitary housing structure or other integral mounting arrangement, it is not necessary to provide an additional printed circuit board on which individual dome switches are mounted. One or more printed circuit boards or other additional structures may, however, be attached to the integral dome switch structure if desired (e.g., to help route signals between dome switches  70  and other circuit components in button controller  22 ). Arrangements in which the housings for multiple switches  70  are formed a unitary structure such as a single molded plastic part are sometimes referred to as integral frame and switch structure arrangements. 
     Dome switches  70  and/or structure  66  (whether structure  66  is formed as an integral portion of one or more dome switch housings or as a separate structure) may be connected to housing  32  using adhesive  68  or other suitable fastening mechanisms (e.g., rivets, screws, snaps, etc.). If desired, switches  70 , structure  66 , and housing  32  may be formed as an integral part (e.g., using one molded plastic part). 
     A perspective view of an illustrative dome switch is shown in  FIG. 7 . As shown in  FIG. 7 , dome switch  70  may have a housing such as dome switch housing  82 . Housing  82  may be formed from a material such as liquid crystal polymer, glass-filled nylon, or other material (e.g., a material that flows well when molding small parts and that is rigid and strong). Switch  70  may have terminals  86  that are soldered to respective contact pads  84  on structure  66 . Structure  66  may be, for example, a substrate such as a flex circuit or a rigid printed circuit board. 
     As illustrated in  FIG. 7 , protrusions (tabs)  72  may be formed as an integral portion of housing  82 . Hemispherical dome switch diaphragm  78  may be mounted in housing  82 . Nub  80  may be formed from epoxy or other suitable material and serves as a durable point of contact between dome switch  70  and the lower surface of button member  30  during operation of switch  70 . 
     Although only a single switch  70  is shown in the example of  FIG. 7 , additional switches  70  may be rigidly connected together. For example, individual switches  70  may be mounted on the same substrate  66 . If desired, the length of housing  82  may be extended so that multiple switches  70  can be formed using a single unitary structure. This unitary switch housing structure may be sufficiently strong that substrate  66  can be omitted or so that substrate  66  may be made of a flexible material (i.e., a flex circuit substrate). 
     A cross-sectional end view of an illustrative dome switch is shown in  FIG. 8 . As shown in  FIG. 8 , dome switch  70  may have a dome member such as hemispherical conductive dome member  78  that is mounted in housing  82 . Protrusions  72  may extend laterally in directions  88  and  90  to mate with corresponding holes  64  in button member  30  ( FIG. 6 ). Terminals  86  may be formed using metal foil members  92  or other conductive structures. These structures may be electrically connected to dome  78  and inner switch contact pad  94 . When dome  78  is compressed, peripheral pad  96  and central pad  94  are shorted to each other, thereby closing switch  70 . 
     The cross-sectional side view of  FIG. 9  shows how terminals  86  may be formed from metal structures that pass through holes in substrate  66 . This type of configuration may help retain switch  70  and its housing  82  on substrate  66 . Solder  98  may be used to help attach structures  86  to traces on substrate  66  and may help retain structures  86  in the holes of substrate  66 . As shown by dashed line  100  and solder  102 , metal terminal structures and other such structures that hold switch  70  to substrate  66  may be formed under switch  70  (e.g., to avoid the lateral size constraints imposed by using metal terminal structures that run along the exterior edges of housing  82 ). 
     As shown in  FIG. 10 , terminal structures  86  may be formed using bent metal springs. With the spring arrangement of  FIG. 10 , the bent metal of each terminal  86  contacts a respective contact pad (i.e., contact pads  104 ) on the surface of substrate  66 . This type of configuration avoids the need to use solder, which may facilitate assembly and rework operations. 
       FIG. 11  is a cross-sectional side view of an illustrative configuration that may be used for switch  70  in which substrate  66  is mounted within a recess in the underside of switch housing  82 . Switch housing  82  may be, for example, a unitary housing structure that receives multiple hemispherical dome members  78  and that serves as a structural support member (e.g., a frame). Substrate  66  may be a printed circuit board (e.g., a flex circuit) and need not provide structural support for switches  70 . Solder connections  98  may be used to interconnect traces on circuit board  66  to switch terminals  86 . Other circuits (e.g., microphone  34 , integrated circuits, and other circuitry) may be mounted on printed circuit board  66  if desired. Such other circuits may be mounted on the upper side of circuit board  66  (e.g., so that these components protrude into recesses within the underside of housing structure  82 ) or on the lower surface of printed circuit board  66  (e.g., so that these components protrude downward in direction  74 . 
     A perspective view of an illustrative button member for button controller  22  is shown in  FIG. 12 . As shown in  FIG. 12 , button member  30  may have a frame structure  108  and button structure  106 . Button structure  106  and frame member  108  may be formed as a single unitary piece of material (e.g., using metal, plastic, or other suitable materials). In the example shown in  FIG. 12 , button structure  106  and button frame member  108  are formed from separate materials. Frame  108  may be formed from metal or other materials and may have holes  64  that engage tabs  72  on dome switches  70 . Button structure  106  serves as a button cover and may be formed from plastic, metal, or other materials. With one suitable arrangement, frame  108  is formed from metal and button structure  106  is formed from plastic (e.g., a thermoplastic) that is molded onto frame  108 . 
     Button structure  106  may have grooves  112  and frame  108  may have notches  110 . These recessed portions of structures  106  and  108  may be interposed between respective buttons (i.e., between button  28  and  26  and between button  26  and  24 ). Because there is less material in button member  30  in the vicinity of grooves  112  and notches  110 , button member  30  exhibits enhanced flexibility in these thinned regions. This enhanced flexibility helps to isolate the buttons from each other, so that only a desired button flexes when pressed by a user. 
     An interior portion of button controller assembly  22  is shown in  FIG. 13 . In the example of  FIG. 13 , button controller structures  114  are of the type that are configured to mate with button member  30  of  FIG. 12 . Structures  114  include three dome switches: switch  70 A, switch  70 B, and switch  70 C. Each dome switch may have associated tabs  72  that extend laterally outward for engagement with holes  64  in frame  108  ( FIG. 12 ). Support structure  116  may be formed from plastic, metal, printed circuit board material, or other suitable materials. With one suitable arrangement, structure  116  and the housings of switches  70 A,  70 B, and  70 C are formed from a single unitary piece of plastic (i.e., structure  116  may be a dome switch housing member). Opening  120  may be used to accommodate housing  40  of microphone  34  (e.g., microphone  34  of  FIG. 3 ) and other circuitry and components for button controller assembly  22 . 
     Button controller structures  114  may sometimes be referred to herein as a low profile switch assembly and a small form factor switch assembly (e.g., relative to audio cable  20  and the average size of a user&#39;s finger). Support structure  116  may form an enclosure for the electrical components associated with switches  70 A,  70 B, and  70 C. Instead of having structure  116  only support discrete and self-contained switches, switches  70 A,  70 B, and  70 C may be built into a single body such as structure  116  (sometimes referred to as a unitary switch body (e.g., the switches may be integrated in, embedded in, integral with, molded in, or internally disposed within structure  116 ). Structure  116  may be referred to herein as a unitary switch body (e.g., a single piece of material such as a single piece of molded plastic having integral switches  70 A,  70 B, and  70 C. This type of arrangement may help to reduce the number of components in a switch assembly (which may facilitate building smaller switch assemblies and which may also facilitate manufacturing of the switch assemblies by reducing the number of components). 
     An illustrative printed circuit  66  on which housing  40  of microphone  34  may be mounted for assembly with structures  114  of  FIG. 13  is shown in  FIG. 14 . As shown in  FIG. 14 , housing  40  of microphone  34  may be mounted in a portion of printed circuit  66  that allows housing  40  to protrude into opening  120  of  FIG. 13  when printed circuit board  66  is mounted to the underside of structures  114  of  FIG. 13 . Printed circuit board  66  may be formed from any suitable structure such as a printed circuit board, a rigid printed circuit board, a rigid-flex printed circuit board, a flexible printed circuit board, a flexible circuit, one or more integrated circuits or chips, and any other suitable structure or medium for circuitry. Printed circuit board  66  and may have extending regions  56  on which circuitry  50  and other components may be mounted (as described in connection with extending portions  56  of substrate  44  in  FIG. 3 ). With one suitable arrangement, printed circuit board  66  may be integrated into structure  116  to form switch assembly  114 . As examples, printed circuit board  66  may be integral with, internal to, within, or internally disposed within the confines of unitary structure  116 . In general, printed circuit board  66  may include any desired circuits and circuit components. For example, circuit board  6  may include electrical components associated with switches  70 A,  70 B, and  70 C and/or other electrical components such as components associated with microphone  34  and other circuitry. 
       FIG. 15  is an exploded perspective view of printed circuit board  66  and microphone housing  40  of  FIG. 14  in alignment with opening  120  and the underside of structure  114  of  FIG. 13 . As shown in  FIG. 15 , structure  116  may have a printed circuit board recess formed from shallow sidewalls  124 . Printed circuit board  66  may have a substantially rectangular shape that is received within the recess formed by sidewalls  124 . When printed circuit board  66  is mounted in this recess, microphone housing  40  may protrude into opening  120  and additional circuitry  50  may protrude into recesses  122 . Structure  116  and tabs  72  may be formed from a single structure (e.g., a plastic structure) that serves as both a housing for each of the dome switches ( 70 A,  70 B, and  70 C) and as a structural support for the switches that allows direct attachment of button member  30  to the switches. 
       FIG. 16  is a perspective view of button controller structure  114  after printed circuit  66  of  FIG. 15  has been mounted in the recess in structure  116  that is formed by sidewalls  124 . 
       FIG. 17  is a side view of button member  30  of  FIG. 12  before assembly with dome switch structure  114 . 
       FIG. 18  is a side view of button member  30  of  FIG. 12  and structure  114  of  FIG. 13  after these two parts have been assembled to each other. In the assembled state of  FIG. 18 , tabs  72  of dome switch housing structure  116  protrude into holes  64  in frame  108  of button member  30 . Holes  64  capture tabs  72 . Because holes  64  have inner dimensions that are slightly larger than the outer dimensions of tables  72  (at least in vertical dimension  126 ), button member  30  and button cover structure  106  may travel relative to structures  116 . Structures  116  may be formed as an integral portion of lower housing  32  of button controller  22  ( FIG. 2 ) or may be attached to housing  32  (e.g., using adhesive, snaps, or other fasteners). The travel allowed by the relative sizes of holes  64  and tabs  72  allows the controller buttons to be pressed by a user to actuate the dome switches. 
     As shown in the cross-sectional side view of  FIG. 19 , the housing for microphone  34  may be formed as an integral part of dome switch structure  116 . Transducer  36  may be mounted above hole  64  in substrate  66 . Circuitry  38  and circuitry  50  may also be mounted to substrate  66 . Substrate  66  may be mounted to the underside of structure  116  (e.g., in a recess of the type shown in  FIG. 15 ). Cavity  52  may be formed from a recess in structure  116 . When substrate  66  is mounted to structure  116  as shown in  FIG. 19 , microphone transducer  36  and circuitry  38  may be sealed within microphone cavity  52  (i.e., a cavity of the type formed by housing  40  of  FIG. 3 ). Other recesses in structure  116  may receive protruding circuitry  50 . Substrate  66  of  FIG. 19  may be plastic, metal, a printed circuit board such as a rigid or flexible printed circuit board, etc. and may be attached to structure  116  using epoxy or other suitable adhesives (as an example). 
     If desired, button member  30  may be assembled by sliding button member  30  into place over dome switch tabs  72 . This type of assembly approach is shown in  FIG. 20 . As shown in  FIG. 20 , button member  30  may be provided with grooves such as grooves  128 . Grooves  128  may be configured to mate with tabs  72  of dome switch housing  82 . Button member  30  may be mounted to dome switches  70  by sliding button member  30  onto dome switches  70  in direction  130 , taking care to align grooves  128  with tabs  72 . Snaps or other engagement features may be used to hold button member  30  in place following assembly. 
     Button member  30  can be configured to flex relative to the dome switches without exhibiting travel of the type permitted by using holes  64  that are larger than tabs  72 .  FIG. 21  is a cross-sectional end view of a button controller structure showing how button member  30  may be attached to dome switch housing  82  (i.e., an integral support structure for multiple dome switches) at protruding dome switch ledges  132  using adhesive  134 . With this type of configuration, button member  30  is rigidly attached to the dome switches, so button actuation events involve flexing of button member  30 . Button member  30  may, for example, be formed from a thin metal or plastic (e.g., a thermoplastic) that is sufficiently flexible to be resiliently deformed. When an exposed button surface is pressed downwards by a user, button member  30  will flex sufficiently to actuate dome switch member  78 . When the user releases the button surface, button member  30  returns to its nominal shape and releases the switch. Because button member  30  flexes, switches can be actuated without allowing the entire button member to travel relative to dome switches  70 . 
     Another view of the interior portion of button controller assembly  22  illustrated in  FIG. 13  is shown in  FIG. 22 . As shown in the example of  FIG. 22 , tabs  72  associated with each dome switch may lie in a common plane with the upper surface of support structure  116  (e.g., tabs  72  may lie flush with the top of structure  116 ).  FIG. 22  also illustrates that support structure  116  (e.g., button controller structures  114 ) may have dimensions such as thickness  138 , width  136 , and length  140 . In general, support structure  116  may have any suitable dimensions. With one suitable arrangement, structure  116  may have a thickness such as thickness  138  that is between 0.5 and 6.0 mm, a width such as width  136  that is between 1.0 and 10.0 mm, and a length such as length  140  that is between 20.0 and 40.0 mm. As one example, structure  116  may have a thickness of approximately 1.0 mm (e.g., a thickness between 0.9 and 1.1 mm), a width of approximately 3.0 mm (e.g., a width between 2.9 and 3.1 mm), and a length of approximately 21.0 mm (e.g., a length between 20.9 and 21.1 mm). With another suitable arrangement, structure  116  may have a height such as height  138  of 6.0 mm or less, a width such as width  136  of 10.0 mm or less, and a length such as length  140  of 40.0 mm or less. The height (i.e., the thickness) of structure  116  may include the height (i.e., the thickness) of the dome switches (e.g., dome switches  70 A,  70 B, and  70 C) above the upper surface of structure  116  (e.g., thickness  138  may extend from the bottom surface of structure  116  to the top of the dome switches). 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20140224
Publication Date: 20141007
Grant Date: 20141007
Priority Date: 20090727
Inventors: PREST CHRISTOPHER D.
DI LEO CLAUDIO V.
MINOO JAHAN C.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H2233/096", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H9/0228", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2221/074", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2239/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2203/038", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/76", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/7057", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2239/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/074", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2203/056", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/10", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H9/0228", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/7057", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H13/81", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2239/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2203/038", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2239/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2203/038", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/86", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2233/096", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/7057", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H13/7057", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2239/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2239/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2203/038", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04R1/1041", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H13/10", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2239/01", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/76", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2239/048", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/7057", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 42668551