Patent Grant
9653228
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/994,804, filed on Sep. 21, 2007, the entire contents of which are incorporated herein by reference in their entirety.
This invention is directed to a switch that has cosmetic attributes.
Recent technological advances have facilitated the decrease in size of portable electronic devices such as portable music and video players and cellular telephones. Engineers have been able to reduce the size of circuitry and electronic components in electronic hardware such as the storage, memory and power supply units. However, the overall size of these devices is heavily influenced by the size and shape of its external mechanical components such as enclosures, input mechanisms (for example, switch components) and cosmetic components. These mechanical components pose several constraints on the reduction of the size of the devices. For example, switches used for powering or operating electronic devices can be relatively bulky because several mechanical components may be needed to transfer mechanical force applied by a user to switching an electrical circuit. Moreover, additional mechanical components may be required on the switches for cosmetic and informative purposes.
Typically, engineers attempt to minimize the size of these mechanical components by rearranging the device's electronic components to allow for a more compressed layout. Such rearranging can be cumbersome and at times nearly impossible given the constraints imposed by electrical circuit layouts and the size of the electronic components.
Accordingly, there is a need for smaller and more compact switching assemblies.
The systems and methods described herein are directed to a switch for use in an electronic device. The systems and methods described herein combine the electrical and mechanical components of the switch; the actuator has a conductive inner surface that connects to an electrical circuit and a cosmetic outer surface for providing information and an input interface to a user. The systems and methods described herein provide for thinner switching assemblies thereby allowing for a reduction in the size of the electronic device. For purposes of clarity, and not by way of limitation, the systems and methods may be described herein in the context of switching assemblies that are associated with electronic devices. However, it may be understood that the systems and methods described herein may be applied to any mechanical component associated with an electronic device.
The systems and methods provide switching assemblies for electronic devices, for example a dome switch having a cosmetic actuator. The switching assemblies may include an elastically deformable actuator having a conductive inner surface and a cosmetic outer surface. The actuator may be disposed on an exterior surface of an enclosure that houses the electric circuit board of the electronic device. The enclosure may have one or more openings for providing an electrical connection between the actuator and the enclosed circuit of the electronic device. When the actuator is pressed or displaced, an electrical circuit may be closed and electric current may flow through the conductive inner surface of the actuator. The actuator may be combined with a perimeter element for snapping on and off the enclosure.
In one aspect, the systems and methods described herein may include switch assemblies for an electronic device. The switch assemblies may include a housing for enclosing circuitry. The housing may include an exterior surface having an indentation, and at least two openings in the indentation for enclosing electrical contacts connected to the circuitry. The switch assemblies may further include a cover disposed over the indentation, overlapping the at least two openings and adapted to attach to the housing. The cover may include an elastically deformable actuator having an inner conducting surface for actuating the circuitry when connected to the electrical contacts. The cover may additionally include a perimeter element formed on the perimeter of the actuator and adapted to attach to the housing along the perimeter of the indentation. In some embodiments, the exterior surface of the housing on the indentation may be adapted to accommodate a circuit board.
The perimeter element may be co-molded with the actuator. In some embodiments, the perimeter element may be mechanically coupled to the housing along the perimeter of the indentation. In such embodiments, the housing may include a recess extending along the perimeter of the indentation and shaped to receive the perimeter element such that the perimeter element may mechanically couple with the recess to attach to the housing. The perimeter element may snap fit or press fit to the housing along the perimeter of the indentation. Alternatively, or in addition, the perimeter element may be coupled to the housing using an adhesive tape, a mechanical fastener, or any other suitable coupling mechanism.
In some embodiments, the perimeter element may include a portion formed from an elastomeric material. The actuator may be formed from at least one of metal, plastic, composite material and elastomers.
In some embodiments, the housing includes a plurality of retention openings near the perimeter of the indentation, and the perimeter element includes one or more retention legs adapted to couple with the retention openings for attaching the cover to the housing.
In another aspect, the systems and methods described herein may include a switch assembly for an electronic device. The switch assembly may include a housing for enclosing circuitry, the housing including at least two openings for enclosing electrical contacts connected to the circuitry. The assembly may include a cover disposed on a surface of the housing over the at least two openings. The cover may include an elastically deformable actuator having an inner conducting surface for actuating the circuitry when connected to the electrical contacts. The cover may further include a perimeter element attached to a perimeter of the actuator. In certain embodiments, the assembly may include a retaining flange attached to the housing, disposed along the perimeter of the cover and overlapping a portion of the perimeter element.
In some embodiments, the flange may include one or more protrusions for restraining the cover in between the housing and the retaining flange. The flange may be formed from at least one of metal, plastic and composite materials. The flange may be attached to the housing using adhesive, tape, press fit, welding, or any other suitable attachment mechanism.
In yet another aspect, the systems and methods described herein may include a switch assembly for an electronic device. The switch assembly may include a housing enclosing circuitry and several retention openings. The assembly may include a cover disposed on a surface of the housing over the several retention openings. The cover may include an elastically deformable actuator having an inner conducting surface for actuating the circuitry. The cover may further include at least one retention leg attached to the actuator and configured to fit through the plurality of retention openings for attaching the cover to the housing.
In some embodiments, one or more retention legs may be attached to the actuator by at least one of welding, soldering, co-molding and adhesion. The retention legs may be mechanically coupled to the housing. The retention legs may occupy the retention openings and may be snap fit to the housing.
In still another aspect, the systems and methods described herein may include a switch assembly for an electronic device. The switch assembly may include a housing for enclosing circuitry, the housing including several openings for enclosing electrical contacts connected to the circuitry. The assembly may also include a cover disposed on a surface of the housing. The cover may include an elastically deformable actuator having an inner surface with several spaced apart conducting regions for actuating the circuitry when positioned over the several openings and connected to the electrical contacts. In some embodiments, the assembly may include a retaining flange attached to the housing and disposed along the perimeter of the cover to retain the cover in position on the housing.
In another aspect, the systems and methods described herein may include methods of manufacturing a switch assembly for an electronic device. The method may include providing a housing and a cover. The housing may enclose electronic circuitry, and have an indentation on an exterior surface, and several openings in the indentation. The cover may include an elastically deformable actuator having an inner conducting surface and a perimeter element formed on the perimeter of the actuator. The method may include connecting one or more conducting elements to the circuitry such that the conducting elements pass through the several openings. The cover may be attached to the housing by coupling the perimeter element with the perimeter of the indentation of the housing.
In still another aspect, the systems and methods described herein may include a switch assembly. The switch assembly may include a housing with an exterior surface having an indentation, and at least two openings on the exterior surface and within the indentation. The switch assembly may further include an electrical circuit board disposed within the housing such that a portion of the circuit board is accessible through the openings. The assembly may also include a cover and at least two conducting elements. The cover may be disposed over the indentation, overlapping the at least two openings and adapted to attach to the housing. The cover may include an elastically deformable actuator having an inner conducting surface. The cover may further include a perimeter element formed on the perimeter of the actuator and adapted to attach to the housing along the perimeter of the indentation. In some embodiments, the at least two conducting elements, for example conducting springs, may be disposed within the openings and connected to the electrical circuit board such that at least one of the conducting elements is connected to the inner conducting surface of the cover. The cover may electrically connect the at least two conducting elements when the elastically deformable actuator is depressed.
The above and other objects and advantages of the invention will be 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:
As will be seen from the following description, in some aspects, the systems and methods provide for switching assemblies for electronic devices (e.g., a dome switch having a cosmetic actuator). The switching assemblies may include an elastically deformable actuator having a conductive inner surface and a cosmetic outer surface. The actuator may be disposed on an exterior surface of an enclosure that houses the electric circuit board of the electronic device. The enclosure may have one or more openings for providing an electrical connection between the actuator and the enclosed circuit of the electronic device. When the actuator is pressed or moved, an electrical circuit may be closed and electric current will flow through the conductive inner surface of the actuator. The actuator may be combined with a perimeter element for snapping on and off the enclosure.
Switch 110 may include any suitable switch. For example, switch 110 may include a dome switch. In some embodiments, switch 110 may be constructed such that it is exposed and directly actuated by the user (e.g., without a cap being placed over the dome switch). Switch 110 may include dome 112 operative to be mounted in indentation 122 of housing 120. Dome 112 may be constructed from any suitable material, including for example metal (e.g., aluminum or steel), plastic, a composite material, an elastomer, or any other suitable material. In some embodiments, dome 112 may be finished (e.g., polished, etched, or decorated) to provide an aesthetically pleasing and cosmetic surface. Switch 110 may include surface decals, adhesives and/or other suitable markings for providing instructions and guidance to a user. Dome 112 may be constructed such that, in response to a user actuation of switch 110 (e.g., in response to a user pressing dome 112), dome 112 may elastically deform (e.g., into free space 114) such that a portion of dome 112 contacts board 130 (e.g., a flex) or spring 132 (e.g., a copper or conductive rubber flexible component) to short an electric circuit and provide an electric signal to the electronic device of assembly 100.
Switch 110 may be mounted in housing 120 using any suitable approach. In some embodiments, a switch may be coupled to a housing by placing a film coupled to the housing (e.g., using an adhesive) over the switch. In some embodiments, a switch may be press fit into a housing.
Outer surface 216 of ring 214 may have any suitable shape. In some embodiments, outer surface 216 may be constructed in a shape operative to increase the force required to remove ring 214 from recess 224, thus preventing accidental removal of switch 210 from housing 220.
In some embodiments, the switch may be mounted to the housing using a retaining flange placed over the dome.
Flange 430 may be constructed from any suitable material. For example, flange 430 may be constructed from a metal, plastic, composite material, or any other suitable material. Flange 430 may be coupled to housing 420 using any suitable approach. For example, flange 430 may be coupled to housing 420 using an adhesive, tape (e.g., clear tape), a press fit, welding (e.g., at contact point 436 between flange 430 and housing 420), or any other suitable approach. In some embodiments, flange 430 may include one or more posts or protrusions (e.g., snaps) operative to engage housing 420 to restrict dome 412 and ring 414 to the space between housing 420 and flange 430. In some embodiments, one or more flanges 430 may be operative to couple several switches 410 to housing 420. The flange 430 may be finished (e.g., polished, etched, or decorated) to provide an aesthetically pleasing and cosmetic surface.
In some embodiments, one or both of the dome and ring may include posts with tabs extending from the surface of the dome and ring, respectively, and operative to engage the housing.
Posts 516 and 526 may be coupled to ring 514 and dome 522, respectively, using any suitable approach. For example, posts 516 and 526 may be welded, soldered, molded, formed, coupled using an adhesive or tape, mechanically coupled (e.g., using a press fit or a snap), heat treated (e.g., melted to ring 514 or dome 522), or coupled to ring 514 and dome 522, respectively, using any other suitable approach. Posts 516 and 526 may be coupled to the housing using any suitable approach. For example, posts 516 may be coupled to the housing using one or more of a press fit, an adhesive, tape, a mechanical engagement (e.g., a snap), welding, soldering, or any other suitable approach. In some embodiments, the length of posts 516 and 526 may exceed the length required to be coupled to the housing. The excess length may allow easier placement of switch 510 or 520 in the housing by permitting the posts to be pulled or manipulated to properly place the switch in the housing. The excess length of the posts may be subsequently removed prior to completing the assembly of the electronic device or accessory (e.g., cutting the excess length once the switch is coupled to the housing).
In some embodiments, a housing may include several switches (e.g., dome switches). The switches may be coupled to the housing using any suitable approach. For example, the switches may be coupled to the housing individually, or as a sheet of switches. In some embodiments, switches may be manufactured by stamping switches in a strip of material (e.g., metal), punching each individual switch, and subsequently mounting each individual switch in the housing. In some embodiments, the housing may instead include a sheet having several switches.
Each switch may be operative to provide an electrical signal indicating that the switch has been actuated using any suitable approach.
Switch assembly may include any suitable number of springs 840 and 842 (e.g., three springs). Springs 840 and 842 may include any suitable conductive portion operative to provide an electrically conductive path between flex 830 and flex 850 through housing 820 or springs with a conductive element (e.g. constructed from a metal or conductive rubber). For example, springs 840 and 842 may include copper springs placed in apertures of housing 820. When switch 810 is actuated (e.g., a user presses switch 810), at least two points of the inner surface of switch 810 may be brought into contact with flex 830 such that the circuit including flex 830, springs 840 and 842 and flex 850 may be shorted, thus sending an electrical signal that control circuitry can process.
In some embodiments, flex 830 may be eliminated.
Variations, modifications, and other implementations of what is described may be employed without departing from the spirit and scope of the invention. More specifically, any of the method, system and device features described above or incorporated by reference may be combined with any other suitable method, system or device features disclosed herein or incorporated by reference, and is within the scope of the contemplated inventions. The systems and methods may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative, rather than limiting of the invention. The teachings of all references cited herein are hereby incorporated by reference in their entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20090078553 A1 | Mar 2009 | US |
