PATENT DOCUMENT

Publication Number: US-7880106-B2
Application Number: US-82419107-A
Country: US
Kind Code: B2

Title: Switch assembly constructions

Abstract:
Electronic devices are provided with switch assembly input components that can have adhesives adhered to the side and/or bottom surfaces of support plates for retaining switches between the adhesives and the tops of the support plates. The switch assembly input components can include buttons with one or more absorption elements for receiving impact energy, reducing the impact energy, and transferring the reduced impact energy onto the switches.

Claims:
1. A switch assembly, comprising:
 a support plate; 
 a switch; and 
 an adhesive adhered to at least one of a side surface of the support plate and a bottom surface of the support plate for retaining the switch between the adhesive and a top surface of the support plate, wherein the adhesive is not adhered to a portion of the top surface extending between an edge of the top surface and an edge of the switch. 
 
     
     
       2. The switch assembly of  claim 1 , wherein the adhesive is adhered to a first side surface of the support plate and the bottom surface. 
     
     
       3. The switch assembly of  claim 1 , wherein the switch includes a first dome switch element stacked on top of a second dome switch element. 
     
     
       4. The switch assembly of  claim 1  further comprising:
 a user button for deforming the switch in a first direction with a first force when the user button is pushed in a second direction with a second force; and 
 at least one absorption element coupled to the user button for reducing the second force to the first force. 
 
     
     
       5. The switch assembly of  claim 1 , wherein the adhesive is adhered to a first side surface of the support plate and a second side surface of the support plate. 
     
     
       6. The switch assembly of  claim 5 , wherein the first side surface is opposite the second side surface. 
     
     
       7. The switch assembly of  claim 1 , wherein the adhesive includes at least one perforation. 
     
     
       8. The switch assembly of  claim 7 , wherein the at least one perforation is located at a portion of the adhesive adjacent an intersection of the top surface and any side surface of the support plate. 
     
     
       9. The switch assembly of  claim 7 , wherein the at least one perforation is located at a portion of the adhesive adjacent an intersection of the bottom surface and any side surface of the support. 
     
     
       10. A switch assembly, comprising:
 a support plate; 
 a switch; 
 an adhesive adhered to the support plate for retaining the switch between the adhesive and a top surface of the support plate, wherein the adhesive is not adhered to a portion of the top surface of the support plate extending between an edge of the top surface and an edge of the switch; 
 a user button for deforming the switch in a first direction with a first force when the user button is pushed in a second direction with a second force; and 
 at least one absorption element coupled to the user button for reducing the second force to the first force. 
 
     
     
       11. The switch assembly of  claim 10 , wherein the at least one absorption element is a thermoplastic elastomer. 
     
     
       12. The switch assembly of  claim 10 , wherein the at least one absorption element is a thermoplastic polyurethane. 
     
     
       13. The switch assembly of  claim 10 , wherein the distance between a top surface of the button and the top surface of the support plate is between 0.5 millimeters and 3.5 millimeters. 
     
     
       14. The switch assembly of  claim 10 , wherein the distance between a top surface of the button and the top surface of the support plate is between 1.0 millimeter and 3.0 millimeters. 
     
     
       15. The switch assembly of  claim 10 , wherein the distance between a top surface of the button and the top surface of the support plate is between 1.5 millimeters and 2.5 millimeters. 
     
     
       16. The switch assembly of  claim 10 , wherein the distance between a top surface of the button and the top surface of the support plate is about 2.1 millimeters. 
     
     
       17. An electronic device, comprising:
 a housing having a first surface; and 
 the switch assembly of  claim 10 , wherein a top surface of the button is exposed through an opening in the first surface of the housing. 
 
     
     
       18. The switch assembly of  claim 10 , wherein the at least one absorption element is molded with the user button. 
     
     
       19. The switch assembly of  claim 18 , wherein the at least one absorption element is twin shot molded with the user button. 
     
     
       20. A method of forming a switch assembly including a switch, a support plate, and an adhesive, the method comprising:
 placing the switch on a top surface of the support plate; 
 wrapping the adhesive over the switch; and 
 adhering the adhesive to at least one of a side surface of the support plate for retaining the switch between the adhesive and the top surface of the support plate, wherein the adhesive is not adhered to any portion of the top surface extending between an edge of the top surface and an edge of the switch. 
 
     
     
       21. The method of  claim 20 , further comprising: perforating a portion of the adhesive.

Description:
FIELD OF THE INVENTION 
     This can relate to apparatus and methods for improving the construction of switch assemblies of electronic devices. 
     BACKGROUND OF THE DISCLOSURE 
     There is a need for improving the construction of switch assemblies of various electronic devices. Specifically, there is a need for reducing the size of switch assemblies of various electronic devices. 
     Some known electronic devices (e.g., MP3 players and portable telephones) include at least one input component that allows a user to manipulate the function of the device, at least one output component that provides the user with valuable device generated information, and a protective housing that at least partially encloses the input and output components. Some known input components are conventional switch assemblies that may include a switch (e.g., a dome switch) affixed to a support plate by an adhesive. The adhesive typically is layered over the switch and adhered to the top of the support plate surrounding the switch. Switch manufacturers typically specify a minimum adhesion border around the switch needed for proper adhesion of the adhesive to the top of the support plate. 
     However, as electronic devices become smaller, the size of the switch assemblies also may need to be reduced. In conventional switch assemblies, the reduction in the size of the assemblies can be limited, at least in part, by the minimum adhesion border specified by the switch manufacturers. 
     Accordingly, what is needed are apparatus and methods for reducing the size of switch assemblies while limiting the need for adhesion borders. 
     SUMMARY OF THE DISCLOSURE 
     Apparatus and methods for improving the construction of switch assemblies of electronic devices are provided. 
     According to a particular embodiment of the present invention, there is provided a switch assembly that includes a support plate, a switch, and an adhesive. The adhesive is adhered to at least one of a side surface of the support plate and a bottom surface of the support plate for retaining the switch between the adhesive and a top surface of the support plate. 
     According to another particular embodiment of the present invention, there is provided a switch assembly that includes a support plate, a switch, an adhesive, a user button, and at least one absorption element. The adhesive is adhered to the support plate for retaining the switch between the adhesive and a top surface of the support plate. The user button is for deforming the switch in a first direction with a first force when the user button is pushed in a second direction with a second force. The at least one absorption element is coupled to the user button for reducing the second force to the first force. 
     According to yet another particular embodiment of the present invention, there is provided a method of forming a switch assembly including a switch, a support plate, and an adhesive. The method includes placing the switch on a top surface of the support plate, wrapping the adhesive over the switch, and adhering the adhesive to at least one of a side surface of the support plate and a bottom surface of the support plate for retaining the switch between the adhesive and the top surface of the support plate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other features of the present invention, its nature and various advantages will become more apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which: 
         FIG. 1  is a perspective view of an exemplary electronic device in accordance with the principles of the present invention; 
         FIG. 2  is a partial horizontal cross-sectional view of the electronic device of  FIG. 1 , taken from line II-II of  FIG. 1 , showing a switch assembly in an original position in accordance with the principles of the present invention; 
         FIG. 3  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1 and 2 , similar to  FIG. 2 , showing the switch assembly of  FIG. 2  in an actuated position in accordance with the principles of the present invention; 
         FIG. 4  is a top elevational view of the electronic device of  FIGS. 1-3 , taken from line IV-IV of  FIG. 2 , showing the switch assembly of  FIGS. 2 and 3 , but with the housing of the electronic device and the adhesive of the switch assembly omitted; 
         FIG. 5  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1-4 , taken from line V-V of  FIG. 1 , showing another switch assembly in an original position in accordance with the principles of the present invention, but with the housing of the electronic device omitted; 
         FIG. 6  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1-5 , similar to  FIG. 5 , showing the switch assembly of  FIG. 5  in an actuated position in accordance with the principles of the present invention; 
         FIG. 7  is a top elevational view of the electronic device of  FIGS. 1-6 , taken from line VII-VII of  FIG. 5 , showing the switch assembly of  FIGS. 5 and 6 ; 
         FIG. 8  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1-7 , taken from line VIII-VIII of  FIG. 1 , showing yet another switch assembly in an original position in accordance with the principles of the present invention, but with the housing of the electronic device omitted; 
         FIG. 9  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1-8 , taken from line IX-IX of  FIG. 1 , showing yet another switch assembly in an original position in accordance with the principles of the present invention; 
         FIG. 10  is a partial horizontal cross-sectional view of the electronic device of  FIGS. 1-9 , similar to  FIG. 9 , showing the switch assembly of  FIG. 9  in an actuated position in accordance with the principles of the present invention; and 
         FIG. 11  is a partial horizontal cross-sectional view, similar to  FIG. 2 , of another embodiment of a switch in accordance with the principles of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DISCLOSURE 
     Apparatus and methods for improving the construction of switch assemblies of electronic devices are provided and described with reference to  FIGS. 1-11 . 
       FIG. 1  shows an embodiment of electronic device  1  including at least one switch assembly input component of the invention. The term “electronic device” can include, but is not limited to, music players, video players, still image players, game players, other media players, music recorders, video recorders, cameras, other media recorders, radios, medical equipment, calculators, cellular telephones, other wireless communication devices, personal digital assistants, programmable remote controls, pagers, laptop computers, printers, or combinations thereof. In some cases, the electronic devices may perform a single function (e.g., a device dedicated to playing music) and, in other cases, the electronic devices may perform multiple functions (e.g., a device that plays music, displays video, stores pictures, and receives and transmits telephone calls). 
     In any case, these electronic devices are generally any portable, mobile, hand-held, or miniature electronic device having an input component constructed in accordance with the principles of the present invention so as to allow a user to listen to music, play games, record videos, take pictures, and/or conduct telephone calls wherever the user travels. Miniature electronic devices may have a form factor that is smaller than that of hand-held electronic devices, such as an iPod™ available by Apple Inc. of Cupertino, Calif. Illustrative miniature electronic devices can be integrated into various objects that include, but are not limited to, watches, rings, necklaces, belts, accessories for belts, headsets, accessories for shoes, virtual reality devices, other wearable electronics, accessories for sporting equipment, accessories for fitness equipment, key chains, or combinations thereof. Alternatively, electronic devices that incorporate an input component of the invention may not be portable at all. 
     Electronic device  1  can include at least one input component (see, e.g., input component  10 ) that allows a user to manipulate a function of the device, at least one output component (see, e.g., output component  2 ) that provides the user with valuable device generated information, and a protective housing (see, e.g., housing  4 ) that at least partially encloses the one or more input and output components of the device. 
     As shown in  FIG. 1 , for example, housing  4  of device  1  can be hexahedral. Although, it should be noted that housing  4  of device  1  is only exemplary and need not be substantially hexahedral, and that, in certain embodiments, the housing of device  1  could generally be formed in any other suitable shape, including, but not limited to, substantially spherical, ellipsoidal, conoidal, octahedral, or a combination thereof, for example. 
     As described above, a disadvantage of conventional electronic devices is that the reduction of their size can be limited by certain switch assembly input components with adhesives requiring specific adhesion border dimensions on the tops of support plates about switches. Therefore, according to certain embodiments of the present invention, device  1  can include at least one input component that is a switch assembly whose size is not limited by adhesion border dimensions on the top surface of a support plate about a switch. 
     For example, as shown in  FIGS. 1-4 , input component  10  can be a switch assembly that may include a switch  20 , a support plate  30 , and an adhesive  40 . Switch  20  may be retained between support plate  30  and adhesive  40  by adhering at least a portion of adhesive  40  to support plate  30 . A user (not shown) may activate switch assembly  10  of device  1  by exerting an activation force on top surface  22  of switch  20  in the direction of arrow A (see, e.g.,  FIGS. 2 and 3 ). This user activation force may depress or deform switch  20  from an original position (e.g., as shown in  FIG. 2 ) to an actuated position (e.g., as shown in  FIG. 3 ) to change a functional state of device  1  (e.g., whether the device should power up or turn itself off). 
     As shown in  FIGS. 2 and 3 , for example, switch assembly input component  10  can also include one or more contact points (e.g., contact point  36 ). Contact point  36  may be provided on support plate  30 . Each of the one or more contact points  36  of input component  10  can be coupled to a processor (not shown, but described in greater detail hereinbelow) of device  1  contained within housing  4 . When switch  20  is at its actuated position of  FIG. 3 , bottom surface  24  of switch  20  may contact or otherwise impart an activation energy onto contact point  36 . This interaction between bottom surface  24  of switch  20  and contact point  36  may change a function or logic of the processor of device  1 . 
     When the user terminates the activation force on top surface  22  of switch  20 , switch  20  may return to its original position of  FIG. 2 , thereby terminating its activation energy onto contact point  36 . It is to be understood, however, that although described above to include a contact point  36  on support plate  30 , switch assembly  10  may be configured in various other suitable ways such that activation of switch  20  from its original position to its actuated position can change a functional state of device  1  within the spirit and scope of the present invention. 
     Switch  20  may be a dome-shaped switch, a snap-acting pressure disc, a snap-acting force disc, a low profile tactile switch, or any other suitable type of switch. Switch  20  may be an elastically deformable switch. Switch  20  may be made of any suitable material, including, but not limited to, metal (e.g., stainless steel), plastic, or combinations thereof. 
     In some embodiments, switch  20  may include a single switch (e.g., a single dome-shaped switch as shown in  FIGS. 2 and 3 , for example). In other embodiments, a switch may include two or more switches coupled to one another or at least placed on top of one another in a stack. As shown in  FIG. 11 , for example, stacked switch  20 ′ may include two switches  20 A and  20 B in a stack. Top surface  22 A of switch  20 A may act similarly to top surface  22  of switch  20 , and bottom surface  24 B of switch  20 B may act similarly to bottom surface  24  of switch  20 . In some embodiments, bottom surface  24 A of switch  20 A may be coupled to top surface  22 B of switch  20 B using any suitable adhesive or glue therebetween, for example. 
     Stacked switch  20 ′ may be used in switch assemblies of the present invention similarly to how switch  20  is used in assembly  10 . However, if stacked switch  20 ′ is provided with two switches in its stack (e.g., as shown in  FIG. 11 ), the actuation point of the stacked switch  20 ′ may be double that of each individual switch in the stack. For example, if each of switches  20 A and  20 B is provided with an actuation force of 2 Newtons, stacked switch  20 ′ may have an actuation force of 4 Newtons. However, if single switch  20  of  FIG. 2  were provided with an actuation force of 4 Newtons, the switch may have a shorter life or require a larger diameter than a 4 Newton switch provided by stacked switches (e.g., switch  20 ′), due to the higher internal stresses in the single switch, for example. 
     Switch assembly input component  10  can be held in place at least partially within housing  4  in any one of various suitable ways such that at least top surface  22  of switch  20  is accessible to a user external to housing  4 . For example, as shown in  FIGS. 2 and 3 , plate  30  can be held in place about its top surface  32  and bottom surface  34  by external bracket portions  3  and internal bracket portions  5  of housing  4 , respectively. Housing  4  is not shown in many of the other illustrations described below (e.g.,  FIGS. 4-8 ) for the sake of clarity only. 
     In one embodiment of the invention, a switch may be retained between a top surface of a support plate and an adhesive by layering the adhesive over the switch and adhering at least a portion of the adhesive to a bottom surface of the support plate. For example, as shown in  FIGS. 2 and 3 , switch  20  may be retained between top surface  32  of support plate  30  and adhesive  40  by adhering at least a portion of adhesive  40  to bottom surface  34  of support plate  30 . Adhesive  40  may include an exterior surface  42  and an interior surface  44 . Interior surface  44  of adhesive  40  may be layered over top surface  22  of switch  20 , wrapped about side surfaces  33  of support plate  30 , and adhered to at least a portion of bottom surface  34  of support plate  30  (e.g., at one or more bottom adhering portions  54 ), such that switch  20  may be retained between top surface  32  of support plate  30  and adhesive  40 . By adhering at least a portion of interior surface  44  of adhesive  40  to at least a portion of bottom surface  34  of support plate  30  at one or more bottom adhering portions  54 , switch  20  can be retained between adhesive  40  and support plate  30  without adhering any portion or at least any substantial portion of adhesive  40  to any portion of top surface  32  of support plate  30 . Therefore, the size of switch assembly  10  need not be limited by any specific adhesion border dimensions of top surface  32  of support plate  30  about switch  20 . 
     For example, as shown in  FIG. 4  (without housing  4  and adhesive  40  for sake of clarity), the dimensions by which top surface  32  of support plate  30  extend beyond the edge (e.g., edge  21  between surfaces  22  and  24 ) of switch  20  need not be of at least a specific size for allowing proper adhesion of adhesive  40  to top surface  32  about switch  20 . Distance b between the edge of switch  20  and the edge of top surface  32  (e.g., edge  31 ) for example, may be reduced to minimize the overall size of support plate  30  (e.g., total width w of top surface  32 ). Although, top surface  22  of switch  20  is shown to be substantially circular and top surface  32  of plate  30  is shown to be substantially rectangular, it should be noted that each of top surfaces  22  and  32  of  FIGS. 2-4  is only exemplary, and that, in certain embodiments, one or both of top surfaces  22  and  32  could generally be formed in any other suitable shape, including, but not limited to, substantially triangular, elliptical, octagonal, or a combination thereof, for example. 
     An adhesive may be wrapped about the side surfaces and adhered to at least a portion of the bottom surface of a support plate such that the adhesive may substantially only contact the intersects (i.e., “edges” if the intersects are of two walls, and “corners” if the intersects are of three walls (or three edges)) of the side surfaces and may not contact the walls of the side surfaces themselves and/or the wall of the top surface itself. As shown in the left side of  FIGS. 2 and 3 , for example, interior surface  44  of adhesive  40  may only substantially contact the wall of bottom surface  34  (e.g., at bottom adhering portion  54   a ), edge  31   a  (i.e., the edge formed by the intersection of side surface  33   a  and top surface  32 ), and edge  35   a  (i.e., the edge formed by the intersection of side surface  33   a  and bottom surface  34 ). Adhesive  40  may not substantially contact the wall of side surface  33   a  itself. 
     Similarly, as shown in the right side of  FIGS. 2 and 3 , for example, interior surface  44  of adhesive  40  may only substantially contact the wall of bottom surface  34  (e.g., at bottom adhering portion  54   b ), edge  31   b  (i.e., the edge formed by the intersection of side surface  33   b  and top surface  32 ), and edge  35   b  (i.e., the edge formed by the intersection of side surface  33   b  and bottom surface  34 ). Adhesive  40  may not substantially contact the wall of side surface  33   b  itself. Moreover, in one embodiment, adhesive  40  may contact edge  31   a  and edge  31   b  without substantially contacting the wall of top surface  32  itself. Any suitable sticky material may be provided along one or more various portions of interior surface  44  of adhesive  40  for retaining switch  20  between adhesive  40  and plate  30 . 
     According to another embodiment of the invention, one or more perforations may be included at one or more portions of an adhesive for providing bend relief such that the adhesive may better conform to the shape of the support plate. As shown in FIGS.  1  and  5 - 7 , for example, device  1  may include a switch assembly  110  that may be similar to switch assembly  10  but includes an adhesive  140  with one or more perforation portions. Adhesive  140  of switch assembly  110  may be provided with a perforation portion  141   a  at the location where interior surface  144  of adhesive  140  contacts edge  131   a  of support plate  130 . Perforation portion  141   a  may permit interior surface  144  of adhesive  140  adjacent perforation portion  141   a  to better bend about edge  131   a  and adhere or at least conform to a greater portion of one or more of the wall surfaces of support plate  130  adjacent edge  131   a  (e.g., the wall of top surface  132  and/or the wall of side surface  133   a ). 
     Adhesive  140  may alternatively or additionally be provided with perforation portions at one or more of the other locations where adhesive  140  contacts an edge of support plate  130  (e.g., perforation portions  141   b ,  145   a , and  145   b ), as shown in  FIGS. 5-7 . Perforation portions  141   b ,  145   a , and  145   b , along with perforation portion  141   a , may allow adhesive  140  to bend about each edge (e.g., edges  131   a ,  131   b ,  135   a , and  135   b ) and adhere or at least conform to substantially the entire wall of each side surface of the support plate (e.g., side surfaces  133   a  and  133   b  at side adhering portions  153   a  and  153   b ). Each side adhering portion  153  may include multiple adhering instances spaced along its respective side surface  133  or it may include one adhering instance spanning a portion or substantially the entire length of its respective side surface  133 . The perforation portions may allow adhesive  140  to adhere to greater portions of bottom surface  134  of support plate  130  (e.g., at one or more bottom adhering portions  154 ). Perforation portions  141   a  and  141   b  may also allow adhesive  140  to bend about edges  131   a  and  131   b  and adhere or at least conform to one or more portions of top surface  132 . 
     Each of the one or more perforation portions provided on adhesive  140  may help facilitate the operation of switch  120  of assembly  110  by permitting air and other gas therethrough, and thereby reducing pressure that may otherwise be created under the switch during use. When switch  120  is depressed and moved in the direction of arrow A from its original position (see, e.g.,  FIG. 5 ) to its actuated position (see, e.g.,  FIG. 6 ), the area of space  165  defined by bottom surface  124  of switch  120 , top surface  132  of plate  130 , and interior surface  144  of adhesive  140  may be reduced. One or more perforation portions on adhesive  140  (e.g., perforation portions  141   a  and  141   b  of  FIGS. 5-7 ) may permit air and other gas to pass therethrough between space  165  and the atmosphere external to switch assembly  110 . Each perforation portion may be any type of hole, slit, or aperture created either partially or completely through adhesive  140  between surfaces  142  and  144 . 
     A perforation portion may be provided by one perforation spanning one or more fractions or the entire portion of an adhesive where it contacts an edge of a support plate. Alternatively, a perforation portion may be provided by a plurality of perforations spaced along one or more fractions or the entire portion of an adhesive where it contacts an edge of a support plate. For example, as shown in  FIG. 7  (with switch  120  and support plate  130  each shown in broken lines below adhesive  140 ), perforation portion  141   a  may include one perforation  142   a  spanning substantially the entire portion of adhesive  140  that contacts edge  131   a  of support plate  130 . As also shown in  FIG. 7 , for example, perforation portion  141   b  may include a plurality of perforations  142   b  spanning separate fractions of the portion of adhesive  140  that contacts edge  131   b  of support plate  130  (e.g., each perforation may be in the shape of a dot or dash provided either partially or completely through the adhesive). 
     In one embodiment of the invention, a switch may be retained between a top surface of a support plate and an adhesive by layering the adhesive over the switch, adhering a first portion of the adhesive to a first side surface of the support plate, and adhering a second portion of the adhesive to a second side surface of the support plate. As shown in  FIGS. 1 and 8 , for example, device  1  may include a switch assembly  210  that may be similar to switch assembly  10  and switch assembly  110  but that may include a switch  220  retained between a top surface  232  of a support plate  230  and an adhesive  240  that does not adhere to bottom surface  234  of support plate  230 . Instead, interior surface  244  of adhesive  240  may be layered over top surface  222  of switch  220 , wrapped about side surfaces  233   a  and  233   b  of support plate  230 , and adhered to at least a portion of each of side surfaces  233   a  and  233   b  of support plate  230  at one or more side adhering portions  253  (e.g., side adhering portions  253   a  and  253   b ). 
     By adhering at least a portion of interior surface  244  of adhesive  240  to at least a portion of each of side surfaces  233   a  and  233   b  of support plate  230  at one or more side adhering portions  253 , switch  220  can be retained between adhesive  240  and support plate  230  without adhering any portion or at least any substantial portion of adhesive  240  to any portion of top surface  232  of support plate  230 . Therefore, the size of switch assembly  210  need not be limited by any specific adhesion border dimensions of top surface  232  of support plate  230  about switch  220 , as described above with respect to switch assembly  10  (see, e.g.,  FIG. 4 ). 
     Adhesive  240  may be provided with one or more perforation portions at one or more of the locations where adhesive  240  contacts an edge of support plate  230  (e.g., perforation portion  241   a  at edge  231   a ), as shown in  FIG. 8 , for example. As described above with respect to the perforation portions of  FIGS. 5-7 , perforation portion  241   a  may allow adhesive  240  to bend about edge  231   a  of support plate  230  and adhere or at least conform to a greater portion of side surface  233   a  of support plate  230 . Therefore, perforation portion  241   a  may enlarge side adhering portion  253   a . In some embodiments, surfaces or edges or corners of the support plate may be curved or smoothed to help the adhesive conform thereto. The support plate may be made of any suitable material, including, but not limited to, metal (e.g., stainless steel), PCB, plastic, and combinations thereof. 
     In an embodiment of the invention, a switch assembly may include a user button for receiving a user&#39;s input and thereby activating the switch of the switch assembly. As shown in  FIGS. 1 ,  9 , and  10 , for example, device  1  may include a switch assembly  310 , which may be similar to any of switch assemblies  10 ,  110 , and/or  210  of the invention or which may be any known switch assembly. Switch assembly  310  may include a switch  320  resting on a top surface  332  of a support plate  330 . An adhesive  340  may also be provided for retaining switch  320  between top surface  332  and the adhesive, as described above with respect to adhesives  40 ,  140 , and/or  240 . Switch assembly  310  may also include a user button  360  for receiving a user&#39;s input and thereby activating switch  320 . 
     For example, a user (not shown) may activate switch assembly  310  of device  1  by exerting an activation force on top surface  362  of user button  360  in the direction of arrow A (see, e.g.,  FIGS. 9 and 10 ). This user activation force on button  360  may depress or deform switch  320  from an original position (e.g., as shown in  FIG. 9 ) to an actuated position (e.g., as shown in  FIG. 10 ) to change a functional state of device  1  (e.g., whether the device should power up or turn itself off). 
     Switch assembly  310  may also include one or more contact points (e.g., contact point  336 ). As shown in  FIGS. 9 and 10 , for example, contact point  336  may be provided on support plate  330 . Each of the one or more contact points  336  of input component  310  can be coupled to a processor (not shown, but described in greater detail hereinbelow) of device  1  contained within housing  4 . When switch  320  is at its actuated position of  FIG. 10 , bottom surface  324  of switch  320  may contact or otherwise impart an activation energy onto contact point  336 . This interaction between bottom surface  324  of switch  320  and contact point  336  may change a function or logic of the processor of device  1 . 
     When the user terminates the activation force on top surface  362  of button  360 , switch  320  may return to its original position of  FIG. 9 , thereby terminating its activation energy onto contact point  336 . It is to be understood, however, that although described above to include a contact point  336  on support plate  330 , switch assembly  310  may be configured in various other suitable ways such that activation of switch  320  from its original position to its activation position can change a functional state of device  1  within the spirit and scope of the present invention. 
     Switch assembly input component  310  can be held in place at least partially within housing  4  in any one of various suitable ways such that at least top surface  362  of button  360  is accessible to a user external to housing  4 . For example, as shown in  FIG. 9 , assembly  310  can be held in place about top surface  362  of button  360  and bottom surface  334  of plate  330  by external bracket portions  3  and internal bracket portions  5  of housing  4 , respectively. 
     In some embodiments of the invention, a switch assembly input component of electronic device  1  may be constructed with one or more impact absorption elements such that the switch assembly is resistant to severe impacts on housing  4  and/or the switch assembly itself. For example, as shown in  FIGS. 9 and 10 , switch assembly input component  310  of device  1  may be provided with one or more impact absorption elements  370  such that switch assembly  310  may absorb direct impacts without damaging or destroying the switch assembly itself. 
     As described above, user button  360  of assembly  310  may be operative to actuate switch  320  in response to a user press on top surface  362  in the direction of arrow A. Switch  320  may be any suitable switch, including, for example, a dome switch. Switch  320  may be pre-loaded to provide tactile feedback when the user presses button  360 . In some embodiments, button  360  may be constructed from a hard material (e.g., a hard plastic) to increase the tactile feedback from actuation of button  360 . 
     A number of different approaches may be used to limit the damage to button  360  and switch  320  caused by impacts (e.g., to prevent switch  320  from becoming stuck in an inverted, bi-stable position). In some embodiments, button  360  may be constructed from a soft material (e.g., an elastomer) to absorb impacts. In some embodiments, button  360  and switch  320  may be constructed such that the overall depth of switch assembly  310  (see, e.g., depth d of  FIG. 9 ) is large enough to absorb impacts on button  360 . For example, some existing switch assembly input mechanisms use tactile switches and side-tactile switches having depths that range from between about 5.25 millimeters and about 6.70 millimeters (e.g., the switch assemblies used in the RAZR™ and KRZR™ cellular telephones available by Motorola, Inc. of Chicago, Ill.). These relatively large depths may allow the switches to absorb impacts and limit damage. 
     However, rather than increasing the size of the switch assembly input mechanism, depth d of switch assembly  310  may be reduced and other approaches may be used to reduce the damage of impacts on the switch assembly. For example, assembly  310  may be provided with one or more impact absorption elements  370  coupled to bottom surface  364  of button  320  such that switch assembly  310  may absorb direct impacts without damaging or destroying the switch assembly itself. Instead of bottom surface  364  contacting switch  320  (either directly or via an adhesive, such as adhesive  340 , for example), the one or more absorption elements  370  may be operative to contact switch  320  (or adhesive  340 ) in response to user presses of top surface  362  in the direction of arrow A. 
     Each of the one or more absorption elements  370  may be constructed from any suitable material, including, for example, materials having properties that aid in absorbing the strength of impacts on button  360 . For example, each of the one or more absorption elements  370  may be an elastomer that has a high Young&#39;s modulus to allow for extensive elastic deformation. When button  360  is subjected to an impact, button  360  may transfer the energy of the impact to one or more absorption elements  370 , which may in turn absorb a significant portion of the energy of the impact, and finally provide a reduced portion of the energy of the impact to switch  320 . By reducing the amount of energy transferred from button  360  to switch  320 , each of the one or more absorption elements  370  may reduce the damage caused by impacts to switch assembly  310 . 
     In some embodiments, each of the one or more absorption elements  370  may be twin shot molded with button  360  itself, rather than being a separate element that may require assembly and retention to the button. This may help keep depth d to a minimum. For example, button  360  may be a polycarbonate button twin shot molded with one or more absorption elements  370  of thermoplastic polyurethane (TPU) or any other type of thermoplastic elastomer (TPE). In some embodiments, because an absorption element of elastomer may be softer than a hard plastic absorption element, an elastomer absorption element of the present invention may be pre-loaded such that it may always be slightly compressed and such that it may help give the switch assembly a crispier and more tactile feel. 
     In some embodiments, button  360 , each of the one or more absorption elements  370 , and switch  320  may be constructed to reduce the overall depth d of switch assembly  310 . For example, button  360 , each of the one or more absorption elements  370 , and switch  320  may be constructed such that the overall depth d of switch assembly  310  is about 2.1 millimeters. In some embodiments, the overall depth d of switch assembly  310  may be in the range of 0.5 millimeters to 3.5 millimeters. In some embodiments, the overall depth d of switch assembly  310  may be in the range of 1.0 millimeter to 3.0 millimeters. In some embodiments, the overall depth d of switch assembly  310  may be in the range of 1.5 millimeters to 2.5 millimeters. Despite being at least half as thin as the known switch assemblies described above, switch assembly  310  may be just as durable and just as able to absorb the energy of an impact thereon. 
     In certain embodiments, electronic device  1  can also include at least one user input component that may be of a variety of forms other than that of a switch assembly (e.g., input components  10 ,  110 ,  210 , and  310 ). For example, as shown in  FIG. 1 , device  1  can also include one or more input components  410  that may take other various forms, including, but not limited to sliding switches, keypads, dials, scroll wheels, touch screen displays, electronics for accepting audio and/or visual information, antennas, infrared ports, or combinations thereof. 
     According to certain embodiments of the present invention, the position of one or more of input components  10 ,  110 ,  210 ,  310 , and/or  410  can be widely varied relative to the position of another one or more of input components  10 ,  110 ,  210 ,  310 , and/or  410 . For example, they can be adjacent one another or spaced apart. Additionally, each one of the one or more input components  10 ,  110 ,  210 ,  310 , and/or  410  can be placed at any external surface (e.g., top, bottom, side, front, back, or edge) of housing  4  that may be accessible to a user during manipulation of the electronic device. 
     Furthermore, in certain embodiments of the present invention, each one of the one or more input components  10 ,  110 ,  210 ,  310 , and/or  410  of device  1  can be configured to provide one or more dedicated control functions for making selections or issuing commands associated with operating the device. By way of example, in the case of a music file player, the switch assembly functions of each one of components  10 ,  110 ,  210 , and/or  310  can be associated with powering up or down the device, opening or closing a menu, playing or stopping a song, changing a mode, and the like. 
     As mentioned above, certain embodiments of electronic device  1  can also include at least one output component that provides the user with valuable device generated information. For example, as shown in  FIG. 1 , device  1  can also include one or more output components  2  that may take various forms, including, but not limited to audio speakers, headphones, audio line-outs, visual displays, antennas, infrared ports, or combinations thereof. 
     Furthermore, in certain embodiments of the present invention, each one of the one or more switch assembly input components  10 ,  110 ,  210 , and/or  310  can be integrated with some other input component  410  and/or output component  2  on electronic device  1 , such as switches, push-buttons, keys, dials, trackballs, joysticks, touch pads, touch screens, scroll wheels, displays, microphones, speakers, cameras, and the like. Each of these individual interfaces may include switch assemblies either incorporated therein, such as a switch assembly on a joystick, or forming an integral part thereof, such as a switch assembly with a push-button thereon. 
     Housing  4  of electronic device  1  can also include a processor (not shown), a storage device (not shown), communications circuitry (not shown), a bus (not shown), and a power supply (not shown) for powering the device. The bus of device  1  can provide a data transfer path for transferring data, to, from, or between at least the processor, the storage device, and the communications circuitry. The processor (not shown) of device  1  can control the operation of many functions and other circuitry included in the device  1 . For example, the processor can receive user inputs from switch assembly input component  10  and drive output component  2 . 
     The storage device (not shown) of device  1  can include one or more storage mediums, including, for example, a hard-drive, a permanent memory such as ROM, a semi-permanent memory such as RAM, or cache, that may store media (e.g., music and video files), software (e.g., for implementing functions on device  1 ), wireless connection information (e.g., information that may enable device  1  to establish wireless communication with another device or server), subscription information (e.g., information that keeps track of podcasts, television shows, or other media that the user subscribes to), and any other suitable data. 
     The communications circuitry (not shown) of device  1  can include circuitry for wireless communication (e.g., short-range and/or long-range communication). For example, the wireless communication circuitry of device  1  can be wi-fi enabling circuitry that permits wireless communication according to one of the 802.11 standards. Other wireless protocol standards could also be used, either in alternative or in addition to the identified protocol. Another network standard may be Bluetooth®. The communications circuitry can also include circuitry that enables device  1  to be electrically coupled to another device (e.g., a computer or an accessory device) and communicate with that other device. Furthermore, additional electrical components (not shown) can be provided by device  1  for sending and receiving media, including, but not limited to, microphones, amplifiers, digital signal processors (DSPs), image sensors (e.g., charge coupled devices (CCDs)) or optics (e.g., lenses, splitters, filters, etc.), antennas, receivers, transmitters, transceivers, and the like. 
     While there have been described electronic devices with switch assembly input components having adhesives adhered to the side and/or bottom surfaces of support plates for retaining switches between the adhesives and the tops of the support plates, it is to be understood that many changes may be made therein without departing from the spirit and scope of the present invention. It will also be understood that various directional and orientational terms such as “front” and “back,” “left” and “right,” “top” and “bottom,” “side” and “edge” and “corner,” “height” and “width” and “depth,” and the like are used herein only for convenience, and that no fixed or absolute directional or orientational limitations are intended by the use of these words. For example, the devices of this invention can have any desired orientation. If reoriented, different directional or orientational terms may need to be used in their description, but that will not alter their fundamental nature as within the scope and spirit of this invention. Those skilled in the art will appreciate that the invention can be practiced by other than the described embodiments, which are presented for purposes of illustration rather than of limitation, and the invention is limited only by the claims which follow.

Metadata:
Filing Date: 20070628
Publication Date: 20110201
Grant Date: 20110201
Priority Date: 20070628
Inventors: MIDDLEMAN ADAM DUCKWORTH
TAN TANG YEW
WANG ERIK L.
DINH RICHARD HUNG MINH
HOBSON PHILLIP MICHAEL
JENKS KENNETH A.
Assignee: APPLE INC
CPC Classifications: [{"code": "H01H13/78", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2213/016", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2229/046", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/084", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/48", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2221/064", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/48", "inventive": true, "first": true, "tree": "[]"}, {"code": "H01H2221/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/05", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2225/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2227/036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2229/046", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2205/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2225/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2227/036", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2215/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2213/016", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/084", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2229/028", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/88", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2213/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2205/026", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2221/064", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2215/004", "inventive": false, "first": false, "tree": "[]"}, {"code": "Y10T29/49105", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H2213/002", "inventive": false, "first": false, "tree": "[]"}, {"code": "H01H13/78", "inventive": true, "first": false, "tree": "[]"}, {"code": "H01H2229/028", "inventive": false, "first": false, "tree": "[]"}]
Family ID: 40159061