KR20130054390A - Very small form factor consumer electronic product - Google Patents

Abstract

The small form factor home appliance comprises at least a single piece of housing having an integral front wall and a side wall that cooperate to form a cavity in cooperation with the front opening, wherein the side The edge of the wall defines the back opening and at least some of the edges have flanges. The household appliance also includes a user input assembly having a size and shape along the front opening, a clip assembly having a size and shape along the rear opening and having an external user operable clip, a plurality of internal hooking features, and a plurality of internal latching features. It includes. The clip assembly is secured by engaging the flanges on the edges of the housing with at least some of the hooking features and engaging the latching features with the corresponding attachment features on the inner support plate.

Description

VERY SMALL FORM FACTOR CONSUMER ELECTRONIC PRODUCT}

The described embodiments relate generally to consumer electronic products and, more particularly, to highly portable micro media playback devices.

Recently, small form factor electronics such as media players and cellular telephones have become smaller, lighter and more versatile by merging more powerful operating components into smaller, denser packaged configurations. This size reduction and density increase can be attributed, in part, to the manufacturer's ability to manufacture various operating components such as microprocessors and memory devices in smaller sizes while increasing their capability and / or speed of operation. However, the smaller size and increased component density and capabilities pose a number of ongoing design and assembly challenges.

For example, small form factor home appliances, such as media players, may require the assembly of multiple components into enclosures with extremely small volumes. Assembling the various components into such a small sized housing can require complex, expensive and time consuming assembly techniques. In addition, aesthetic considerations can severely restrict the placement, size, and number of components used in the manufacture of small form factor home appliances. For example, it may be extremely difficult to achieve proper alignment of external features such as buttons when the small size of the household appliance itself can severely reduce the tolerance stack of assembled components.

Another problem to be addressed relates to suitable techniques for mounting structures in small form factor home appliances. For example, using conventional assembly techniques, various internal component structures can be attached to the housing using fasteners such as screws, bolts, rivets, and the like and sandwiched in layers. However, using this technology in small form factor devices is time consuming, expensive and error prone.

In light of the above, there is a need for improved component density and associated assembly techniques that reduce cost and improve outgoing quality. There is also a need for improvements in the manner in which handheld devices are assembled, such as improvements that allow structures to be installed quickly and easily in an enclosure.

A compact form factor consumer electronic product is, at least, a single piece having integral front and side walls that cooperate to form a cavity in cooperation with the front opening. Wherein the edge of the side wall defines a rear opening and at least some of the edges have a flange. The household appliance also includes a user input assembly having a size and shape along a front opening, the input assembly including a user input and an inner support plate, the inner support plate having an outward surface to which the user input is attached, and an inwardly having attachment feature. With a face, some of the attachment features are used to secure the internal components of the household appliance in a compact form factor. The household appliance also includes a clip assembly having a size and shape along the rear opening and having an external user operable clip, a plurality of internal hooking features, and a plurality of internal latching features. In the described embodiment, the clip assembly is secured to a small form factor home appliance by engaging the flanges on the edge of the housing with at least some of the hooking features and engaging the latching features with the corresponding attachment features on the inner support plate.

In yet another embodiment, a method for assembly of a compact form factor media player is described. This method may be performed by executing at least the following operations. Providing a housing having at least one side wall having a front opening, a back opening, and a plurality of openings, each sized and arranged to receive an outer feature, the electrical connection of the first component and the second component; Mechanically securing the electrically connected first and second components together, inserting the mechanically fixed first and second components into the back openings such that the first components align with the front openings, and the microminiature Securing a third component to the first and the second component to complete assembly of a form factor media player.

A non-transitory computer readable medium for storing a computer program used by a processor to assemble a compact form factor media player includes at least a front opening, a back opening, and a plurality of resized each arranged to accommodate external features. Computer code for providing a housing having at least one side wall having an opening of the computer code, computer code for electrically connecting the first component and the second component, and mechanically fastening the electrically connected first and second components together. Computer code for inserting, computer code for inserting mechanically fixed first and second components into the back opening so that the first component aligns with the front opening, and a third component to complete assembly of the media player in a compact form factor. Computer code for fastening the to the first and second components It should.

The media player includes an electrically conductive housing that provides chassis ground and has a front opening and a back opening, and a click wheel assembly having a size and shape along the front opening. In the described embodiment, the circular click wheel has an outer surface, each displaying a plurality of icons associated with a particular media player operation. The click wheel assembly also includes an inner support plate having an inward surface with an attachment feature and an outward surface with a circular click wheel attached and each electrically connected to the flex connector and having a plurality of sensors associated with one of the plurality of icons. . When pressure is applied near one of the plurality of icons, a corresponding one of the plurality of sensors responds by providing a signal to the flex connector. The media player further includes a main logic board (MLB) assembly mechanically fixed to the inner support plate using at least one of the attachment features. In the described embodiment, the MLB assembly comprises at least a printed circuit board (PCB), a plurality of electrical components at least one of which is a processor, an audio jack assembly arranged to output audio signals and receive power; And a battery arranged to provide stored power to at least the main logic board. At least a portion of the audio jack assembly and the plurality of electrical components are surface mounted to the PCB. The media player also includes a clip assembly having a size and shape along the back opening. The clip assembly is formed of a user operable clip, a plurality of inner hooking features, and a plurality of inner latching features, wherein the clip assembly engages and latches the flanges on the edge of the housing with at least some of the hooking features. And partially secured by engaging the corresponding attachment features on the inner support plate.

Prevents Moisture Penetration in Small Form Factor Appliances

The small form factor home appliance comprises a single piece of housing having an integral front wall and a side wall that cooperate to form a cavity in cooperation with the front opening, wherein the edge of the side wall is a rear opening. Define. In the described embodiment, at least some of the edges have flanges and at least one of the side walls includes an opening sized to receive the I / O device. The media player also includes a clip assembly having a size and shape along the back opening and having a plurality of attachment features, wherein the plurality of attachment features are used to secure the clip assembly to a single piece of housing. The media player also includes a plurality of moisture barriers, each formed of a moisture proof material, the plurality of moisture barriers cooperating to prevent the migration of moisture from the external environment to the cavity.

In yet another embodiment, a method for assembling a media player is disclosed. The media player includes at least a single piece of housing having an integral front wall and side walls cooperating to form a cavity in cooperation with the front opening, the edge of the side wall defining the back opening. In the described embodiment, at least some of the edges have flanges and at least one of the side walls includes an opening sized to receive the I / O device. The method may be performed by providing a housing, and forming a plurality of moisture barriers each formed of a corresponding moisture proof material, the plurality of moisture barriers preventing penetration of moisture from the external environment into the cavity. Cooperate to

A non-transitory computer readable medium for storing a computer program used by a processor used to control a computer manufacturing system for automatically assembling a media player, at least, allows a flow of moisture from an external environment into an internal cavity of the media player. And computer code for forming a plurality of moisture barriers each formed with a corresponding moisture proof material that prevents the formation of moisture. The ultra small form factor home appliance comprises at least a single piece of housing having an integral front wall and side walls cooperating to form a cavity in cooperation with the front opening, wherein the edge of the side wall defines the back opening, and among the edges At least a portion has a flange and at least one of the side walls includes an opening sized to receive the I / O device. Also included is a clip assembly having a size and shape along the back opening, the clip assembly having a plurality of attachment features used to secure the clip assembly to a single piece of housing, and a plurality of moisture barriers each formed of a moisture resistant material, The plurality of moisture barriers cooperate to prevent moisture from moving from the external environment into the cavity. In the described embodiment, at least one of the plurality of moisture barriers is an audio jack assembly electrical moisture barrier. Audio Jack Assembly Electrical Contact The moisture barrier includes at least an electrical contact that includes a flat pad portion and a central raised portion, wherein the electrical contact is integrally formed with the audio jack assembly housing. Through a sealing tape layer applied to the audio jack assembly housing that includes the pad portion of the electrical contact and leaves the raised portion exposed, and through the raised portion by a solder reflow process. Also included are flex substrate layers that are electrically connected to the electrical contacts. The solder reflow process causes the liquid solder to move and fill into the recessed areas between the raised portions, the sealing tape, and the flex substrate, and the solder filled recesses form a moisture barrier between the inner portion of the home appliance and the external environment in a compact form factor. To provide.

In yet another embodiment, a method is described. This method includes at least the following operations. An audio jack assembly comprising an audio jack barrel having a size and shape in accordance with an audio post connected to an external circuit, the plurality of electrical contacts being integrally formed with the audio jack barrel, Contact is formed of a flat pad portion and a raised portion. The method includes at least applying a layer of sealing tape to the electrical contact such that the sealing tape forms a layer over the pad portion and leaves the raised portion exposed, applying the flex substrate onto the sealing tape layer, and Electrically connecting the flex substrate layer to an electrical contact through a portion, wherein the electrical connection is such that the solder paste associated with the flex substrate is liquefied and flows into the recess between the raised portion of the electrical contact and the sealing tape. Performed by performing a solder reflow operation on the jack assembly, the cooled solder forms a moisture barrier seal that essentially prevents moisture from coming out of the audio jack barrel.

Moisture resistant sealing used in electrical components of the electrical system, where the moisture resistant seal prevents the flow of moisture from the moisture resistant portion of the electrical component to the moisture resistant portion of the electrical system. The moisture resistant sealing structure includes at least a primary seal structure used to provide the first sealing layer, and a finish seal structure applied to the primary seal structure. The finish seal structure, in cooperation with the primary seal structure, prevents the flow of moisture between the moisture tolerant portion of the electrical component and the moisture intolerant portion of the electrical device.

In one aspect, the finish seal structure is formed during the solder reflow operation.

ESD Protection in Small Form Factor Home Appliances

The media player includes a button assembly including a housing formed of an electrically conductive material and an external feature arranged to receive a user input event. This outer feature is connected to an inner switch spaced from the outer feature via an electrically conductive arm that fits a slit in the moisture flow prevention seal. The seal is formed of an insulating material, and at least a portion of the seal is coupled with the conductive dopant to form a conductive path between the electrically conductive arm and the housing. The conductive path allows an amount of charge deposited on the outer feature to flow directly through the electrically conductive arm and the conductive portion of the seal into the housing and bypass the internal switch.

In yet another embodiment, the media player includes a housing and button assembly formed of an electrically conductive material. The button assembly, in turn, includes an outer feature arranged to receive a user input event, an electrically conductive arm arranged to connect the outer feature to the inner switch, and a metal base portion integrally formed with the outer feature. The metal base portion connects the outer feature to the electrically conductive arm, and the metal label is mounted to the metal base portion using the conductive adhesive. A conductive path is formed between the electrically conductive arm and the housing that allows an amount of charge deposited on the outer feature to flow directly through the metal label and metal base into the housing and bypass the internal switch.

Providing a housing formed of an electrically conductive material and having a housing having at least one opening, the external feature arranged to receive a user input event, the external feature being connected to an internal switch spaced from the external feature via an electrically conductive arm; Providing a button assembly comprising: providing a block formed of an electrically insulating moisture resistant material and having a slot sized to receive an electrically conductive arm, wherein at least a portion of the block is electrically conductive Introducing a conductive dopant, inserting an outer feature into the opening of the housing; And inserting an electrically conductive arm through the slot into a slot in electrical contact with the conductive portion of the block. A conductive path is formed between the outer feature and the housing through an electrically conductive arm and the conductive portion of the block, the conductive path allowing a certain amount of charge deposited on the outer feature to flow directly into the housing and bypass the internal switch.

Providing a housing formed of an electrically conductive material, providing a button assembly, the button assembly comprising an external feature arranged to receive a user input event, an electrically conductive arm arranged to connect the external feature to an internal switch, And a metal base portion integrally formed and connecting the outer feature to the electrically conductive arm, and the metal label; conductively mounting the metal label to the metal base portion using a conductive adhesive; A conductive path is formed between the outer feature and the housing through the metal label and the metal base portion, the conductive path allowing a certain amount of charge deposited on the outer feature to flow directly into the housing and bypass the internal switch.

Other aspects and advantages will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate by way of example the principles of the invention.

Embodiments will be readily understood by the following detailed description with reference to the accompanying drawings, wherein like reference numerals refer to similar structural elements.
1 is a front view of an exemplary ultra small form factor media player in accordance with the described embodiments.
FIG. 2 shows a side view of the exemplary micro form factor media player of FIG. 1 with the clip in a closed configuration.
3 shows a side view of the exemplary micro form factor media player of FIG. 1 with the clip in an open configuration.
4 is an exploded view illustrating various subassemblies of components used in the manufacture of media player 10.
5-7 illustrate various perspective views of an exemplary housing in accordance with the described embodiments.
8-11 illustrate various components of a click wheel assembly in accordance with the described embodiments.
12 illustrates a representative clip assembly in accordance with the embodiments described above.
13 illustrates a representative click assembly seal in accordance with an embodiment.
14 illustrates a main logic board (MLB) assembly according to an embodiment.
15A-17 show perspective views of an audio jack assembly in accordance with the described embodiments.
18 and 19 illustrate an internal moisture detection system in accordance with the described embodiments.
20 illustrates an assembly tool used to surface mount an audio jack assembly in accordance with the described embodiments to a paneled printed circuit board.
21-24 illustrate aspects of hold button assemblies according to the described embodiments.
25 illustrates a technique for reducing the allowable stack of playlist buttons for a housing in accordance with an embodiment of the present invention.
26 shows a flowchart detailing an assembly process according to the described embodiments.
FIG. 27 shows a flowchart detailing a process for shunting electrostatic charge to chassis ground in accordance with the described embodiments.
28 illustrates an exemplary media player according to the embodiments described above.
29-32 illustrate techniques and structures well suited to forming a moisture ingress seal for an audio jack assembly in accordance with the described embodiments.

In the following document, numerous specific details are set forth in order to provide a thorough understanding of the underlying concepts of the described embodiments. However, it will be apparent to one skilled in the art that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order not to unnecessarily obscure the underlying concepts.

This document discusses aesthetically pleasing portable computing devices as well as techniques for preventing the penetration of moisture into portable computing devices. The portable computing device can have a size and weight that allows the portable computing device to be easily carried. For the remainder of this discussion and in the light of a compact form factor media player arranged to store a plurality of digital media items that can be selected and decoded for playback without loss of generality, the portable computing device will be discussed. will be. However, due to its small size and light weight, any decoded media item signal (such as audio) is not broadcast through an audio transducer such as a speaker. Rather than broadcasting the audio signal as sound, the media player may use an interface such as an audio jack to deliver the decoded signal to external circuitry for further processing. For example, if the decoded media file is an audio file, the decoded audio signal can be delivered to external circuitry included or attached to headphones, external speakers, an audio recorder, or the like, via the audio jack.

The ultra small form factor media player can be sized to attach to a strap or to hang on the neck, waist, wrist, or the like, for easy portability in a hand or pocket. Partly due to its small size and lack of available space, ultra-small form factor media players can have limited functionality. Limited functionality means that a compact form factor media player can be targeted to perform certain tasks, such as storing, retrieving, and decoding a limited number of digital files. Since further processing of the decoded digital file is easy to be performed outside of the compact form factor media player, the input functions used to control the operation of the media player are simple such as media file selection, media file decoding, and volume up / down. It may be limited to operating parameters. Thus, the number and type of input features may also be limited. For example, selection of a stored media item (or items) may be performed by a user manipulating a mechanical input along a line of mechanical buttons, such as a dome switch. Mechanical input can also be used to modify other functions performed by the media player, such as volume increase / decrease, fast forward / rewind, and the like. In some cases, it may be beneficial to provide certain input features arranged to perform certain functions. For example, an input feature in the form of a sliding switch can be used to activate a hold or pause function, while a simple feature such as a button can be used to perform complex actions such as selecting a playlist (group of related media items). Can be.

The micro form factor media player may include a seemingly single piece of housing formed from any number of durable materials. In certain embodiments, the housing may be formed of a conductive material suitable to provide good chassis ground. Thus, the housing can be formed of a material such as a metal, a conductive plastic, or a conductive composite material. One of the advantages of using metal for the housing is the metal's ability to provide good electrical ground to any internal components that require a good ground plane. Good ground planes can be used to help mitigate the deleterious effects caused by, for example, electromagnetic interference (EMI) and / or electrostatic discharge (ESD). In a particularly useful configuration, the housing may be formed of a single billet of metal, such as aluminum. From a single billet of aluminum, a single piece of housing may be shaped and sized to receive a plurality of internal components. In addition, due to the single piece construction, various openings in the housing for accommodating various switches, connectors, etc. can be formed without the need for adding additional structural supports. By surface-treating aluminum, the aesthetic appearance and feel of the media player can be significantly improved along with long term durability against corrosion and scratches. For example, anodizing an aluminum housing can create a layer on the surface of the aluminum that enhances the luster and gloss of the aluminum housing while at the same time increasing the resistance to scratches and corrosion.

Simple and efficient design and assembly techniques are available that enable both the aesthetic appearance and functionality of the ultra small form factor media player. For example, due to the small size and compactness of the operating components in the media player, any external moisture that finds its way into the media player significantly increases the likelihood of damage through corrosion or electrical shorts. Minimizing or at least disturbing the penetration of moisture into the media player's interior can be an important factor in the long term operability of the media player. Thus, as part of the overall design, multiple moisture / pollutant protectors can be strategically placed within the media player. The preventers can take many forms, such as moisture proof tape, adhesives, thermoformed plastic caps, and the like. The protectors may include, for example, a waterproof membrane along the lines of Kapton, Mylar, and the like. The protectors may also take the form of blocks of compressible moisture proof material, such as silicone rubber. In the described embodiments, the block-shaped moisture protector may remove some to form a slit sized to receive a mechanical arm used to activate a mechanical input such as a switch. In the described embodiments, the mechanical arm can pass through a slit formed in the moisture resistant material to effectively isolate the portion of the arm in contact with the active circuit and the outer portion exposed to the external environment. In this way, the strategic placement of moisture protectors can significantly reduce the risk of moisture entering the interior of the media player causing corrosion and electrical shorts.

In addition to providing a good moisture protector, in some embodiments, a portion of the selected moisture protector may be reinforced in such a way that a conductive path can be formed. For example, with respect to the silicone rubber moisture protector described above, by application of selected dopants (such as silver microspheres), the silicone rubber will become somewhat conductive to the point where a good path to ground can be formed. Inherent insulation properties of the silicone rubber can be modified. In this way, the moisture protector not only significantly impedes the passage of moisture into the media player, but also provides ESD protection by providing a mechanism for dissipating the accumulated charge in a ground plane in the form of a housing.

These and other embodiments are discussed below with reference to FIGS. 1 to 28. However, those skilled in the art will readily understand that the detailed description given herein in connection with these drawings is for illustrative purposes only and should not be regarded as limiting.

Referring first to FIGS. 1-3, a representative micro form factor media player 10 (hereinafter simply referred to as media player 10) is shown in various perspective views. The media player 10 may process data, and more specifically, media data such as audio, video, images, and the like. By way of example, media player 10 may generally correspond to a device that may operate as a music player. Media player 10 may have operational components surrounded and supported by housing 12. The media player 10 may have an upper surface portion 14, a side surface portion 16, and a lower surface portion 18. Media player 10 may include one or more input devices. One or more input devices may include a touch sensitive input device that may take the form of a click wheel assembly mounted to the front portion of the housing 12 as shown in FIG. 1. The click wheel assembly may include at least the click wheel 20. The click wheel 20 may be formed of an elastic material such as plastic or metal. The click wheel 20 is a raised annular portion provided on the surface with a number of icons 24 each corresponding to a particular button function that can be performed by the media player 10 in response to a user touch event. 22). The button function may include selecting and playing a song, fast forwarding or fast rewinding the song, increasing / lowering the volume, and the like. In the described embodiment, various button functions can be implemented using mechanical click actions.

Each icon 24 may be associated with a sensor arrangement (described below) to convert user touch events into signals that may be processed and acted upon by the media player 10. When pressure is applied to a particular icon, the associated portion of click wheel 20 may respond by mechanically engaging a corresponding one of the plurality of sensors. In the simplest case, an electrical signal is generated each time the sensor is connected. In most cases, the signal is monitored by an electronic interface that converts the signal into information. This information can then be used by the media player 10 to perform the desired control function. The click wheel 20 may also include a center button 26. The center button 26 may be formed of plastic or metal. When pressure is applied to the center button 26, a signal may be generated that may cause the media player 10 to perform a predetermined function. For example, when pressure is applied to the center button 26, a signal can be generated and forwarded to the processing circuitry that can cause the media player 10 to start or stop playback of the media item. It should also be noted that the shape of the click wheel 20 can vary widely. For example, the click wheel 20 may be circular, rectangular, square, oval, triangular, or the like.

The button portion 18 may include a clip assembly 28 that may have a closed configuration as shown in FIG. 2 and an open configuration as shown in FIG. 3. have. Clip assembly 28 may be used to secure media player 10 to external features such as clothes, lanyards, and the like. The clip assembly 28 may comprise a clip 30 integrally formed with a torsion spring block 32 comprising a torsion spring, the torsion spring block 32 being referred to as a door 34. ) Is attached to the clip plate 34. Clipboard 34 may include various attachment features (not shown), and is hooked to attach clip assembly 28 to housing 12 and to completely enclose internal components of media player 10. And both latching types can be used. In order to securely attach the media player 10 to the object using the clip assembly 28, pressure P is applied to the clip 30 around the torsion block 32 such that the clip 30 rotates from the clip plate 34. It is possible to cause the clip assembly 28 to transition from the closed configuration of FIG. 2 to the open configuration of FIG. 3. In this way, a gap 36 of sufficient size to accommodate an object or a portion of the object, such as a shirt sleeve, lapel, strap, or the like, may be formed between the clip plate 34 and the clip 30. Thus, by removing the pressure P applied to the clip 30, the spring force generated by the torsion spring of the torsion spring block 32 is transferred to the clip 30 when the clip assembly 28 returns to the closed configuration. Can engage an object. In this way, the clip 30 can grab and fix the object without damaging either the object or the media player 10, thereby making it easy to fix the media player 10 to an object such as clothes, straps, or the like. Can be.

Media player 10 may also include one or more switches, such as a playback switch, hold switch, and the like, accessible through various openings in housing 12. For example, the hold switch button 38 may be used to activate or deactivate the click wheel 20. This is generally done to prevent unwanted commands from being generated by the click wheel 20, such as when the media player 10 is stored in a pocket of a user. Hold switch button 38 may take many forms, such as two, three, or more position buttons. For example, when configured as a three position switch as shown in FIGS. 2 and 3, the hold switch button 38 has a first, second, and third position with respect to the housing 12. It can have Label 40 may be provided to provide a user with a quick and clear indication of the location of hold switch button 38. The label 40 is distinguished (such as the different colored portions shown in FIGS. 2 and 3 in the form of green portions GP and blue portions BP) to indicate the position of the hold switch button 38. Provide visual markers. For example, at position 2 (corresponding to the center position of the hold switch button 38), the label 40 shows both the green portion GP and the blue portion BP of the label 40 simultaneously. It can clearly indicate that the hold switch button 38 is in position 2. In order to remain clear and distinct over the expected operating life of the media player 10, the label 40 may be formed of an elastic material such as metal.

Media player 10 may include an audio jack port 42. The audio jack port 42 mechanically and electrically couples the media player 10 to external circuitry so that audio information can be output from the media player 10 and data can be imported into the media player 10. In some cases, power may be delivered to the media player 10 through circuitry associated with the audio jack port 42. The audio jack port 42 may receive a post (not shown) that may enable the transfer of information (or power) between the media player 10 and external circuitry. For example, audio signals from decoded digital audio files can be delivered to external audio rendering devices such as headphones, speakers, and the like. In order to minimize the number and complexity of mechanical input assemblies required to operate the media player 10, a number of multifunctional mechanical inputs may be provided. For example, playlist button 44 may be used to activate complex functions such as selecting a playlist of media items for playback by media player 10. As is well known to those skilled in the art, a playlist is a collection of media items such as songs selected as a group to be played one at a time. Thus, by simply pressing the playlist button 44, any song identified as belonging to a particular playlist can be selected, decoded, and played. In this way, the need for complex user interactions such as scrolling is eliminated, making the media player 10 simple and easy to operate.

4 is an exploded view illustrating various subassemblies of components used in the manufacture of media player 10. The subassembly may include a housing 100, a click wheel assembly 200, a clip assembly 300, a main logic board (MLB) assembly 400, and a hold switch assembly 500, Each is described in detail below.

The housing 100 of the first perspective view of the embodiment of the housing 12 shown in FIG. 5 may be formed of any number of materials, such as plastic or metal, which can be forge, molded or otherwise processed into the desired shape. have. If the media player 10 has a metal housing and includes RF based functionality, it may be beneficial to provide at least a portion of the housing 100 in the form of a wireless (or RF) transparent material such as ceramic or plastic. In any case, the housing 100 may be configured to at least partially enclose any suitable number of internal components associated with the media player 10. Housing 100 may enclose and internally support various structural and electrical components (including integrated circuit chips and other circuits) that provide computational operations for media player 10. Integrated circuits may take the form of chips, chipsets, modules that may be surface mounted on a printed circuit board, ie, a PCB, or other support structure.

Thus, housing 100 is substantially a chassis or “exoskeleton” for the entire device, which includes device components and can serve as a starting point for assembling the entire device. The housing 100 may also include various openings, some of which may be used to install an insert including various internal components, as well as buttons, ports, audio jacks, and the like, as described below. have. For example, the front opening 102 can be sized to receive the click wheel assembly 200, while the back opening 104 can receive the clip assembly 300. The opening 106 (shown more clearly in FIGS. 6 and 7, respectively providing second and third perspective views of the housing 100, respectively) can be sized to receive the audio jack port 42, while the opening 108 may receive playlist button 44, while opening 110 may receive hold switch button 38. The fastening feature 112 can be used to assist in securing the internal components to the housing 12 using a fastener such as a screw. The flange 114 may support a moisture proof seal arranged to prevent at least penetration of moisture into the interior of the media player 10.

When the housing 100 is formed of a good conductor such as aluminum, the housing 100 can function as chassis ground providing a good ground plane for the internal electrical components. In addition to providing a good ground plane for the internal electrical components, the metallic nature of the housing 100 can help prevent the build up of static charge, thereby reducing the likelihood of electrostatic discharge damaging sensitive electrical components. give. However, in order to improve the aesthetic appearance of the housing 100, a substantially non-conductive surface layer may be formed on the housing 100. This surface layer can provide excellent corrosion and scratch protection, but nevertheless can prevent good electrical contact to the base metal. For example, when the housing 100 is formed of aluminum, an anodizing process allows a layer to be formed on the surface (both inner and outer surfaces) of the housing 100. This layer can severely degrade the ability of the housing 100 to provide chassis ground by preventing good electrical contact to the base base aluminum. Good electrical contact to the base aluminum base layer may be achieved by selectively removing at least a portion 116 of the protective layer from the inner surface 118 of the housing 100 as shown in FIG.

8-11 illustrate components of the click wheel assembly 200 and the relationships between the components. The click wheel assembly 200 is self contained in that once it is fully assembled, the click wheel assembly 200 can be fully functional and functionally tested before being incorporated into the media player 10. Note the facts. Referring first to FIG. 8, the click wheel assembly 200 may include a button ring assembly 202. The button ring assembly 202 may include a membrane 204 and a click wheel 20 (described above) that may be attached to the inner portion of the click wheel 20 by adhesive. As shown in more detail in FIG. 9, membrane 204 may be formed of an elastic material, such as silicone rubber. Membrane 204 may be sized to fully receive click wheel 20. For example, the click wheel 20 has a raised periphery 206 of the membrane 204 meshing with the outer edge 208 of the click wheel 20 such that the top surface 210 of the membrane 204 is an example. On and within membrane 204 in such a way that a seal can be formed between click wheel 20 and membrane 204 when it is attached to click wheel 20 using adhesive, for example. Can be placed completely. In this way, the button ring assembly 202 can be considered as a single sealed subassembly. Before the membrane 204 is attached to the click wheel 20, the clamps in the recess 214 associated with each icon 24 in the annular area 22 of the click wheel 20 and the center button 26. (shim, 212) can be set. The shims 212 can be used to adjust the mechanical response of the click wheel 20 to a touch event by a user. The shims 212 can adjust the distance the click wheel 20 can move in response to a touch event at a particular one of the icon 24 or the center button 26. In this way, the subjective click wheel 20 can be modified as needed.

10 illustrates a representative button plate 218 in accordance with the described embodiments. Surface 216 of membrane 204 may be used to secure button ring assembly 202 to button plate 218. The button plate 218 may be formed of a strong elastic material such as metal or any suitable composite material. However, in the embodiments described herein, the button plate 202 will be considered to be formed of metal without losing its generality. Accordingly, the metal button plate 218 can be formed of metals such as stainless steel and aluminum. The metal button plate 218 is attached to the button ring assembly 202 by attaching the surface 216 of the membrane 204 to the surface 220 of the metal button plate 218 using any suitable adhesive, such as a double-sided adhesive tape. It can be attached to. Surface 220 of metal button plate 218 may include sensor 222 associated with the corresponding one of icons 24 and 26. As described above, when pressure is applied to the click wheel 20 near the icon 24 or 26, the corresponding sensor 222 is used by the control circuit to modify the operation of the media player 10. By generating a viable signal, it can respond to an applied pressure.

In the described embodiment, the sensor 222 may take the form of a mechanical switch, such as a dome button 222 (also referred to as a tact switch, shortened tactile switch). The number of arrangement of the dome button 222 may vary widely. For example, the anti-rotation ring 224 may be arranged in a manner to prevent rotation of the click wheel 20 surrounding the dome button 222 associated with the center button 26. In the particular embodiment shown, the dome button 222 forms an array of five switches connected to the click wheel flex 226, each of which is associated with an associated one of the icons 24 and 26 on the click wheel 20. Aligned. Click wheel flex 226 may include a connector flex 228 that may be used to electrically connect click wheel assembly 200 to operating circuits within media player 10. . In particular, the connector flex 228 can be connected to the main logic board, i. E. MLB, using a zero insertion force (ZIF) connection described and shown below.

The metal button plate 218 may include a metal boss 230 welded to the downwardly facing surface 234. The metal boss 230 can be used to attach the metal button plate 218 (along with the click wheel assembly 200) to an internal component such as a printed circuit board, ie a PCB. Tabs 232 may be used to secure click wheel assembly 200 to clip assembly 300 during an assembly operation. For example, clip assembly 200 may be latched to metal button plate 218 using tab 232. In this manner, the button metal plate 218 can be used to support the button ring assembly 202 while the surface 220 of the metal button plate 218 can be welded to the surface 234 shown in FIG. 11. It can be considered dual use in that it can be used to support a component such as a printed circuit board by metal boss 230 and to support clip assembly 300 by tab 232. Connector 236 may be used to electrically connect flex connector 228 to an electrical component such as an MLB. In addition, the opening 238 is aligned with the opening 112 formed in the housing 100. In this way, a fastener can be used to secure at least the metal button plate 234 directly to the housing 100.

12 shows an embodiment of a clip assembly 300. The clip assembly 300 may be pre-assembled and tested before being used to complete the assembly of the media player 10. The clip assembly 300 may be pre-assembled using the fastener 302. The fastening mechanism 302 may take the form of a screw 302. The screw 302 can be used to mount the clip door 34 to the torsion block 32 that houses the torsion spring 304. The torsion spring 304 can hold the clip 30 taut against the clip door 34 in a closed configuration. The clip assembly 300 may be attached to the metal button plate 218 by a hooking feature 306 that engages the tab 232 on the metal button plate 218. Attachment feature 308 may take the form of a hook that can engage opening 240 formed in metal button plate 218.

As shown in more detail in FIG. 13, the seal 310 may be formed of a moisture proof material such as silicone rubber. The seal 310 may be shaped to conform to the opening 106 of the housing 100 near a flange 114 formed with the opening 106. Seal 310 may lie on housing 100 near flange 306. In this way, the seal 310 can prevent moisture or other liquids from the external environment from penetrating into the inner portion of the housing 100. This is particularly important because of the presence of various openings in the housing 100, each of which provides a potential moisture penetration path.

The seal 310 can be sized and shaped according to the housing 100, in particular according to the opening 106. The seal 310 may be shaped to prevent moisture penetration into portions of the housing 100 having openings for input devices such as buttons or switches that are exposed to the interior of the housing 100, in particular to the external environment. . For example, the opening 312 of the seal 310 may correspond to a battery used to power the media player 10. On the other hand, the opening 314 may correspond to the main logic board, that is, MLB in parallel with the battery. Because the MLB includes a number of electrical components that are sensitive to moisture, the portion 314 may be configured to provide a stronger barrier to penetration of moisture than that provided by the portion 312.

During assembly of the media player 10, the seal 310 can be placed directly on the flange 114 of the housing 100. Once placed, the clip assembly 300 can be placed directly on the seal 310 and pressure is applied to the clip assembly 300. The pressure applied to the clip assembly 310 can cause the hook 306 to engage the tab 224 of the metal button plate 218 and the attachment feature 308 to engage the opening 240. In this way, the click wheel assembly 200 and the clip assembly 300 can be firmly attached to each other in a manner that minimizes the penetration of moisture into the media player 10. This requirement of using a fastener such as a screw to mount the clip assembly 300 to the housing 100 results in the absence of a visible fastener to provide a clean and efficient appearance to the media player 10.

Due to the small size and compact nature of the media player 10, the effects of moisture penetrating into the media player 10 can have serious consequences. For example, due in part to the high packing density of internal components in media player 10, even small amounts of moisture can cause leakage paths between the components, leading to degradation or even breakage. This is especially true because there is very little unused space in the media player 10, so the likelihood of damage caused by moisture is much higher. In addition to the damage potentially caused by moisture penetration, electrostatic discharge, ie damage from ESD, can be serious. Once again, due to the small size and tight geometry, the field strength can be increased to allow for significant voltage spikes. This is especially true when considering the close contact of sensitive components of the MLB with external switches such as the playlist button 44 and the hold button 38. By simply engaging the switch or simply picking up the media player 10, the user can easily cause electrostatic discharge with the potential to electrically break any number of sensitive electrical components. Thus, ESD protection and moisture / contamination prevention are important considerations in the design and layout of the media player 10.

14 illustrates a main logic board (MLB) assembly 400 according to an embodiment. MLB assembly 400 may include MLB 402. The MLB 402 may include a printed circuit board (PCB) 404 on which a plurality of integrated circuits 406 are mounted and electrically connected. Integrated circuits may include at least a microprocessor, semiconductor memory (such as FLASH), various support circuits, and the like. Power may be supplied to the integrated circuit by a battery 408 connected to the PCB 404 via the electrical connector 410. The battery 408 may be a lithium ion type battery. Playlist tact switch 412 and "side firing" hold tact switch 414 are also shown. It should be noted that the term "side trigger" is intended to convey the concept that the hold switch 38 may be spaced from the position of the hold tact switch 414 due in part to layout considerations and component density. In this way, an armature (described in more detail below) may connect hold switch 38 and hold tact switch 414. Connector 416 may connect to flex connector 228 at contact 236. In one embodiment, the connector 416 may be a zero insertion force (ZIF) connector well known in the art. The opening 418 can align with the welded metal boss 230 and can be sized to receive a fastener such as a screw that can be used to secure the MLB assembly 400 to the click wheel assembly 200. In this way, the fixture can firmly couple the MLB assembly 400 and the click wheel assembly 200.

The MLB 402 may include an audio jack assembly 420 that may be surface mounted on the PCB 404 via the audio jack body 422. The audio jack assembly 420 is an audio jack barrel formed integrally with an audio jack body 422, each sized appropriately and positioned on the PCB 404 to align with the opening 106 in the housing 100. barrel 424). In this way, the audio jack barrel 424 can receive an audio jack post through the audio jack port 42, which is described and illustrated in greater detail in FIGS. 15 and 16. It has electrical contacts that align with and electrically connect with the exposed portions of the audio jack contacts 426. More specifically, FIG. 15 shows a side view of an audio jack assembly 420 showing the relative position of the audio jack barrel 424, the audio jack body 422, and the audio jack contact 426 relative to the PCB 404. do. In the described embodiment, the audio jack contact 426 can include a portion 427 embedded within the audio jack body 422. However, in order to make good electrical contact with the corresponding electrical contact on the audio jack post inserted into the audio jack port 42, a portion of the audio jack contact 426 is the audio jack pad 430 of the audio jack barrel 424. May be exposed to the interior 428.

It should be noted that the internal volume 428 may be directly exposed to the external environment, which may contain significant amounts of contaminants and moisture. Thus, any path between the interior volume 428 and the interior of the media player 10 that could potentially allow the passage of contaminants and moisture must be carefully considered. Thus, the path 432 is a potential flow path between the contact posts 434 placed through the PCB opening 436 used to connect the audio jack pad 430 to the circuit 438 surface mounted to the PCB 404. Can be considered to be.

In order to prevent or at least minimize the possibility of infiltration of contaminants and moisture from the interior volume 428, it is strictly limited even if it does not completely stop any direct flow of contaminants and / or moisture along the path 432. To prevent moisture may be used. The moisture protector may include more than one component. For example, a number of moisture flow protectors may be included in the path 432 to limit or eliminate the possibility of moisture or contaminants passing along the path 432 into the media player 10. In one embodiment, PCB opening 436 may be filled with solder during a surface mount procedure used to electrically connect post 434 to an electrical trace on PCB 404. As part of the standard assembly procedure, the PCB 404 may go through a wave solder process, whereby the solder overflows over the PCB 404 surface. The flow of solder may fill the PCB opening 436 through a wicking action. Aspiration action may have the effect of sealing any gaps that may exist at the interface between the PCB 404 and the connection post 434 as well as between the audio jack body 422 and the connection post 434.

In lieu of or in addition to the solder, other moisture protectors that may be incorporated within the path 432 may include at least layer 440. Layer 440 may be formed of a material that is well suited to prevent the flow of moisture or contaminants. Layer 440 may take the form of a thin film or tape, such as Kapton and Mylar, which may conform to the external shape of audio jack barrel 424 and audio jack body 422, for example. For example, the moisture flow barrier 440 may be placed in direct contact with the audio jack barrel 424 and the audio jack body 422 extending to an area covering the contact holder area 442 shown in more detail in FIG. 16. have. In some cases, the adhesive material is required to ensure that the membrane 440 is substantially compliant with the shape of the audio jack barrel 424 and the audio jack body 422. For example, an adhesive layer may be placed on top of the membrane 440 to force the membrane 440 to conform to the surface features of the audio jack barrel 424 and the audio jack body 422. Placing an adhesive on top of the membrane 440 may be particularly beneficial when the membrane 440 is thin and crumbly. The gap between the membrane 440 and the audio jack body 422 and the audio jack barrel 424 may itself provide an additional path inside the media player 10 for penetration of moisture / pollutants. In order to ensure full compatibility and to maximize the prevention of the flow of moisture and contaminants into the interior of the media player 10, the contact post 434 passes through the membrane 440, such that the interior 428 and the media player 10 It is possible to further prevent the flow of moisture / contaminants between the interior of the).

In another embodiment, the moisture flow protector may take the form of a structure such as a cap 444 that may be mounted directly to the audio jack assembly 420 as shown in FIG. 17. Cap 444 may be formed of a moisture resistant material that may be formed by a thermoforming process having a shape conforming to the shape of audio jack assembly 420. In particular, the cap 444 may include an opening sized to receive a mounting post 446 and a contact post 434 used to attach the audio jack assembly 420 to the PCB 404. In some cases, it may be beneficial to use adhesive to secure cap 444 to audio jack assembly 420. Cap 444 may be placed and secured during the assembly process. Since the cap 444 is shaped to conform to the contour of the audio jack assembly 420, the possibility of a gap between the cap 444 and the audio jack body 422 and the audio jack barrel 412 is virtually eliminated. Can be. In this way, the anti-wrinkling procedure required when the membrane 440 is used is not needed by the use of the cap 444.

In order to monitor whether the interior of the media player 10 has been exposed to moisture, a plurality of moisture indicators may be disposed within the media player 10. One of the most common moisture indicators generally provides a visual indication by changing color (eg, from white to red) when in contact with moisture. Visual indications can be seen through the observation port structure. In this way, any moisture penetration can be easily identified. Due to the direct exposure of the audio jack interior 428 to the outside environment, there is a possibility that moisture in the audio jack interior 428 may penetrate into the media player 10 by other moisture infiltration paths than the path 432. . Thus, determining the path taken by the moisture inside the media player 10 from the external environment may represent important data for both customer service and related matters as well as design purposes. Any abusive behavior can have the effect of invalidating the manufacturer's warranty. For example, if there is an indication that moisture has penetrated the interior of the media player 10, it is a reasonable conclusion that the media player 10 has been exposed to an environment with high concentrations of moisture, such as a lake, pool, or stream. In this way, there is the possibility of unprotected repair costs due to breach of warranty conditions.

A moisture detection system can be provided to determine if moisture has penetrated the interior of the media player 10. However, it should be noted that moisture is expected and expected inside the audio jack 428. Thus, the moisture detection system described herein must distinguish between the expected presence of moisture inside the audio jack 418 and the moisture that has penetrated the interior of the media player 10.

18 shows a moisture detection system 450 according to the embodiment described above. The moisture detection system 450 may be located inside the media player 10. The moisture detection system 450 generally provides a visual indication by changing the color (eg, from white to red) when the moisture comes into contact with the moisture detection layer, indicating that moisture has penetrated the interior of the media player 10. Can be represented. The moisture detection system 450 may be connected to an observation port 452 located at the end 454 of the audio jack barrel 422 by an adhesive layer (not shown). The adhesive layer may be any suitable adhesive material such as a double-sided pressure-sensitive adhesive film (double sided tape), adhesive without film backing, and the like. The moisture detection system 450 can include a frame 456 connected to the observation port structure 452.

The moisture detection system 450 may include a number of layers, such as a wicking layer 458 and a dyeing layer 460. The suction layer 458 may be formed of another material, in this case a suction material that can provide the ability to attract moisture or provide capillary action. Suction layer 458 may have a pre-specified color when dry and when no foreign material is sucked up. For example, the suction layer 458 may have a "unwicked" color, which is typically white but may be grey, light color, or the like. In order to emphasize the color change when exposed to moisture, an ink layer 462 partially covering the suction layer 458 may be provided. The ink layer 462 may be colored to contrast with the "suction" color of the suction layer 458, in particular to provide a better viewing experience when viewing through the small openings represented by the audio jack port 42. . For example, if the "non-absorbing" color of the suction layer 458 is white, then the ink layer 462 changes the color of the ink layer 462 when and when the suction layer 458 changes the color. The small openings represented by the audio jack ports 38, in contrast to the unchanged colors, can also be matched white, making the color change more apparent.

In the described embodiment, the dye layer 460 may be disposed adjacent to the suction layer 458. Dye layer 460 may be formed of a predefined color, typically red, dry dye, or a coloring material. When the dye layer 460 is in a dry form, the suction layer 458 has no suction capability and the two are kept separate. Once the dye layer 460 is wet or moist, the dry dye is moistened and drawn into the suction layer 458. In this way, the suction layer 458 can be seen through the viewing port 452 having a shape affected by the ink layer 462, where the dye is a color that contrasts with the color of the ink layer 462. Has If there was no moisture invasion of the dry dye, the suction layer 458 through the observation port 452 appears to have a dry color, such as white, because no suction occurred. However, when moisture enters the dry dye, the dye is now moistened and sucked into and through the suction layer 458 such that the color of the dye passing through the suction layer 458 is apparent through the viewing port 452. Become. Once the dye is drawn into the suction layer 458, the dye will remain after the suction layer 458 is dried.

19 shows an exterior view of the moisture detection system 450.

To facilitate placement of the audio jack assembly 420 on the PCB 404, an assembly tool 470 may be used that supports and aligns the audio jack assembly 420 on the PCB 404. Thus, FIG. 20 shows panel 472 formed of a plurality of PCBs connected to each other via tab 474. As is well known in the art, printed circuit boards are generally fabricated in large numbers in the form of sheets, or panels, of printed circuit boards bonded together by panel tabs. After all the appropriate circuits and assemblies are mounted to the paneled PCB, the integrated circuits and assemblies are electrically connected to the traces of the PCB using any number of connection processes, such as soldering using a wave soldering process. Can be connected to. However, prior to the connection process, the audio jack assembly 420 can be placed on the PCB 404 without substantial support. In this way, there is a possibility that the audio jack assembly is moved or otherwise misaligned before or during the soldering process.

Accordingly, the assembly tool 470 can be used to place and temporarily secure the audio jack assembly 420 to each PCB of the PCB panel 472. The assembly tool 470 can take the form of a post that can be disposed within the port 48, which post extends completely through the audio jack barrel 422 (also referred to as "spearing"). It has a length so that it can be done. In this way, the assembly tool 470 can be supported by the tab structure 478 and the PCB 404. In this way, assembly tool 470 can support each paneled PCB. In this way, the audio jack assembly 420 may be surface mounted to a corresponding one of the paneled PCBs while being supported by the assembly tool 460. After the audio jack assembly 420 is successfully surface mounted, the assembly tool 470 can be removed and discarded.

Referring now to FIGS. 21 and 22, a hold switch assembly 500 according to the described embodiment is shown in more detail. Hold switch assembly 500 may include a hold switch carrier 502. Hold switch carrier 502 may be formed of any suitable elastic material, such as plastic. In order to minimize the penetration of moisture from the external environment through the hold switch carrier 502, a hold switch carrier seal 504 may be placed on the hold switch carrier 502. Hold switch carrier seal 504 may be formed of a moisture resistant material, such as silicone rubber. In this way, hold switch carrier seal 504 may have a shape that fits within hold switch carrier 502. In addition, the hold switch carrier seal 504 may have a number of openings that allow the passage of a mechanical actuator. For example, playlist button 44 may be received in opening 506 in hold switch carrier seal 504. However, in order to minimize the possibility of moisture penetrating into the media player 10, the playlist button plunger 508 extending from the playlist button 44 to the playlist tact switch 412, Hold switch carrier seal through opening 510 in a manner that effectively seals the playlist button plunger 508 so that there is little or no room for moisture to pass from the external environment into the media player 10. May pass 504.

To further reduce the likelihood of moisture accessing the interior of the media player 10, it is attached to the hold switch button 38 at one end and hold switch side firing tact switch 414 at the other end. Hold switch arm 512 attached thereto may pass through slit 514 formed in hold switch seal block 516. Hold switch block seal 516 may be formed of an elastic material, such as silicone rubber, and may fit tightly into carrier 502. The pressure applied to the block seal 516 may compress the silicone rubber against a portion of the arm 512 in the slot 514 while substantially affecting the movement of the arm 514. In this way, moisture present in the hold button 38 can be prevented from entering the inside of the media player 10.

It should be noted that in some cases, doping the silicone rubber of the block seal 516 with a conductive material such as the silver sphere 518 shown in FIG. 23 may be beneficial in terms of ESD mitigation. A conductive path 520 from the hold switch 38 to the chassis ground of the housing 100 through the arm 512 may be provided. In this way, the charge at or near hold switch 38 can be conducted to chassis ground in the form of housing 100. However, it should be noted that in order to provide a good electrical contact point in the housing 100, a portion of the surface layer (if any) of the housing 100 must be removed to expose the metal substrate. For example, if the housing 100 is formed of anodized aluminum, the laser etched portion 522 of the housing 100 may be doped to provide good electrical contact to the electrically conductive seal 516. Can be.

24 illustrates another embodiment of a hold switch assembly 500 in which a conductive path 524 may be provided between the hold switch button 38 and the housing 100. A metal label 40 may be attached to the hold switch arm 512 using a conductive adhesive along the solder line to form a conductive layer 526 between the label 40 and the hold switch arm 512. In this way, charge on hold switch button 38 can be directed along housing path 524 to housing 100. However, to ensure good electrical contact between hold switch arm 512 and housing 100, portion 114 of housing 100 may be polished to expose the base metal substrate, which in this example is aluminum. In one embodiment, the surface layer associated with the portion 114 may be removed by etching the appropriate amount of surface layer from the portion 114 using a laser. In this way, the hold switch arm 512 moves so that the label 38 is in direct contact with the base metal layer of the housing 100 at the laser etched portion 114.

In addition to providing a good electrical contact point, it should be noted that by exposing the softer aluminum base layer of the housing 100 to the metal label 38 at the portion 114, the wear and tear of the label 38 is significantly reduced. do. For example, if the aluminum of the housing 100 is anodized, the surface layer formed is scratched by repeated sliding against the surface layer of anodized aluminum of the housing 100, even if the label 38 is formed of stainless steel. Or hard enough to be damaged in other ways. However, when laser etched, the native aluminum base layer of the housing 100 exposed at the portion 114 does not noticeably damage or damage the label 38.

Due to the very small size of the media player 10, it may be difficult and time consuming to properly align external features such as the playlist button 44 with the housing 100. 25 illustrates a particularly useful sorting technique used to install and sort the playlist button 44 (or any other external feature) in accordance with the described embodiments. In particular, FIG. 25 illustrates PCB 404 with at least a portion of tab 478 remaining. The playlist button 44 may include a plunger 508 that can press the playlist tact switch 412. In order to minimize the allowable stack between the playlist button 44 and the housing 100, the tab 478 may be laser cut at a laser cut line 2502 opposite the reference 2504 on the PCB 404. . In this way, the permission stack can be significantly reduced, thereby substantially improving the look and feel of the playlist button 42.

26 shows a flowchart detailing an assembly process 2600 in accordance with the described embodiments. Assembly process 2600 may begin at 2602 by providing a housing. The housing may be formed of metal or any other suitable material. The housing may also include a plurality of openings that are sized and arranged to accommodate the insertion and assembly of the various internal components. In the described embodiment, the housing includes at least a front opening appropriately sized to receive the click wheel assembly and a back opening properly sized to receive the clip assembly. In any case, the media player is assembled using a technique referred to as an inside-out assembly technique described in more detail below. Once the housing is provided, a fully assembled and functionally tested input device can be provided at 2604 that can take the form of a click wheel assembly. The click wheel assembly may include a front facing click wheel having a plurality of input features that can be actuated by a user. For example, the input feature can take the form of a clickable switch that can respond to a user press event by engaging an actuator arranged to generate a signal in response to a press event. The click wheel assembly also has a dual purpose with an outward surface having an actuator for generating a signal and an inward surface having an attachment feature used to secure the main logic board assembly, ie internal components such as MLB. It may include a metal plate. At 2606, a fully assembled and functionally tested MLB can be provided. The MLB may include a number of integrated circuits, switches, and I / O devices. The switch may include at least a direct firing playlist button tact switch and a side firing hold button tact switch laterally spaced from an external hold button. The MLB may also include a surface mount audio jack assembly and a battery.

At 2608, the MLB assembly and click wheel assembly may be electrically connected to each other via a flex connector from the click wheel assembly to the zero insertion force (ZIF) electrical connector of the MLB assembly. At 2610, the MLB assembly and click wheel assembly are mechanically coupled to each other. In the described embodiment, the boss on the inward surface of the metal plate of the click wheel assembly receives a fastener such as a screw. The screw is used to mechanically secure the MLB assembly to the click wheel assembly. At 2612, the click wheel assembly / MLB assembly is inserted into the back opening of the housing and aligned with the front opening of the housing. The playlist button and the hold button are aligned with the corresponding openings in the housing as in the case of the audio jack unit. At 2614, a door seal is placed at the outer edge of the back opening. The door seal is formed of an elastic material such as silicone rubber and prevents the flow of moisture / pollutants from the external environment into the media player.

Then, at 2616, the clip assembly is inserted into the back opening, and at 2620 the clip assembly is housed at 2618 almost simultaneously with the latch connection to the latching feature on the click wheel assembly. It is snap connected to the housing using the flange on the top.

27 shows a flowchart detailing a process 2700 for providing ESD protection in a portable device according to the described embodiment. Process 2700 may be used to shunt the electrostatic charge deposited on the hold button toward the chassis ground, which in this example is a housing. Process 2700 may be executed at 2702 by providing a hold button seal formed of a substantially electrically insulating material. In the described embodiment, the hold button seal may be formed of an elastic material such as silicone rubber. In general, the materials used to form hold button seals are generally insulating in that they do not allow charge flow. At 2704, at least a portion of the hold button material is electrically conductive. In the described embodiment, changing at least a portion of the hold button seal from insulating to conductive can be accomplished by doping a portion of the hold button material with a conductive dopant material, such as silver microspheres. At 2706, the doped hold button seal can be used to enclose a hold button arm that mechanically links the outer hold button to the inner hold button switch. At 2708, the conductive portion of the hold button seal is placed in electrical contact with the chassis ground. In the described embodiment, the chassis ground may take the form of an electrically conductive housing formed of, for example, aluminum. Then at 2710, the electrostatic charge deposited on the outer hold button is shunted from the inner hold button switch to chassis ground.

28 is a block diagram of a media player 2800 in accordance with the described embodiments. Media player 2800 includes a processor 2802 associated with a microprocessor or controller for controlling the overall operation of the media player 2800. Media player 2800 stores media data associated with the media item in file system 2804 and cache 2806. The file system 2804 is usually a storage disk or a plurality of disks. The file system typically provides a high capacity storage capability for the media player 2800. However, since the access time to the file system 2804 is relatively slow, the media player 2800 also includes a cache 2806. The cache 2806 is, for example, random-access memory (RAM) provided by semiconductor memory. The relative access time to the cache 2806 is considerably shorter than the access time to the file system 2804. However, cache 2806 does not have the massive storage capacity of file system 2804.

File system 2804 also consumes more power than cache 2806 when active. Power consumption is particularly important when the media player 2800 is a portable media player powered by a battery (not shown).

Media player 2800 also includes a user input device 2808 that allows a user of media player 2800 to interact with media player 2800. For example, the user input device 2808 may take various forms such as a button, keypad, dial, and the like. Again, media player 2800 includes a data bus 2810 that may facilitate data transfer between at least the file system 2804, cache 2806, processor 2802, and CODEC 2812. .

In one embodiment, media player 2800 serves to store a plurality of media items (eg, songs) in file system 2804. When the user wants the media player to play a particular media item, a list of available media items is displayed on display 2810. Then, using the user input device 2808, the user can select one of the available media items. The processor 502, upon receiving a selection of a particular media item, supplies media data (e.g., an audio file) for the particular media item to a coder / decoder (CODEC) 2812. CODEC 2812 then generates an audio output signal for audio jack 2814 and outputs it to external circuitry. For example, headphones or earphones connected to the media player 2800 will be considered an example of external circuitry.

In another implementation, a computer-readable medium is provided that includes computer program instructions for performing the various steps of assembly described in FIG. 26. Specifically, computer program instructions are operable to control various automatic installation components, such as, for example, robot arms, automatic screwdrivers, etc. that can assemble a device without the need for human intervention (or minimize human intervention). can do. In this way, computer instructions can be programmed to control the machine to insert various components into the housing without substantial human intervention. The computer instructions may also be programmed to control the machine to perform laser etching and laser routing in addition to any other process required for assembly and testing of the media player.

29-32 illustrate techniques and structures well suited to forming a moisture penetration seal for an audio jack assembly 420 according to the described embodiment. Although discussed in the context of the audio jack assembly 420, the described techniques and structures can be configured to operate in almost any device configured and operated in such a way that at least one portion is moisture tolerant while other portions in the vicinity must maintain moisture insolubility. It should be understood that it can be used at. A good example of such a situation is the audio jack assembly 420, where the inner volume 428 of the barrel 424 should be moisture tolerant because the audio port 42 is exposed to the external environment without any prerequisites. For example, the portable media player 10 is immersed in a liquid such as water so that water (of course the audio posts are not inserted into the audio jack barrel 422) is introduced into the internal volume 428 through the audio port 42. May be more likely to enter). The presence of moisture in the interior volume 428 is generally not a problem, but the moisture infiltration path 432 provides a mechanism by which moisture present in the interior volume 428 can permeate the interior of the media player 10. Can provide.

Thus, moisture present in the interior volume 428 should be effectively prevented in a cost effective and manufacturing efficient manner from accessing the path 432 (or any other path to the problem). A particularly useful approach to sealing the interior volume 428 relies on forming a sealing structure that effectively blocks the transfer of moisture from the interior volume 428 and the interior of the media player 10. In one embodiment, the sealing structure may be used to seal the electrical contact (s) 430. The electrical contact sealing structure can be formed in a manner that includes a primary seal and a subsequently applied finishing seal. In one implementation, the primary seal can be formed from a layer of pressurized sealing tape applied to a portion of the electrical contact and the audio jack housing. Subsequent to the formation of the primary seal, a finish seal may be formed during the component attachment process in which the electrical connector is electrically connected to the exposed portion of the electrical contact. The component attachment process can take many forms. However, in the described embodiment, the component attachment process can take the form of surface mounting assembly (SMA) technology. One particularly useful SMA technique, called solder reflow, relies on heating the solder paste associated with the connector flex to form liquid solder. The liquid solder can then flow into and near the junction area of the flex connector and the electrical contacts. If cooling is allowed, the liquid solder solidifies in place to provide an electrically conductive path between the connector flex and the electrical contact through the exposed portion. The hardened solder may also seal the area between the sealing tape and the exposed portion of the electrical contact. In this way, the solder not only forms an electrical connection but can also provide a mechanism for sealing that electrical connection, making it a cost effective and efficient manufacture well suited to improve the resistance to moisture penetration of the media player 10. Provide a process.

29 illustrates an implementation of the audio jack assembly 420 described above. In particular, FIG. 29 shows electrical contact 2902. Electrical contact 2902 may be in physical contact with a corresponding conductive ring included in the audio post having a size and shape according to audio jack barrel 424. The electrical contact 2902 can, in turn, include a (flat) contact pad portion 2904 and a (raised) dimple portion 2906. The pad portion 2904 may be sized to receive a sealing tape (or film) applied to the electrical contact 2902 in such a way that most of the dimple portion 2906 is exposed and maintained without the sealing tape. For example, as shown in FIG. 30, the primary seal is in the form of a sealing tape layer 2908 that can be created by applying a sealing tape to both the audio jack body 422 and the contact pad portion 2904. Can be taken. In this way, most of the dimple portion 2906 remains exposed. The sealing tape can take many forms. For example, the sealing tape may be a pressure applied tape along the lines of Kapton ™. Once the sealing tape layer 2908 is formed, the flex substrate 2910 can be overlaid on the sealing tape layer 2908 as shown in FIG. 31. During the subsequent solder reflow process of electrically connecting the flex substrate 2910 to the electrical contact 430 via the dimple portion 2906, a finish seal may be created using the solder paste associated with the flex substrate 2910. . In this embodiment, the solder paste can be heated to at least its melting point to form liquid solder. Solder in liquid form can now flow into the junction region 2912 between the dimple portion 2906 and the sealing tape layer 2908. Free flowing solder may fill the gap and any void space between sealing tape layer 2908 and dimple portion 2906. For example, the contiguous region 2912 may include voids or gaps that may provide a path of penetration of moisture into the interior of the media player 10. Thus, when liquid solder is allowed to cool and return to a solid state by allowing these gaps and voids in the junction region 2912 to be filled, the solder flowing in the junction region 2912 utilizes the junction region 2912. Thus, the seal 2914 may be formed to effectively prevent moisture penetration. In this manner, seal 2914 effectively seals electrical contact 2902, preventing moisture from passing into the interior and inner portions 428 of media player 10.

32 shows a flowchart detailing a process 3200 in accordance with the described embodiments. Process 3200 may be executed by providing an audio jack assembly at 3202. Next, at 3204, a primary water ingress seal is formed by applying a sealing tape layer to the electrical contacts of the audio jack assembly. Electrical contacts are formed from flat pad areas and raised portions called dimples. In the described embodiment, the dimple remains exposed. Next, at 3206, a flex substrate layer is applied to the housing that is in direct contact only with the dimples of the electrical contacts, and the flat pad portion is protected by the applied sealing tape. Next, at 3204, a finish seal is created by performing a solder reflow operation on the audio jack assembly. Solder reflow operation causes the solder paste associated with the flex substrate to electrically connect the flex substrate to the electrical contacts through the dimples. The solder reflow process also causes the solder paste to flow into the recess surrounding the dimple portion. When the solder cures, the cured solder seals the dimples, sealing tape, and housing to prevent water from penetrating into the media player through the audio jack contacts.

Various aspects, embodiments, implementations, or features of the described embodiments may be used separately or in any combination. Various aspects of the described embodiments may be implemented by software, hardware, or a combination of hardware and software. The described embodiments may also be embodied as computer-readable code on a computer-readable medium for controlling a fabrication process, or as computer-readable code on a computer-readable medium for controlling a fabrication line. A computer readable medium is any data storage device that can store data that can thereafter be read by a computer system. Examples of computer readable media include read-only memory, random access memory, CD-ROM, DVD, magnetic tape, and optical data storage devices. The computer readable medium may also be distributed over network-coupled computer systems such that computer readable code is stored and executed in a distributed fashion.

In the foregoing description, for purposes of explanation, specific nomenclature has been used to provide a thorough understanding of the described embodiments. However, it will be apparent to one skilled in the art that the specific details are not required in practicing the invention. Thus, the foregoing description of specific embodiments has been presented for purposes of illustration and description. This description is not intended to be exhaustive or to limit the invention to the precise form disclosed. It will be apparent to those skilled in the art that many modifications and variations are possible in light of the above teaching.

Claims (80)

As a very small form factor consumer electronic product,
A single piece of housing having integral front and side walls cooperating to form a cavity in cooperation with the front opening, wherein the edges of the side walls define a back opening and at least one of the edges. Some have flanges;
A user input assembly having a size and a shape according to the front opening, the user input assembly including a user input and an inner support plate, the inner support plate having an outward side attached to the user input and an interior of a household appliance of the ultra small form factor Has an inward side with attachment features used in part to secure the components; And
Clip assembly having a size and shape along the back opening
Lt; / RTI >
The clip assembly comprises an external user operable clip, a plurality of internal hooking features, a plurality of internal latching features,
The clip assembly is partially secured to the household appliance of the small form factor by engaging at least some of the hooking features with the flanges on the edges of the housing and engaging the latching features with corresponding attachment features on the inner support plate. Home appliances in a compact form factor. The method of claim 1,
Observable portion having a substantially circular click wheel, the click wheel comprising a raised annular area, the raised annular area having a plurality of icons, each icon being driven by the household appliance Identifying the specific action performed-and
Inner part with attached member
Small form factor home appliance comprising a. The apparatus of claim 1 or 2, wherein the outwardly facing surface of the inner support plate includes a plurality of switches, each switch corresponding to one of the plurality of icons, and a pressing event on the icon causes a corresponding switch to cause the appliance to A small form factor consumer product that allows for the generation of a signal that is used to modify product behaviors. 4. The printed circuit board of claim 1, wherein the fixed internal components are surface mounted with a plurality of components to form a main logic board (MLB). 5. A small form factor home appliance comprising at least The household appliance of claim 4 further comprising a battery electrically coupled to the PCB, the battery providing power to at least the MLB. The household appliance of any one of claims 1 to 5, wherein the household appliance of the ultra small form factor is a media player. The household appliance of any one of claims 1 to 6, wherein the housing is formed of metal and the housing provides chassis ground. Providing a housing, the housing having at least one side wall having a front opening, a back opening, and a plurality of openings each sized to receive an outer feature;
Electrically connecting the first component and the second component;
Mechanically fixing the electrically connected first component and the second component together;
Inserting the mechanically fixed first component and the second component into the back opening such that the first component is aligned with the front opening; And
Securing a third component to the first component and the second component to complete assembly of the compact form factor media player
Assembling the media player of the ultra small form factor
≪ / RTI > The method of claim 8, wherein the first component is a click wheel assembly. 10. The method of claim 8 or 9, wherein the second component is a printed circuit board. The method of claim 8, wherein the printed circuit board comprises a plurality of components for forming a main logic board (MLB). 12. The method of any of claims 8-11, wherein the third component is a clip assembly. The method of claim 12, wherein fixing the clip assembly comprises:
Latching the clip assembly to the click wheel assembly; And
Snapping the clip assembly to the housing simultaneously with the latching
≪ / RTI > The method of claim 13, wherein the securing does not require any visible screws. A non-transitory computer readable medium for storing a computer program used by a processor to assemble a compact form factor media player,
Computer code for providing a housing, the housing having a front opening, a back opening, and at least one side wall having a plurality of openings each sized to receive an outer feature;
Computer code for electrically connecting the first component and the second component;
Computer code for mechanically securing the electrically connected first component and second component together;
Computer code for inserting the mechanically fixed first and second components into the rear opening such that the first component is aligned with the front opening; And
Computer code for securing a third component to the first component and the second component to complete assembly of the compact form factor media player
A non-transitory computer readable medium comprising a. 16. The non-transitory computer readable medium of claim 15, wherein the first component is a click wheel assembly, the second component is a printed circuit board, and the third component is a clip assembly. The computer code of claim 15 or 16, wherein the computer code for fixing the clip assembly is
Computer code for latching the clip assembly to the click wheel assembly; And
Computer code for snapping the clip assembly to the housing simultaneously with the latching
A non-transitory computer readable medium comprising a. As a media player,
An electrically conductive housing having a front opening and a back opening and providing chassis ground;
A click wheel assembly having a size and shape according to the front opening, wherein the click wheel assembly comprises a circular click wheel having an outer surface displaying a plurality of icons each associated with a particular media player operation, and an inner support plate; The inner support plate includes an outward surface to which the circular click wheel is attached, and an inward surface having attachment features, the outward surface having a plurality of sensors electrically connected respectively to a flex connector, each of the plurality of sensors being the plurality of sensors. Associated with one of the icons of, wherein when pressure is applied in the vicinity of one of the plurality of icons, a corresponding one of the plurality of sensors responds by providing a signal to the flex connector;
A main logic board (MLB) assembly mechanically fixed to the inner support plate using at least one of the attachment features, the MLB assembly comprising: a printed circuit board (PCB), a plurality of electrical components at least one of which is a processor; An audio jack assembly arranged to output an audio signal and receive power, and a battery arranged to provide power to at least the main logic board, wherein at least a portion of the audio jack assembly and the plurality of electrical components are connected to the PCB. Surface mounted; And
Clip assembly having a size and shape along the back opening
Lt; / RTI >
The clip assembly comprising a user operable clip, a plurality of inner hooking features, and a plurality of inner latching features,
And the clip assembly is partially secured by engaging at least some of the hooking features with the flanges on the edges of the housing and engaging the latching features with corresponding attachment features on the inner support plate. 19. The media player of claim 18 wherein the click wheel assembly is assembled and functional tested prior to inclusion in the media player during an assembly operation. The method of claim 18 or 19, wherein the media player,
Playlist button; And
Playlist tactile switch
Further comprising:
The playlist button engages the playlist tactile switch, the tactile switch generates a playlist signal sent to the processor, the processor retrieves the playlist from a memory device, decodes the playlist, And respond to the playlist signal by causing an audio jack assembly to output a decoded playlist audio signal to an external circuit coupled to the audio jack assembly. The media player of claim 18, wherein the media player further comprises a hold switch assembly,
The hold switch assembly,
Hold Button,
Hold button armature; And
Hold button tact switch connected to the hold button via the hold button armor
Lt; / RTI >
In a first position, the hold button causes the processor to deactivate the click wheel assembly to cause the processor to ignore any signals from the plurality of sensors. The media player of claim 21 wherein the hold button is laterally displaced from the hold button tact switch. 23. The media player of any one of claims 18 to 22 wherein the media player is connected to a lanyard through the user operable clip. As a small form factor home appliance,
A single piece housing having integral front and side walls cooperating to form a cavity in cooperation with the front opening, wherein the edges of the side walls define a back opening, at least some of the edges having flanges, of the side walls At least one including openings sized to receive an I / O device;
A clip assembly having a size and shape according to the back opening, the clip assembly having a plurality of attachment features used to secure the clip assembly to the single piece housing; And
A plurality of moisture barriers each formed of a moisture resistant material
/ RTI >
Wherein the plurality of moisture barriers cooperate to prevent migration of moisture from the external environment to the cavity. The method of claim 24, further comprising a main logic board (MLB) assembly,
The main logic board assembly,
Printed circuit boards (PCBs);
A plurality of circuit elements surface-mounted on the first surface of the PCB;
An audio jack assembly surface mounted to a second surface of the PCB; And
A battery arranged to provide power to the small form factor home appliance and connected to the MLB via a power line
Containing, home appliances of the ultra small form factor. 26. The device of claim 24 or 25, further comprising a hold button assembly, wherein the hold button assembly fits into a corresponding opening in the housing,
The hold button assembly,
Hold Button,
A switch mechanism displaced laterally from the hold button, and
Hold button arm connecting a multi-position hold button to the switch mechanism
Including, ultra-small form factor home appliances. 27. The method according to any one of claims 24 to 26,
The plurality of moisture barriers includes a housing moisture barrier including a housing seal having a size and a shape along the back opening, the housing seal comprising a gasket portion disposed between the flanges and the clip assembly. A small form factor home appliance comprising a gasket portion. The method of claim 27, wherein the housing moisture barrier,
A first inner portion integrally formed with the housing seal, the first inner portion comprising a substantially intact layer of the moisture proof material, the first inner portion being in accordance with the first surface of the PCB; Having a shape and size, the first inner portion substantially covering all of the first surface of the MLB; And
A second inner portion having a shape and size according to the battery and defined by edges conforming to the shape of the battery
Further comprising, household appliances of a very small form factor. 27. The hold button assembly seal of claim 26, wherein the plurality of moisture barriers further comprise hold button assembly moisture seals, wherein the hold button assembly seals are pressed on the hold button arms. Having a centrally located slit arranged to receive the hold button arm so as to prevent the flow of moisture from the hold button to the hold button switch without substantially affecting the movement of the hold button arm. Small form factor home appliances made of silicone rubber. 30. The household appliance of any one of claims 24 to 29 wherein the plurality of moisture barriers comprise an audio jack assembly moisture barrier. 31. The household appliance of claim 30 wherein the audio jack assembly moisture barrier comprises a layer of moisture proof material conformally applied to an exterior surface of the audio jack assembly. 31. The system of claim 30, wherein the audio jack assembly moisture barrier comprises a preformed cap formed of a moisture proof material, the preformed cap being shaped and sized to fit over at least a portion of the audio jack assembly. The preformed cap is attached to the covered portion of the audio jack assembly using an adhesive. A method for assembling a media player comprising at least a single piece of housing having integral front and side walls cooperating to form a cavity in cooperation with a front opening, wherein the edges of the side walls define a back opening and the edges At least some of the flanges have at least one of the side walls including openings sized to receive the I / O device;
Providing the housing; And
Forming a plurality of moisture barriers each formed of a corresponding moisture proof material
Lt; / RTI >
And the plurality of moisture barriers cooperate to prevent the ingress of moisture from the external environment into the cavity. The method of claim 33, wherein the media player,
A printed circuit board (PCB), a plurality of circuit elements surface-mounted on a first surface of the PCB, an audio jack assembly surface-mounted on a second surface of the PCB, and a small form factor electronics arranged to provide power A main logic board (MLB) assembly including a battery connected to the main logic board (MLB) through; And
A hold button assembly comprising a hold button, a switch mechanism laterally displaced from the hold button, and a hold button arm connecting a multi-position hold button to the switch mechanism, the hold button assembly adapted to a corresponding opening in the housing
≪ / RTI > 35. The method of claim 34, further comprising: forming a housing moisture barrier by disposing a gasket portion of the housing seal between the flanges and the clip assembly; And
Securing the clip assembly to the housing by applying pressure to the clip assembly to seal the clip assembly to the housing by the applied pressure compressing the gasket portion.
≪ / RTI > 36. The method of claim 34 or 35, further comprising: providing a hold button assembly seal formed of silicone rubber having a centrally located slit;
Placing the hold button arm through the centrally located slit; And
Compressing the hold button assembly seal around the hold button arm
Further comprising:
And the compressed hold button seal prevents the flow of moisture from the hold button to the hold button switch without substantially affecting the movement of the hold button arm. 37. The method of any of claims 34-36, wherein the plurality of moisture barriers comprise an audio jack assembly moisture barrier. 38. The method of any one of claims 34-37, wherein the audio jack assembly moisture barrier comprises a layer of moisture proof material conformally applied to an outer surface of the audio jack assembly. 39. The preformed cap of claim 38, wherein the audio jack assembly moisture barrier comprises a preformed cap formed of a moisture proof material, the preformed cap being shaped and sized to fit over at least a portion of the audio jack assembly. And a silver adhesive is attached to the covered portion of the audio jack assembly. 40. The method of claim 39, further comprising: detecting moisture in the cavity by a moisture detection system; And
Determining whether the detected moisture in the cavity is due to abusive behavior
≪ / RTI > 41. The method of claim 40, wherein the moisture detection system is located very close to the audio jack assembly in the cavity. 42. The method of claim 41 wherein the moisture detection system comprises a water dot, the drop being observable from the interior of the audio jack assembly. A non-transitory computer readable medium for storing a computer program executed by a processor used to control a computer manufacturing system for automatically assembling a media player,
And computer code for preventing the flow of moisture that penetrates into an internal cavity of the media player from an external environment and for forming a plurality of moisture barriers each formed of a corresponding moisture proof material. 44. The computer code of claim 43 wherein the computer code for forming the plurality of moisture barriers is:
Computer code for forming a housing moisture barrier; And
Computer code to form hold button moisture barrier
The non-transitory computer readable medium further comprising. 45. The computer code of claim 44 wherein the computer code for forming the housing moisture barrier is:
Computer code for placing a gasket portion of the housing seal between the media player housing and the clip assembly; And
Computer code for securing the clip assembly to the housing by compressing the gasket portion by applying pressure to the clip assembly
A non-transitory computer readable medium comprising a. 45. The computer code of claim 44, wherein the computer code for forming the hold button moisture barrier is:
Computer code for placing the hold button arm through a slit in the hold button seal; And
Computer code for causing the hold button seal to compress against the hold button arm
A non-transitory computer readable medium comprising a. 45. The computer program product of claim 44, further comprising: computer code for detecting moisture in the cavity by a moisture detection system; And
Computer code for determining whether detected moisture in the cavity is due to abuse
The non-transitory computer readable medium further comprising. As a small form factor home appliance,
A single piece housing having integral front and side walls cooperating to form a cavity in cooperation with the front opening, wherein the edges of the side walls define a back opening, at least some of the edges having flanges, of the side walls At least one including openings sized to receive an I / O device;
A clip assembly having a size and shape according to the back opening, the clip assembly having a plurality of attachment features used to secure the clip assembly to the single piece housing; And
A plurality of moisture barriers each formed of a moisture proof material
/ RTI >
The plurality of moisture barriers cooperate to prevent migration of moisture from the external environment into the cavity, at least one of the plurality of moisture barriers being an audio jack assembly electrical moisture barrier,
The audio jack assembly electrical moisture barrier,
An electrical contact integrally formed with the audio jack assembly housing, the electrical contact comprising a flat pad portion and a central raised portion;
A layer of sealing tape applied to the audio jack assembly housing, the pad comprising a pad portion of the electrical contact and leaving the raised portion exposed; And
Flex substrate layer
/ RTI >
The flex substrate layer is electrically connected to electrical contacts through the raised portion by causing the audio jack assembly to undergo a solder reflow process, wherein the solder reflow process allows liquid solder to connect with the raised portion. A compact form factor home appliance, which moves to fill and fills a recess area between the sealing tape and the flex substrate, wherein the solder filled recess provides a moisture penetration barrier between the inner portion of the compact form factor home appliance and the external environment . 49. The household appliance of claim 48 wherein the sealing tape is Kapton ™. 50. The apparatus of claim 48 or 49, wherein the other one of the plurality of audio jack assembly moisture barriers includes a preformed cap formed of a moisture proof material, wherein the preformed cap fits over at least a portion of the audio jack assembly. Molded and sized, wherein the preformed cap is attached to the covered portion of the audio jack assembly using an adhesive. Providing an audio jack assembly, the audio jack assembly formed integrally with the audio jack barrel, the audio jack barrel having a size and shape in accordance with an audio post connected to an external circuit A plurality of electrical contacts, wherein the audio jack electrical contacts are formed of a flat pad portion and a raised portion;
Applying a layer of the sealing tape to the electrical contacts such that a sealing tape forms a layer over the pad portion and leaves the raised portion exposed;
Applying a flex substrate onto the sealing tape layer; And
Electrically connecting the layer of the flex substrate to the electrical contact through the raised portion
Lt; / RTI >
The electrical connection is effected by performing a solder reflow operation on the audio jack assembly such that the solder paste associated with the flex substrate is liquefied and flows into a recess between the raised portion of the electrical contact and the sealing tape and cures. Solder to form a moisture proof seal that essentially prevents moisture from coming out of the audio jack barrel through the sealed plurality of electrical contacts. The method of claim 51, wherein the sealing tape is Kapton. 53. The method of claim 51 or 52, wherein the moisture barrier seal prevents moisture from coming out of the audio jack barrel through the sealed plurality of electrical contacts when the audio jack barrel is immersed to a depth of about 1 meter. Way. 55. The method of any of claims 51-53, further comprising: detecting moisture in the cavity by a moisture detection system; And
Determining whether the detected moisture in the cavity is due to abuse behavior
≪ / RTI > 55. The method of any of claims 51-54, wherein the moisture detection system is located very close to the audio jack assembly within the cavity. 56. The method of any of claims 51-55, wherein the moisture detection system comprises water droplets, the water droplets being observable from the interior of the audio jack assembly. A moisture resistant sealing structure for use in electrical components of an electrical system, wherein the moisture resistant seal is adapted to prevent the flow of moisture from a moisture tolerant portion of the electrical component to a moisture intolerant portion of the electrical system. Prevent-,
A primary seal structure used to provide a first sealing layer; And
Finishing seal structure applied to the primary seal structure
/ RTI >
And the finishing seal structure cooperates with the primary seal structure to prevent flow of moisture between the moisture resistant portion of the electrical component and the moisture resistant portion of the electrical device. 58. The moisture proof sealing structure of claim 57, wherein the electrical component is an audio jack assembly. 59. The moisture resistant sealing structure of claim 57 or 58, wherein the electrical system is a portable media device. 60. The moisture resistant sealing structure of any of claims 57 to 59, wherein the primary seal structure is a layer of pressure applied tape. 61. The moisture proof sealing structure of any of claims 57 to 60, wherein the finish seal structure is formed by reflowing solder, wherein the reflowed solder is used to fill a gap in the primary seal structure. . As a media player,
A housing formed of an electrically conductive material; And
Button assembly containing external features arranged to receive user input events
Lt; / RTI >
The outer feature is connected to an internal switch displaced from the outer feature via an electrically conductive arm that fits a slit in a moisture resistant seal formed of an insulating material, at least a portion of the seal being coupled with a conductive dopant, the electrically conductive arm A conductive path is formed between the housing and the housing, wherein a predetermined amount of charge deposited on the outer feature flows directly into the housing through the electrically conductive arm and the conductive portion of the seal and causes the internal switch to Media player, allowing to bypass. 63. The media player of claim 62 wherein the housing provides a chassis ground and has a cavity sized to enclose a plurality of operating components that are at least partially fragile when exposed to an electrostatic discharge (ESD) event. 63. The media player of claim 62 wherein the dopant comprises a plurality of silver micro-spheres. 63. The media player of claim 62 wherein the electrically conductive material is aluminum. 66. The method of claim 65, wherein when the aluminum is anodized, a sufficient amount of surface layer is removed from the portion of the housing that is in contact with the conductive portion of the seal, thereby providing a good separation between the anodized aluminum of the housing and the electrically conductive portion of the seal. The media player from which electrical contacts are made. As a media player,
A housing formed of an electrically conductive material; And
Button assembly
Lt; / RTI >
The button assembly,
External features arranged to receive user input events,
An electrically conductive arm arranged to connect the outer feature to an inner switch,
A metal base portion formed integrally with said outer feature and connecting said outer feature to said electrically conductive arm, and
A metal label conductively mounted to the metal base portion
/ RTI >
The metal label is conductively mounted to the metal base portion using a conductive adhesive such that a conductive path is formed between the outer label and the housing through the metal label and the metal base portion, the conductive path being the outer portion. And a predetermined amount of charge deposited on the feature that directly flows into the housing and bypasses the internal switch. 68. The media player of claim 67 wherein the conductive adhesive is solder. 69. The media player of claim 68 wherein the electrically conductive material is aluminum. 70. The method of claim 69, wherein when the aluminum is anodized, a good electrical contact is created between the anodized aluminum of the housing and the metal label by removing a sufficient amount of surface layer at the portion of the housing that contacts the metal label. , Media player. 71. The media player of claim 70 wherein the exposed aluminum does not wear the metal label. Providing a housing formed of an electrically conductive material and having at least one opening;
Providing a button assembly comprising an external feature arranged to receive a user input event, the external feature being connected to an internal switch displaced from the external feature via an electrically conductive arm;
Providing a block formed of an electrically insulating moisture proof material and having a slot sized to receive the electrically conductive arm;
Introducing a conductive dopant into at least a portion of the block such that the portion of the block is electrically conductive;
Inserting the outer feature into the opening of the housing; And
Inserting the electrically conductive arm through a slot in electrical contact with the conductive portion of the block
Lt; / RTI >
A conductive path is formed between the outer feature and the housing through the electrically conductive arm and the conductive portion of the block, the conductive path in which a predetermined amount of charge deposited on the outer feature flows directly into the housing and causes the internal switch to flow. How to allow bypass. 73. The cavity of claim 72, wherein the housing is formed of aluminum, provides chassis ground, and has a cavity sized to enclose a plurality of operating components that are at least partially prone to damage when exposed to an electrostatic discharge (ESD) event. Way. 74. The method of claim 72 or 73, wherein the dopant comprises a plurality of silver microspheres. 75. The anodized aluminum of the housing as claimed in any one of claims 72 to 74 by removing a sufficient amount of surface layer at the portion of the housing that contacts the conductive portion of the seal when the aluminum is anodized. A good electrical contact is made between the electrically conductive portions of the seal. Providing a housing formed of an electrically conductive material;
Providing a button assembly, the button assembly comprising: an external feature arranged to receive a user input event, an electrically conductive arm arranged to connect the external feature to an internal switch, integrally formed with the external feature and defining the external feature; A metal base portion connecting to the electrically conductive arm, and a metal label; And
Conductively mounting the metal label to the metal base portion using a conductive adhesive
Lt; / RTI >
A conductive path is formed between the outer label and the housing through the metal label and the metal base portion, the conductive path allowing a predetermined amount of charge deposited on the outer feature to flow directly into the housing and bypass the inner switch. How to allow that. 77. The method of claim 76, wherein the conductive adhesive is solder. 78. The method of claim 77, wherein the electrically conductive material is aluminum. 79. The method of claim 78, wherein when the aluminum is anodized, a good electrical contact is created between the anodized aluminum of the housing and the metal label by removing a sufficient amount of surface layer at the portion of the housing that contacts the metal label. Way. 80. The method of claim 79, wherein the exposed aluminum does not wear the metal label.

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