WO2014165311A1

WO2014165311A1 - Electronic device and method of assembling

Info

Publication number: WO2014165311A1
Application number: PCT/US2014/029732
Authority: WO
Inventors: Petr Adamik; Tarik Khoury; Steven Mcpherson; Arnold Kalla; Eugene J. Takach; Mohammad Aljabari; Tracy Lentz; David P. Mulhouse; Daniel Eppinger
Original assignee: Honeywell International Inc.
Priority date: 2013-03-15
Filing date: 2014-03-14
Publication date: 2014-10-09
Also published as: US10234161B2; US10480805B2; US9388998B2; US20140262481A1; US9709295B2; US9797619B2; US20140262484A1; US20140262490A1; US20140268600A1; US20140262482A1; US9803882B2; US20140268602A1; CN105190413B; US9310095B2; US20140268470A1; US9416988B2; US20140268452A1; US20180023839A1; CN105190413A; US20180092261A1

Abstract

An electronic assembly may have a display, a display holder, and a printed circuit board (PCB). The display may have a front side for viewing the display, a back side, and side walls extending between the front side and the back side. The display holder may have a recess for receiving at least part of the display, where the display holder may extend adjacent part of the front side of the display and adjacent at least part of the side walls of the display. The PCB may be secured relative to the display holder and adjacent the back side of the display. The PCB may be in operative communication with the display. In some cases, a spacer may be situated between the back side of the display and the PCB.

Description

ELECTRONIC DEVICE AND METHOD OF ASSEMBLING

TECHNICAL FIELD

This disclosure generally relates to electronic devices, and more particularly to improved use, assembly, construction, and reliability of such electronic devices.

BACKGROUND

Electronic devices, such as Heating, Ventilation, and Air Conditioning (HVAC) control panels, security system control panels, lighting control panels, irrigation control panels as well as other electronic devices are commonly used today. What would be desirable is an electronic device that has improved ease of use, ease of assembly, better construction and/or increased reliability over what is available today.

SUMMARY

This disclosure relates to electronic devices such as HVAC controller devices, and more particularly, to improved use, assembly, construction, and reliability of such electronic devices. The disclosure also relates to assemblies for protecting electrical components.

In one example, an electronic assembly may include a display, a display holder (e.g., a front cover or a feature of a front cover), and a printed circuit board (PCB). The display may have a front side for viewing the display, a back side, and side walls extending between the front side and the back side. The display holder may have a recess for receiving at least part of the display, where the display holder may extend adjacent part of the front side of the received display and adjacent at least part of the side walls of the display. The PCB may be secured relative to the display holder and adjacent the back side of the display. In some cases, the PCB may be in operative communication with the display.

An illustrative method of assembling an electronic assembly may include inserting a front side of a display into a recess of a display holder, aligning one or more alignment feature of a spacer with one or more corresponding alignment features of the display holder, and placing the spacer adjacent a back side of the display. One or more alignment features of a PCB may be aligned with one or more corresponding alignment features of the display holder and/or spacer, and the PCB may be placed adjacent the spacer. A latch of the display holder may engage with the PCB to secure the PCB relative to the display holder with the display and the spacer secured therebetween.

The preceding summary is provided to facilitate an understanding of some of the innovative features unique to the present disclosure and is not intended to be a full description. A full appreciation of the disclosure can be gained by taking the entire specification, claims, drawings, and abstract as a whole.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may be more completely understood in consideration of the following description of various embodiments in connection with the accompanying drawings, in which:

Figure 1 is a schematic perspective view of an illustrative electronic assembly;

Figure 2 is a schematic exploded perspective view of the illustrative electronic assembly of Figure 1;

Figure 3 is a schematic perspective view of an illustrative sub-assembly of an illustrative electronic assembly;

Figure 4 is a schematic partially exploded side view of the illustrative subassembly of the illustrative electronic assembly of Figure 3;

Figure 5 is a schematic perspective view of an illustrative spacer of an electronic assembly;

Figure 6 is a schematic side view of the illustrative spacer of Figure 5;

Figure 7 is a further schematic side view of the illustrative spacer of Figure 5;

Figure 8 is a schematic perspective view of an illustrative front cover of an electronic assembly;

Figure 9 is a schematic side view of the illustrative front cover of Figure 8;

Figure 10 is a further schematic side view of the illustrative front cover of Figure 8;

Figure 11A is a schematic cross-sectional view of the illustrative electronic assembly of Figure 1, taken along line 1 lA-1 1A of Figure 1 ;

Figure 1 IB is a further schematic cross-sectional view of the illustrative electronic assembly of Figure 1, taken along line 1 lA-1 1A of Figure 1, enlarging the portion contained in the dotted circle 1 IB of Figure 11A; Figure 12 is a schematic exploded perspective front view of an illustrative front cover, gasket, electronic component, spacer, and printed wiring assembly of an illustrative electronic assembly;

Figure 13 is a schematic front view of an illustrative spacer engaged with an illustrative printed wiring assembly of an illustrative electronic assembly;

Figure 14 is a schematic exploded perspective back view of an illustrative front cover, electronic component, and spacer of the illustrative electronic assembly of Figure 13;

Figure 15 is a schematic partially exploded view of an illustrative printed wiring assembly exploded from an illustrative front cover, electronic device, and spacer of the illustrative electronic assembly of Figure 12;

Figure 16 is a schematic exploded perspective view of an illustrative front cover, gasket and electronic component of the illustrative electronic assembly of Figure 12;

Figure 17 is a schematic back view of the illustrative electronic assembly of Figure 12;

Figure 18 is a schematic cross-sectional view of the illustrative electronic assembly of Figure 17, taken along line 18-18;

Figure 19 is a schematic front perspective view of an illustrative back cover and wall plate of an illustrative electronic assembly;

Figure 20 is a schematic exploded back perspective view of an illustrative back cover and wall plate of an illustrative electronic assembly;

Figure 21 A is a schematic cross-sectional view of an illustratively assembled back cover and wall plate;

Figure 2 IB is a schematic magnified view of illustrative mating walls between an assembled back cover and wall plate, taken from Figure 21 A;

Figure 21 C is a schematic magnified view of illustrative pockets in the assembled back cover and wall plate, taken from Figure 21 A;

Figure 22 is a schematic front view of an illustrative back cover of an electronic assembly; and

Figure 23 is a schematic cross-sectional view of an illustrative PWA and a back cover of an illustrative electronic assembly.

While the disclosure is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure.

DESCRIPTION

The following description should be read with reference to the drawings wherein like reference numerals indicate like elements throughout the several views. The description and drawings show several embodiments which are meant to be illustrative in nature.

For convenience, the present disclosure may be described using relative terms including, for example, left, right, top, bottom, front, back, upper, lower, up, and down, as well as others. It is to be understood that these terms are merely used for illustrative purposes and are not meant to be limiting in any manner.

An electronic device or assembly 10 is shown in Figures 1 and 2. It is contemplated that the electronic device or assembly 10 may be, for example, a Heating, Ventilation, and Air Conditioning (HVAC) control panel, security system control panel, lighting control panel, irrigation control panel, or any other suitable device. In one example, the electronic device 10 may be a thermostat, but his is not required.

In some instances, as shown in Figure 2, the illustrative electronic assembly 10 may include a housing 12, a PWA 14, an electronic component 16, and an electrically conductive extender or connector 18, where the PWA 14 and the electronic component 16 may be positioned at least partially within the housing 12. In some cases, a conductive shield may be provided adjacent the PWA 14, such as between the PWA 14 and the electronic component 16. In the illustrative example shown in Figures 1 and 2, the electronic component 16 may be a touch screen display that itself includes a conductive metal backing which can function as a conductive shield. The conductive shield may be electrically coupled to the ground feature of the PWA 14 via the connector 18, as further described below.

As noted above, the PWA 14 may include a grounding feature, such as a ground plane or other grounding feature (e.g., a grounding point, grounding terminal, ground pad, etc.). In some instances, the grounding feature or grounding plane may be an area of copper foil or other conductive material connected to a grounding point of the PWA 14. The grounding feature or grounding plane may serve as a return path for current from electronic components of the electronic assembly 10. The grounding feature or grounding plane is not specifically identified in the Figures, but may take the form of a conductive layer of the PWA 14, a terminal or pad on the PWA 14, or any other form as desired.

Electronic devices and their electronic assemblies 10, such as the illustrative thermostat shown in Figures 1 and 2, may be susceptible to electrostatic discharge (ESD) events. Such ESD events may occur when, for example, the electronic assemblies 10 are contacted by users and static electricity is discharged from the user to the electronic assembly 10. Such ESD events may be harmful to the electronic assemblies 10, as the electronic components of the electronic assemblies 10 may be short circuited or otherwise damaged by the ESD events. Providing some level of ESD protection in configuring an electronic assembly 10 is thus desirable in many situations.

From a hardware perspective, electronic devices and their electronic assemblies 10 may be at least partially protected from ESD events by, for example, including a conductive path for passing the electrostatic discharge safely to ground, and bypassing sensitive electronic components of the electronic assemblies 10. As indicate above, the electronic assembly 10 may include a printed wiring assembly (PWA) 14 that includes a ground feature, such as a ground plane. When provided, the ground plane may itself help shield sensitive electronic components from an outside ESD event.

As indicated above, and in some instances, the electronic component 16 may have a metal backing 22 (e.g., a zinc plating, sheet metal, and/or other metal or conductive material), a portion of a backing that is metal, or a metal feature extending adjacent the back of the electronic component 16. While a metal backing is used in this example, it is contemplated that any suitable conductive layer or shield may be used, if present. In one example, the electronic component 16 may be a display 32 (e.g., a liquid crystal display (LCD) or other display) that is at least partially enclosed by a metal box structure, where at least a back side of the display 32 (e.g., a side opposite a front side for viewing the display 32, where side walls may extending between the front side and the back side) includes a metal backing 22 (see Figure 4 showing subassembly 19 including the electronic component 16, the spacer 24, and the PWA 14). In some cases, the perimeter sides (e.g., side walls) of the display 32, and even a border around the front side of the display 32, may be covered by the metal box structure. Where the electronic component 16 includes metal backing 22 or another conductive feature extending adjacent the back of the electronic component 16, an electrically conductive extender or connector 18 may provide an electrical connection between the metal backing 22 or the other conductive feature and the ground feature of the PWA 14. Such an electrical connection 18 between the PWA 14 and the electronic component 16 may, for example, help ground the metal backing 22 of the electronic component 16 and reduce the chances that an ESD event will cause damage to electronic components mounted on or near the PWA 14.

In some instances, the electronic component 16 and the PWA 14 may be spaced apart from each other when mounted in the housing 12. In one example, the metal backing 22 may be spaced from the PWA 14 and/or from components on the PWA 14 by a distance greater than about two (2) millimeters, greater than about three (3) millimeters, greater than about five (5) millimeters, greater than about ten (10) millimeters, or any other distance as desired. Such a space may provide sufficient space to accommodate one or more electrical components that may be mounted to the side of the PWA facing a spacer 24 and/or electronic component 16, and in some cases, may help dissipate or distribute heat generated by the PWA 14 and/or electronic component 16 within the housing.

To help maintain the space between the electronic component 16 and the PWA 14, the spacer 24 may be provided, as shown in for example Figures 2-7. The spacer 24 may be made from any suitable material(s). For example, the spacer 24 may be made from one or more polymers or other materials having desirable material properties. The spacer 24 may be made from an electrically insulating material, such that the spacer 24 does not create a short circuit between any conductive traces or other components on the PWA 14 and the electronic component 16. Further, the spacer 24 may be configured to help support the electronic component 16 both when users are interacting with the electronic component 16 and when the electronic component 16 may be operating on its own.

In some instances, the spacer 24 may take on a web-like form, such as shown best in perhaps Figures 2, 5, 12, 14, and 16, and may have openings 25 (e.g., one or more openings 25, two or more openings 25, etc.) between structural portions 48. The openings 25 of the spacer 24 may allow for air gaps between the back side of the display 32 and the PCB 34 of the PWA 14, when the spacer is positioned therebetween (see, discussion of the positioning of the spacer 24 below). The spacer 24 may have spacer side walls 42 extending from and/or forming one or more edges of the spacer 24, as best seen in perhaps Figures 5-7. Illustratively, the spacer side walls 42 may extend in the direction of the PWA 14 and/or may extend along an entire edge of the spacer 24 or may extend a partial distance along an edge of the spacer 24, as seen in Figures 5 and 7. When in use with the housing 12, the spacer side walls 42 of the spacer 24 may be formed to mate with the housing 12 (e.g., walls 56 of the front cover 38, the back cover 36, or other feature of the housing 12), which may help provide an ESD path 44 that travels around the ends of the spacer side walls 42, as best shown in perhaps Figures 6 and 1 IB. Because the length of the ESD path 44 is increased by the spacer side walls 42, the PWA 14 may be better protected from an ESD event originating from outside of the housing 12.

The web-like configuration of the spacer 24 may allow for a double sided PWA 14 component placement, whereas a spacer 24 without openings 25 may not permit component placement on the side of the PWA 14 adjacent the electronic component 16. The openings 25 in the spacer 24 may allow components to be mounted on both sides of the PCB 34 without interfering with the electronic component 16 (e.g., display 32) of the electronic assembly 10, by providing space for the components on the side of the PCB 34 facing the component 16.

In instances where the electronic component 16 is a display 32 or other electronic component 16 that may produce heat, the display 32 or other electronic component 16 may be an unintended heat generator, which may heat and/or influence thermistors located at the PWA 14, if such thermistors are present. The spacer 24 may be configured to provide an air gap between the display 32 and the PWA 14 due to its, optional, web-like configuration. The web-like configuration may limit the heat transfer to the PWA 14 from the display 32, while maintaining an overall thin profile of the electronic assembly 10. Further, to prevent direct heat transfer to the thermistors (if present) on the PWA 14 through the material of the spacer 24, the material of the spacer 24 may be cut away in, around and/or over any such thermistors.

Referring now to Figure 8, the housing 12 may have a front cover 38. In the example shown, the front cover 38 may generally be a frame for receiving an electronic component (e.g., a touch screen component or other component or device) and may have an opening 52 extending therethrough, as best shown in Figures 8-10, 12, and 16. In some instances, the front cover 38 may include one or more front cover walls 56 sometimes extending from a bezel 41 (e.g., a thin bezel or other bezel), where the front cover walls 56 may be configured to mate with surfaces of a back cover 36 of the housing 12 and/or the spacer 24, as shown in for example Figures 11A and 1 IB. Similar to the spacer walls 42, the front cover walls 56 may help define an ESD path 44 for the ESD events, as seen in Figure 10, which may enter the housing 12 through a gap in the housing 12 at a parting line 40 or at any other location.

It is known that ESDs travel through a medium or travel along surfaces by following the shortest possible ESD path 44 with the least resistance when discharged from a user or other device or source. A parting line between portions of the housing of an electronic device may be a suitable inlet through which ESD may travel to the inside of the electronic device. For example, where the front cover 38 and the back cover 36 of the housing 12 meet, a parting line 40 may be formed, as best shown in Figures 11A and 1 IB, and it has been found that ESDs may travel to the inside of the electronic assembly 10 through this parting line 40.

During testing, it was determined that ESDs may carry voltage of up to about 15 kilovolts (kV) or more (although, voltage of an ESD may vary greatly), which is a relatively high voltage. Generally, the electric breakdown strength of dry air in substantially ideal conditions is approximate 3kV/millimeter (mm). This means that in ideal conditions, a gap having a distance greater than 5 mm is needed to prevent a discharge directly from an electronic component 16 to the PWA 14. In some instances, the ESD may not dissipate as expected due to materials (e.g., mating walls, dirt, humidity) or other factors slowing the dissipation of the ESD and thus, the ESD may travel farther than it is expected to travel in ideal conditions.

As a result of ESDs traveling farther than they would be expected to travel in ideal conditions, it is desirable to extend the ESDs' path of least resistance with the goal of the ESD dissipating prior to it reaching any electronic components of the electronic assembly 10. As shown in Figures 1 1A and 1 IB, the parting line 40, which may provide an avenue through which ESDs make their path to an interior of the of the electronic assembly 10 to the closest electrically sensitive area, may be extended a distance by the placement of the mating walls of the electronic assembly (e.g., the front cover 38, the back cover 36, and the spacer walls 42 of spacer 24).

For example, the spacer 24 may be positioned within the housing 12, such that the spacer 24 contacts the front cover 38 and the back cover 36. Such positioning of the mating surfaces may extend the distance the ESD must travel to contact an electrically sensitive area within the housing 12 to a distance equal to a length of protective walls 56 of the front cover 38 starting at a gap at an outer surface of the housing 12 between the front cover 38 and the back cover 36 plus a length of the spacer walls 42. In some illustrative instances, the extended distance the ESD may have to travel to an electrically sensitive area may be set at least 5 mm, at least 8 mm, at least 10 mm, or other distances of travel greater than 10 mm.

In some instances, and as disclosed further herein, the spacer 24 may be situated between the electronic component 16 and the PWA 14, and in some cases, may engage both the facing surfaces of the electronic component 16 and the PWA 14. When the spacer 24 is situated between the electronic component 16 and the PWA 14, a component on the PWA 14 may extend through an opening 25 in the spacer 24. For example, the electrically conductive extender or connector 18 extending from the PWA 14 may extend through an opening 25 in the spacer 24, see Figures 2 and 4. In one example, the electrically conductive extender or connector 18 may extend from the PWA 14, through an opening 25 in the spacer 24, and may mechanically engage and electrically connect to the metal backing 22 of the electronic component 16.

In some instances, the front cover walls 56 of the front cover 38 may be configured to engage and/or align other features of the electronic assembly 10. For example, wall extensions 58 may extend from the front cover walls 56 or other portions of the front cover 38 and interact with the PWA 14 or other feature to align the PWA 14 within housing 12, and in some cases, to at least partially secure the PWA 14 within the front cover 38. Additionally, or alternatively, a clip 60 of the front cover 38 may extend from a base 39 of the front cover 38 and optionally engage and/or align the PWA with the front cover 38. Further, in some instances, the front cover walls 56 may have beveled or chamfered outside edges (e.g. beveled or chamfered vertical edges when the electronic assembly 10 is attached to a wall structure), as shown in Figure 10) that may engage and/or abut mating chamfered or beveled walls of the back cover 36, as shown in Figures 1 1A and 1 IB.

Generally, the features of the electronic assembly 10 discussed herein may be configured to give the electronic assembly 10 a slimming look and a thin or minimalist configuration. In some instances, and as best shown in Figures 19 and 20, one or more terminal blocks 70 that may receive electrical wiring configured to connect power and/or control signals to the electronic assembly 10 may be positioned on a wall plate 80 and recessed into the housing 12 so as to not extend the profile of the electronic assembly 10 away from the wall. Despite being designed to create a thin profile, the electronic assembly 10 may be configured to allow plastic material to surround all electronics of the electronic assembly 10 and prevent substantially all of the electronics from being seen by a user from outside of the electronic assembly 10.

In some instances where the electronic component 16 may be or may include a display 32 (e.g., a liquid crystal display (LCD) or other display, where the display 32 may be a color display or other display), the front cover 38 may be or may include a display holder (e.g., an LCD display holder or other display holder). In such instances, and possibly other instances, the electronic assembly's 10 foot print and/or components may be configured around the size of the display 32. For example, the display 32 may include a display having an approximate diagonal D of 4.3 inches with a height H of approximately 3 inches and a width W of approximate 4 inches, as best shown Figure 14. The display 32 of the electronic component 16 may have other dimensions, as desired.

In some examples, where the size of the display 32 is approximately 4.3 inches diagonal (approximately 4 inches wide and 3 inches tall), the PCB 34 of the PWA 14 may be slightly taller than three inches. This extra length of the PCB 34 may accommodate an antenna (e.g., a Wifi antenna or other antenna) that would otherwise be shielded or blocked by metal backing 22 of the electronic component 16 (e.g. display 32). As a result, the base size of the PCB 34 may be approximately 4 inches wide and 3.35 inches tall, and all of the electronics may be consolidated and/or packaged close together to fit within this footprint. Additionally, or alternatively, the electronics may be packaged along with the display 32, which may allow the device to have a thin profile.

Further, the opening 52 of the front cover 38 may be sized to allow a user to view and/or interact with the display 32 or other electronic component 16, while protecting the electronic component 16. For example, the opening 52 in the front cover 38 may be sized to allow free access to a touch pad of the electronic component 16, sized to cover the visual area viewing angles, sized to protect the PWA against contamination, sized to prevent the cover from interacting with an active touch pad area of the electronic component 16, and and/or sized for any other purpose.

In some illustrative instances, the front cover 38 may be configured to accept the electronic component in the X and Y directions, as shown in Figures 16-18, in a tight to loose fit. In the Z direction, the fit may be tight to prevent the electronic component 16 from rattling while a user interacts with the electronic assembly 10. Such a tight fit in the Z direction may be facilitated by using the gasket 106, which may compress to fill any extra space resulting from manufacturing tolerances of the front cover wall 56 and the front cover 38.

The front cover 38 may have a bezel formed at least partially from the base 39 that wraps around the product and which may allow a user to contact the electronic assembly 10 without interacting with the electronic component 16 (e.g., the display 32). Further, the front cover 38 may be a front window assembly (FWA) front cover 100 of the housing 12, as best shown in Figure 12. The FWA front cover 100 may operate like a rigid display 32 and PWA 14 holder, such that the FWA front cover 100, the display 32 and the PWA 14 may be placed in the final electronic assembly 10 as a single sub-assembly 110.

The FWA front cover 100 may be made from a front window 102, adhesive layer 104, front cover 38 (e.g., a display holder), and gasket 106 (e.g., a sealing gasket or other gasket), as best shown in Figure 12-15. These parts may be supplied to an assembly line as a single part, separate parts, or a combination of single parts and combined parts, as desired.

The front cover 38 or display holder may include a recess 53 for receiving at least part of the display 32 (see, Figure 14). When the front cover 38 or display holder receives the display 32, the gasket 106 may be positioned between the front cover 38 and the display 32 (e.g., the front side of the display 32). The display 32 may be placed within the front cover 38 of the FWA front cover 100 through the recess 53 of the front cover 38 or display holder such that the front cover or display holder may extend adjacent part of the front side of the display 32 and adjacent at least part of the side walls of the display 32.

The spacer 24 may be positioned adjacent the display 32, and the subassembly 1 10 may be closed by adding the PWA 14 adjacent to the spacer 24 and securing the PWA 14 to the front cover 38 or display holder adjacent the back side of the display 32 (see, Figure 15). Such a configuration may sandwich the display 32 between the front cover 38 or the display holder and the PCB 34 of the PWA 14. The term "sandwich" or "sandwiched", as used herein, means positioned between or positioned in any other similar position. The PCB 34 of the PWA 14 may include a front side configured to face the front cover 38 or display holder and/or the display 32, a back side opposite the front side, and side walls extending between the front side and the back side. The spacer 24 may have spacer side walls 42 that, when the spacer 24 is positioned between the PCB 34 and the display 32, may extend adjacent to at least part of the side walls of the PCB 34 and/or beyond the back side of the PCB 34, when desired.

In some instances, the display 32, spacer 24, and PWA 14 may be held in position in the sub-assembly 1 10 with one or more features of the front cover 38 or display holder, such as one or more hinges or wall extensions 58 (e.g., releasable hinges or wall extensions), one or more latches or clips 60 extending from the base 39 of the front cover 38, and/or one or more other features. In one instance, the one or more features of the front cover 38 or display holder may be configured to sandwich the display 32 and the spacer between the front cover 38 or display holder and the PCB 34 of the PWA 14. Alternatively, or additionally, the hinges or wall extensions 58 of the front cover 38 or display holder may hinge the PCB 34 of the PWA 14 with respect to the front cover 38 or display holder until the latch(es) or clip(s) 60 latch or clip the PCB 34 of the PWA 14 relative to the front cover 38 or display holder.

Further, the sub-assembly 110 may be configured such that a flex tail 33 of the display 32 may be inserted into a connector 46 on the PWA 14, as best shown in Figure 18, to place the PWA 14 and the PCB 34 thereof in electrical communication with the display 32.

As discussed, the front cover 38 may receive the display 32 therein. In some instances, the display 32 (e.g., the front of the display) may rest against the gasket 106 within the front cover 38. The gasket 106 may have several purposes. For example, the gasket 106 may prevent liquid from getting into the electronic assembly 10, the gasket 106 may help create a tighter fit for the components of the electronic assembly 10, the gasket 106 may help prevent ESDs from entering the electronic assembly 10, etc.

In some instances, the spacer 24 and the front cover 38 or display holder may be mating components and may contain several positioning features that do not allow an operator to assemble them in an incorrect orientation. These orientation features include, but are not limited to: ribs 108 in the spacer 24 configured to engage pockets 1 12 in the front cover 38 or display holder to assist or help in aligning the spacer 24 with the front cover 38 or display holder; grooves in the edges of the spacer 24 and/or the front cover 38; an alignment feature 1 14 (e.g., a rib, a pin, or other alignment feature) of the front cover 38 or display holder configured to engage an alignment feature 1 16 (e.g., a pocket, a pin hole, or other alignment feature) in the spacer 24 to align the spacer and the front cover or the display holder, as best shown in Figure 19; and/or other positioning features used in any uncombined or combined manner, as desired. In addition to facilitating the proper alignment of the front cover 38 and the spacer 24, the positioning features may help prevent the spacer 24 from moving until the PWA 14 is assembled and the sub-assembly 1 10 may be fully assembled and locked together.

Turning now to Figures 22 and 23, in some instances, the back cover 36 may be configured to support the PWA 14 and/or the electronic component 16 (e.g., display 32). Supporting the PWA 14 and/or the electronic component 16 from a back side may assist in preventing unexpected bending of the PWA 14 and/or the electronic component 16 when a user is pressing against the display 32 or other front side features, which could contribute to the electronic device malfunctioning.

In one example, the back cover 36 may include an outer shell 73 and one or more inner walls 130 (e.g., inward extending walls or other inner walls) that extend from the outer shell 73 toward the PWA 14 to support the PWA 14 from the back side when it is fully assembled in the electronic assembly 10. The inner walls 130 may have one or more functions. For example, the inner walls 130 may: provide mechanical support for the PWA 14 and/or the electronic component 16; help to prevent ESDs from progressing to shielded areas of the PWA 14; divide an inner volume between the PWA 14 and the back cover 36 into separate spaces (e.g., pockets and/or areas on the PWA 14) and separate colder areas from warmer areas to assist in improving temperature sensing and/or compensation capabilities such as described in US. Patent No. 8,280,637, which is incorporated herein by reference. Alternatively, or in addition, the inner walls 130 may have one or more other functions that may or may not be combined with the listed functions of the inner walls 130.

In some instances, the inner walls 130 of the back cover 36 may have one or more portions. For example, as shown in Figure 22, the inner walls 130 of the back cover 36 may have: a wall portions 130a configured to surround the pins 62 on a region of the PWA 14 for connection to terminals 70 in the wall plate 80 (e.g., where the outer shell 73 may include an aperture 71 with wall portions 130a extending inward toward the PWA 14 to form a sidewall of the aperture 71 extending substantially to the PWA 14), which may help prevent users from contacting electronic components on the PWA 14 other than the pins 62; wall portions 130b configured to form thermistor pockets 132 and surround one or more thermistors or temperature sensors (e.g., a first temperature sensor and a second temperature sensor in a first area and/or a first pocket) on the PWA 14; wall portions 130c forming a pocket and/or surrounding the battery aperture or opening 37 (e.g., where the wall portions 130c form a sidewall of the battery aperture or opening 37 and provide access to a region on the PWA 14 (see, for example, the discussion of the region with respect to the aperture 71 above) and one or more connectors (e.g., battery holder 92 or other connectors)), which may help prevent users from contacting other electronic components on the PWA 14 when installing and/or removing the battery; wall portions 130d forming pockets separating warm areas of the PWA 14 (e.g., the first area and/or the first pocket with air of a first temperature during operation of the electronic assembly 10) from colder areas of the PWA 14 (e.g., a second area and/or second pocket with air of a second temperature that is cooler than the first temperature during operation of the electronic assembly 10), which may improve the temperature sensing and/or compensating capabilities of the electronic assembly 10; and wall portions 130e forming pockets and/or surrounding a humidity sensor attached to the PWA (e.g., where the humidity sensor is in one of the first pocket, the second pocket, a third pocket, and/or any other pocket). The regions on the PWA 14 discussed above may be regions including the pins 62, the battery holder 92, and/or is substantially devoid of ESD sensitive electronic components, electronic components other than one or more connectors such as a pin or battery connector, or any other electronic component.

Further, in some cases, an interior of the back cover 36 may have one or more alignment feature 136 configured to engage one or more openings in the PWA 14 and align the back cover 36 with respect to the PWA 14, which may be within subassembly 1 10. Additionally, the back cover 36 may include one or more PWA supports 134, which may have the dual purpose of providing a testing opening through back cover 36.

With the above illustrative structure of the back cover 36, the wall portions 130 (e.g., wall portions 130a-130e) may help support PWA 14 by touching or contacting a back side of the PWA 14 at some or at least substantially all of the positions atop the wall portions 130 when the printed circuit board is enclosed in the housing 12. In some instances, the wall portions 130 may facilitate ESD shielding by, for example, walling off a central opening or aperture 71 for connecting pins 62 to terminal 70 on a wall plate 80. Additionally, or alternatively, the wall portions 130 may improve temperature sensing accuracy by at least partially separating cold areas (e.g., an area surrounding the battery) where there are no, or a limited number of, components generating unintended heat, from other areas. In the cold areas of the PWA 14 as defined, for example, by the wall portions 130d of the back cover 36, one or more thermistors and/or one or more humidity sensors may be positioned so as to not be affected so much by heat creating electronic components on the PWA 14.

As indicated by the placement of thermistor pockets 132 in the back cover 36, the thermistors on the PWA 14 may be located at top and bottom edges (or in some cases opposite edges) of the PWA 14. To further isolate at least some of the thermistors on the PWA 14 from unintended heat, the wall portions 130 of the thermistor pockets 132 may substantially entirely surround a thermistor and contact the surface 15 of the PWA 14. Such direct contact between the wall portions 130b and the PWA 14 may assist in isolating the thermistor pockets 132. Dividing the inner volume between the PWA 14 and the back cover 36 into separate spaces (e.g., pockets and/or areas on the PWA 14) and separate colder areas from warmer areas may assist in temperature sensing and/or compensation capabilities of the electronic device such as described in US. Patent No. 8,280,637, which is incorporated herein by reference.

Additionally, or alternatively, the wall portions 130d surrounding a humidity sensor at the bottom of the PWA 14 may protect the humidity sensor and have vents 138 to help bring humidity changes to this compartment. In some illustrative instances, including optionally the examples above, the first thermistor pocket and the second thermistor pocket may be free from air vents 138 through the housing 12 to the external environment. The third pocket, which may house the humidity sensor, may include an air vent 138 extending through the housing 12 to an exterior environment. As a result of these features and others, the back cover 36 may be configured to support the PWA 14 and/or the electronic component 16, protect features on the PWA 14, and provide an electronic assembly 10 that has robust and accurate electronic sensing capabilities.

In some instances, the housing 12, particularly the front cover 38 and the back cover 36, may be formed by any desirable manufacturing process and may be made from any desirable material. For example, the housing 12 may be molded and made from a plastic material. Alternatively, or in addition, the housing may be made from a different mechanical process and/or a different material.

As shown in Figures 19-21C, the back cover 36 (e.g., a back side of a housing 12 having a back side and a front side) may engage a wall plate 80 (e.g., in a releasably connectable manner), where the wall plate 80 may be a portion of the electronic assembly that is used to hang the electronic assembly 10 (e.g., a thermostat) on a wall or other structure. In some cases, the wall plate 80 may have a perimeter defined or at least partially defined by side walls 86, and in some cases, the engaged back cover 36 may partially or substantially enclose the wall plate 80.

In some instances, the wall plate 80 may be secured to a wall or other structure with screws 82 or other fastening mechanisms. The wall plate 80 may include one or more apertures 81 extending through the wall plate 80 that are configured to receive one or more screws or other fastening mechanisms. Where screws 82 are used to fasten the wall plate 80 to a wall or other structure, it is contemplated that the wall plate 80 and/or the back cover 36 may include pockets 84 (e.g. relief features) in the wall plate 80 and/or pockets 63 (e.g., relief features) in the back cover 36 to accommodate a portion of a screw head to help ensure the heads of the screws 82 do not act as a limiting factor in the thinness or thickness of the electronic assembly 10. In instances where there are pockets 84 in the wall plate 80 and pockets 63 in the back cover, the pockets 84, 63 may be aligned with one another.

The housing 12 (e.g., the back cover 36 or other portion of the housing 12) and the wall plate 80 may be provided and/or configured such that the housing 12 and the wall plate 80 initially engage one another, with the wall plate 80 misaligned relative to the housing 12. As the wall plate 80 and the housing 12 are moved (e.g., slid or otherwise guided) together or toward one another, the housing 12 and wall plate 80 may be guided into alignment with one another.

In some instances, the back cover 36 may have a raised perimeter 64 at least partially defining a recess that is configured to accept and/or receive at least a part or portion of the wall plate 80, where the recess may include a recess back wall 65. The recess may have a depth and the wall plate 80 may have a thickness such that the volume of the recess of the housing 12 may receive at least a majority of the thickness of the wall plate 80. Alternatively, or in addition, the wall plate 80 may have a raised portion in a front wall or surface 85 that at least partially defines a recess that is configured to accept and/or receive at least a part or portion of the back cover 36 or other portions of the housing 12, where the recess may include a recessed front wall (not explicitly shown).

Although the engaging and aligning related features are discussed herein with respect to the recess being positioned in the back cover 36 of housing 12, similar engaging and/or aligning related features may be incorporated into the electronic assembly 10 having a recess in the wall plate 80 that receives at least part of the back cover 36 or other portion of the housing 12.

Referring to Figures 19 and 20, the raised perimeter 64 of the back cover 36 may have recess side walls 66 that may correspond with wall plate side walls 86 of the wall plate 80, and may allow at least a part or portion of the side walls 86 of the wall plate 80 to mate with the recess side walls 66 of the back cover 36 of the housing 12. In some cases, the side walls 86 of the wall plate 80 are tilted or slanted at an angle relative to the back wall 65, and the recess side walls 66 of the back cover 36 may be similarly titled or slanted at an angle to mate with the side walls 86 of the wall plate 80. More generally, in some instances, the recess side walls 66 may have a first perimeter 67 adjacent the recessed back wall 65 and a second perimeter 69 toward the back side of the housing 12 and the wall plate 80, where the second perimeter 69 is larger than the first perimeter 67. Likewise, the side walls 86 of the wall plate 80 may have a first perimeter 87 adjacent the housing 12 when the wall plate 80 is engaging the housing 12 and a second perimeter 89 closer to a mounting surface 85 of the wall plate than the first perimeter, where the second perimeter 89 is larger than the first perimeter 87 (see, for example, Figure 2 IB).

In some cases, the respective walls 66, 86 may be used to self-align the back cover 36 with the wall plate 80. For example, in some instances, the side walls 66 of the housing and the side walls 86 of the wall plate 80 may be configured such that the recess in the back of the housing 12 may receive the wall plate 80 with the wall plate 80 misaligned relative to the housing 12, and then as the housing 12 is moved toward the wall plate 80, the side walls 66 of the housing and the side walls 86 of the wall plate 80 progressively further align the housing 12 with the wall plate 80.

In a similar manner, it is contemplated that a recess in the wall plate 80 (not explicitly shown) in conjunction with the back cover 36 or other portion of the housing 12 may be configured such that the recess of the wall plate 80 may initially receive the back cover 36 or other portion of the housing 12 with the wall plate misaligned relative to the back cover 36 or other portion of the housing 12, and then progressively further align the back cover 36 or other portion of the housing 12 with the wall plate 80 as the back cover 36 or other portion of the housing 12 are moved closer to one another.

A method of securing a back cover of a housing 12 and a wall plate 80 may include moving the wall plate 80 into engagement with the back cover 36 (or back side of the housing 12) and sliding an aligning surface of the wall plate 80 (e.g., tilted, slanted, angled, beveled, chamfered side walls 86) along an aligning surface of the housing (e.g., tilted, slanted, angled, beveled, chamfered side walls 66) to align the wall plate 80 with the housing 12 as the wall plate 80 is moved further towards the housing 12.

The tilted, slanted, angled, beveled, or chamfered side walls 66, 86 may be angled at any angle or have any other suitable configuration. For example, the side walls 66, 86 may be angled at between zero (0) degrees and ninety (90) degrees, ten (10) degrees and eighty (80) degrees, twenty (20) degrees and seventy (70) degrees, thirty (30) degrees and sixty (60) degrees, forty (40) degrees and fifty (50) degrees relative to the recess back wall 65 or the mounting surface 85, respectively. In one illustrative example, the side walls 66, 86 may be angled at a forty-five (45) degree angle with respect to the recess back wall 65 or the mounting surface 85, respectively. Alternatively, the side walls 66, 86 may have different angles with respect to one another relative to the respective recess back wall 65 or the mounting surface 85.

In some instances, the back cover 36 may be further configured to have a limited profile. For example, the side walls 68 of the back cover 36 may extend inward, such that the front of the back cover 36 that is adjacent the front cover 38 defines a larger circumference/perimeter than a circumference/perimeter defined by a back of the back cover 36 that is adjacent the wall plate 80.

Those skilled in the art will recognize that the present disclosure may be manifested in a variety of forms other than the specific embodiments described and contemplated herein. Accordingly, departure in form and detail may be made without departing from the scope and spirit of the present disclosure as described in the appended claims.

Other Examples In a first example, an electronic assembly includes a display having a front side for viewing the display, a back side, and side wall extending between the front side and the back side. The electronic assembly further includes a display holder having a recess for receiving at least part of the display, the display holder extending adjacent part of the front side of the display and adjacent at least part of the side walls of the display, and a printed circuit board secured relative to the display holder and adjacent the back side of the display, the printed circuit board in operative communication with the display.

In a second example, the electronic assembly of the first example further includes a spacer situated between the back side of the display and the printed circuit board.

In a third example, the electronic assembly of the second example, where the spacer mates with the display holder and maintains a space between the display and the printed circuit board.

In a fourth example, the electronic assembly of either one of the second example and the third example, further including a back cover configured to engage the display holder and define a gap, side walls of the spacer, side walls of the display holder, and wherein the spacer mates with the display holder such that the respective side walls of the mated spacer and display holder form a distance an electrostatic discharge must travel from the gap to reach an electronic component on the printed circuit board.

In a fifth example, the electronic assembly of the fourth example, where the distance an electrostatic discharge must travel from the gap to reach an electronic component on the printed is at least 5 millimeters.

In a sixth example, the electronic assembly of any one of the second example through the fifth example, where the printed circuit board has a front side facing the display holder, a back side, and side walls extending between the front side and the back side, wherein the spacer has spacer side walls that extend adjacent at least part of the side walls of the printed circuit board beyond the back side of the printed circuit board.

In a seventh example, the electronic assembly of any one of the second example through the sixth example, where: the display holder includes an alignment feature, and the spacer includes an alignment feature, wherein the alignment feature of the spacer is configured to cooperate with the alignment feature of the spacer to align the spacer and the display holder.

In an eighth example, the electronic assembly of the seventh example, where the alignment feature of the spacer includes a rib, and the alignment feature of the display holder includes a pocket, where the pocket of the display holder is configured to cooperate with the rib of the spacer to align the spacer with the display holder.

In a ninth example, the electronic assembly of any one of the first example through the eighth example, further including a spacer including an opening that results in an air gap between the back side of the display and the printed circuit board.

In a tenth example, the electronic assembly of any one of the first example through the ninth example, where the display holder includes one or more features that engage the printed circuit board.

In an eleventh example, the electronic assembly of any one of the first example through the tenth example, where the display holder includes one or more wall extensions that engage the printed circuit board, and a latch that engages the printed circuit board.

In a twelfth example, the electronic assembly of any one of the first example through the eleventh example, where the display is sandwiched between the display holder and the printed circuit board.

In a thirteenth example, the electronic assembly of any one of the first example through the ninth example, where a spacer is situated between the display and the printed circuit board.

In a fourteenth example, the electronic assembly of any one of the first example through the thirteenth example, further including a gasket situated between the display holder and the front side of the display.

In fifteenth example, an electronic assembly includes a display having a front side for viewing the display, a back side, and side walls extending between the front side and the back side, a display holder having a recess for receiving at least part of the display, the display holder extending adjacent part of the front side of the display and adjacent at least part of the side walls of the display, a printed circuit board secured relative to the display holder and adjacent the back side of the display, a spacer situated between the back side of the display and the printed circuit board, the display holder includes an alignment feature, the spacer includes an alignment feature, wherein the alignment feature of the spacer is configured to interact with the alignment feature of the spacer to help align the spacer and the display holder, and the display holder including one or more features to secure the printed circuit board to the display holder.

In a sixteenth example, the electronic assembly of the fifteenth example, where the one or more features of the display holder includes a latch to latch the printed circuit board to the display holder, sandwiching the display and the spacer between the display holder and the printed circuit board.

In a seventeenth example, the electronic assembly of the sixteenth example, where the one or more features of the display holder includes a releasable hinge for hinging the printed circuit board with respect to the display holder until the latch latches the hinged printed circuit board relative the display holder.

In an eighteenth example, the electronic assembly of the seventeenth example, where the display and the spacer are sandwiched between the display holder and the printed circuit board.

In a nineteenth example, the electronic assembly of any one of the fifteenth example through the eighteenth example, where the spacer mates with the display holder and maintains a space between the display and the printed circuit board.

In a twentieth example, the electronic assembly of any one of the fifteenth example through the nineteenth example, where the spacer includes two or more apertures that result in an air gap between the back side of the display and the printed circuit board.

In a twenty first example, the electronic assembly the twentieth example, where the printed circuit board includes one or more components and at least one of the components extends into an aperture of the spacer.

In a twenty second example, a method of assembly an electronic assembly includes inserting a front side of a display into a recess of a display holder, aligning one or more alignment features of a spacer with one or more corresponding alignment features of the display holder, and placing the spacer adjacent a back side of the display, aligning one or more alignment features of a printed circuit board with one or more corresponding alignment features of the display holder, and placing the printed circuit board adjacent to the spacer, and engaging a latch of the display holder with the printed circuit board to secure the printed circuit board relative to the display holder with the display and the spacer secured therebetween. In a twenty third example, the method of the twenty second example, including electrically connecting a connector of the display to a connector on the printed circuit board.

Claims

What is claimed is:

1. An electronic assembly, comprising:

a display having a front side for viewing the display, a back side, and side walls extending between the front side and the back side;

a display holder having a recess for receiving at least part of the display, the display holder extending adjacent part of the front side of the display and adjacent at least part of the side walls of the display; and

a printed circuit board secured relative to the display holder and adjacent the back side of the display, the printed circuit board in operative communication with the display.

2. The electronic assembly of claim 1, further comprising a spacer situated between the back side of the display and the printed circuit board.

3. The electronic assembly of claim 2, wherein the spacer mates with the display holder and maintains a space between the display and the printed circuit board.

4. The electronic assembly of either one of claim 2 or claim 3, further comprising:

a back cover configured to engage the display holder and define a gap;

side walls of the spacer;

side walls of the display holder; and

wherein the spacer mates with the display holder such that the respective side walls of the mated spacer and display holder form a distance an electrostatic discharge must travel from the gap to reach an electronic component on the printed circuit board.

5. The electronic assembly of claim 4, wherein the distance an electrostatic discharge must travel from the gap to reach an electronic component on the printed is at least 5 millimeters.

6. The electronic assembly of any one of claims 2-5, wherein the printed circuit board has a front side facing the display holder, a back side, and side walls extending between the front side and the back side, wherein the spacer has spacer side walls that extend adjacent at least part of the side walls of the printed circuit board beyond the back side of the printed circuit board.

7. The electronic assembly of any one of claims 2-6, wherein:

the display holder includes an alignment feature;

the spacer includes an alignment feature, wherein the alignment feature of the spacer is configured to cooperate with the alignment feature of the spacer to align the spacer and the display holder.

8. The electronic assembly of claim 7, wherein:

the alignment feature of the spacer includes a rib; and

the alignment feature of the display holder includes a pocket, where the pocket of the display holder is configured to cooperate with the rib of the spacer to align the spacer with the display holder.

9. The electronic assembly of any one of claims 1-8, further comprising: a spacer including an opening that results in an air gap between the back side of the display and the printed circuit board.

10. The electronic assembly of any one of claims 1-9, wherein the display holder includes one or more wall extensions that engage the printed circuit board, and a latch that engages the printed circuit board.

1 1. The electronic assembly of any one of claims 1-10, wherein the display is sandwiched between the display holder and the printed circuit board.

12. The electronic assembly of any one of claims 1-1 1, wherein a spacer is situated between the display and the printed circuit board.

13. The electronic assembly of any one of claims 1-12, further comprises a gasket situated between the display holder and the front side of the display.

14. A method of assembling an electronic assembly, the method comprising:

inserting a front side of a display into a recess of a display holder;

aligning one or more alignment features of a spacer with one or more corresponding alignment features of the display holder, and placing the spacer adjacent a back side of the display;

aligning one or more alignment features of a printed circuit board with one or more corresponding alignment features of the display holder, and placing the printed circuit board adjacent to the spacer; and

engaging a latch of the display holder with the printed circuit board to secure the printed circuit board relative to the display holder with the display and the spacer secured therebetween.

15. The method of claim 14 further comprising, electrically connecting a connector of the display to a connector on the printed circuit board.