Button assembly and method of manufacturing the same

Abstract

The present invention relates to a method of manufacturing a housing assembly (200) having button functionality, comprising pre-forming a composite button component or insert (645) having a resiliently flexible button membrane (404) mounted on a rigid frame (303), and then molding a housing (206) over the button insert. The composite button insert is formed in a common molding operation, and can include a rigid island (423) in the flexible button membrane for supporting a decorative keycap (251).

Description

[0001] This application is a divisional application of patent application number 201980017496.4, which was filed on March 5, 2019, and is entitled "Button assembly and manufacturing method thereof".

[0002] Related applications

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 638,669, filed March 5, 2018, which is incorporated herein by reference in its entirety. Background Technology

[0004] Many electronic products offer one or more functions that users can select by manually operating a button mechanism. In some such products, the elastic recovery of the button after being pressed is achieved by an elastic diaphragm or elastomer washer, which deforms when the button is pressed.

[0005] In many applications, this button diaphragm also provides a sealed closure for the housing on which the button is mounted. The button diaphragm is typically a molded / injection-molded part bonded to the housing to provide this sealing engagement.

[0006] However, cost-effective and reliable molding of button membranes onto housings or enclosures is often hampered by complex or inaccessible housing geometries. Another difficulty frequently encountered with such conventional button assemblies is the poor adhesive compatibility between the elastomeric material used for the membrane and the rigid plastic material typically used to mold the housing or enclosure. Attached Figure Description

[0007] The accompanying drawings illustrate only exemplary embodiments of the invention and should not be construed as limiting the scope of the invention. For ease of comparison between the marked components in the description and the accompanying drawings, the first number of each marked component corresponds to the drawing in which that component first appears. In the accompanying drawings:

[0008] Figure 1 This is a schematic diagram of a three-dimensional view of an electronic device according to an exemplary embodiment, the electronic device being in the form of a pair of smart glasses with one or more functions, which can be operated by using a pair of buttons mounted on the frame of the glasses device.

[0009] Figure 2 It is according to an exemplary embodiment for incorporating in accordance with Figure 1 A schematic cross-sectional view of a housing assembly in the frame of an exemplary electronic device, the housing assembly including a pre-formed co-molded button insert, the housing having been overmolded onto the button insert.

[0010] Figure 3 It is based on Figure 2 An independent three-dimensional view of the co-molded button insert of an exemplary embodiment.

[0011] Figure 4 It is based on Figure 3 An independent cross-sectional view of the button insert in an exemplary embodiment.

[0012] Figure 5 This is for use before attaching the button cover to the button insert, and before installing the electronic components inside the housing assembly, in conjunction with, for example, according to Figure 1 A three-dimensional view of a housing assembly in an electronic device according to an exemplary embodiment.

[0013] Figure 6 This is a schematic flowchart illustrating an exemplary embodiment of a method for manufacturing a housing assembly with button functionality according to an exemplary embodiment.

[0014] The titles provided in this article are for convenience only and do not necessarily affect the scope or meaning of the terms used. Summary of the Invention

[0015] One aspect of the invention provides a pre-formed composite button component or insert—comprising a resilient, flexible button membrane mounted on a rigid frame, with a housing then molded onto the button insert. In some embodiments, the composite button insert is formed in a co-molding operation.

[0016] In this specification, "rigid" or "substantially rigid" means that the material or component is rigid enough that it does not exhibit easily identifiable deformation or shape change when subjected to the force of a manual button press. Such a material is also referred to herein as a hard plastic material. Conversely, "flexible" and "deformable" mean that the material or component does exhibit easily identifiable deformation or shape change when subjected to the force of a manual button press.

[0017] In other words, one aspect of the present invention provides a method comprising:

[0018] Forming a button insert, the button insert comprising:

[0019] A button frame defining an access opening extending through it, the button frame being made of a substantially rigid plastic material; and

[0020] A button membrane, attached to a button frame and covering at least a portion of an access opening through the button frame, the button membrane being made of an elastic, flexible material; and

[0021] A housing for electronic components is overmolded onto a composite button insert, such that the housing is attached to a button frame, wherein a button diaphragm is located in a button hole defined by the housing, and the button hole is closed by the button insert.

[0022] In some embodiments, the button insert is substantially waterproof. In such embodiments, an overmolding operation establishes a substantially waterproof connection between the button insert and the housing, such that the button insert seals the button hole of the housing. In some embodiments, the button frame is integrated into the wall of the housing, such that the material of the housing is bonded to the outer periphery of the button frame.

[0023] In some embodiments, forming the button insert includes molding a button frame and overmolding a button film onto the button frame. In some embodiments, this is performed in a co-molding operation, such as in a two-color injection mold.

[0024] In some embodiments, the co-molding operation causes the button insert to further include a rigid island or cover platform coupled to the flexible button membrane, movable relative to the button frame as the button membrane elastically deforms. In such embodiments, the rigid island is made of a substantially rigid plastic material and is positioned to align with a button hole defined by the housing.

[0025] In some embodiments, the method may include attaching a button cover to a rigid island portion that provides an interface for manual user interaction. In some such embodiments, the button cover is attached to the rigid island portion or cover platform in an ultrasonic bonding operation. In other embodiments, an adhesive is formed between the button cover and the rigid island portion, for example, by applying liquid adhesive.

[0026] Other aspects of the invention provide a housing assembly formed according to the above method, and an electronic device incorporating such a housing assembly. Detailed Implementation

[0027] The following description includes apparatus, systems, methods, and techniques embodying illustrative embodiments of the present disclosure. In this description, numerous specific details are set forth for purposes of explanation in order to provide an understanding of various embodiments of the disclosed subject matter. However, it will be apparent to those skilled in the art that embodiments of the disclosed subject matter can be practiced without these specific details. Generally, well-known examples of instructions, protocols, structures, and techniques are not necessarily shown in detail.

[0028] Figure 1The image shows an example of an electronic device in the form of an eyeglasses device 100, illustrating at least some button operation. The eyeglasses device 100 includes a body 103, which includes a front member or frame 106 and a pair of temples 109 connected to the frame 106 for supporting the frame 106 in a suitable position on the user's face when wearing the eyeglasses device 100. In this exemplary embodiment, the frame 106 is provided at least partially by one or more molded components formed of a substantially rigid polymeric plastic material.

[0029] The eyewear device 100 has a pair of optical elements in the form of a pair of optical lenses 112, held by corresponding optical element holders that are part of a pair of lens frames 116. The frames 116 are connected by a bridging member 118. In other embodiments, one or both of the optical elements may be a display, a display assembly, or a combination of lenses and a display. In such embodiments, the eyewear device 100 may provide a virtual reality headset or an augmented reality display.

[0030] Frame 106 includes a pair of end members 121 defining the lateral ends of frame 106. In this example, various electronic components are housed in one or both end members 121, as discussed in more detail below. In some embodiments, frame 106 is formed from a single piece of material, thus having an integral or monolithic structure. In this exemplary embodiment, as will be referred to below... Figure 2-5 In more detail, each end member 121 is formed from a separate molded plastic part.

[0031] In this specification, directional terms such as front, back, forward, backward, outward, and inward should be understood with reference to the direction of the user's gaze when wearing the eyeglasses device 100. Thus, the frame 106 has an outward-facing front side 134 that faces away from the user when worn, and conversely, an inward-facing rear side 137 that faces the user when wearing the eyeglasses device 100. Similarly, the terms horizontal and vertical used in this specification with reference to different features of the eyeglasses device 100 should be understood to correspond to the orientation of the eyeglasses device 100 when it is horizontal on the face of a user looking forward. The horizontal or lateral direction of the eyeglasses device 100 thus extends substantially between the end members 121, while the vertical or elongated direction of the eyeglasses device 100 extends laterally than the horizontal direction, such that the lens 112 has a substantially vertical or elongated orientation.

[0032] The eyeglasses device 100 has built-in electronics 124, which includes a computing device such as a computer. In various embodiments, this computing device can be of any suitable type for carrying by the body 103. In some embodiments, various components including the built-in electronics 124 are at least partially housed in one or both temples 109. In this embodiment, the various components of the built-in electronics 124 are housed in the lateral end members 121 of the frame 106. The built-in electronics 124 includes one or more processors having memory, wireless communication circuitry, and a power source (in this embodiment, a rechargeable battery, such as a lithium-ion battery). The built-in electronics 124 includes low-power, high-speed circuitry and, in some embodiments, includes a display processor. These elements in various embodiments may have different configurations or be integrated together in different ways.

[0033] The eyeglasses device 100 has a camera function, which in this example includes a camera 130. The camera 130 is mounted in one of the end members 121 and faces forward so as to be generally aligned with the line of sight of the wearer of the eyeglasses device 100. The camera 130 is configured to capture digital still life and digital video content. The operation of the camera 130 is controlled by a camera controller provided by a built-in electronics 124, and the image data represented by the pictures or videos captured by the camera 130 is temporarily stored in a memory that forms part of the built-in electronics 124. In some embodiments, the eyeglasses device 100 may have a pair of cameras 130, for example, housed in corresponding end members 121.

[0034] The eyeglasses device 100 also includes one or more input and output devices that allow communication with and control of the camera 130. Specifically, the eyeglasses device 100 includes one or more input mechanisms for enabling a user to control one or more functions of the eyeglasses device 100. In this embodiment, the input mechanism includes a button mechanism 115 mounted on the frame 106 so that it can be accessed and pressed by a user from the top of one of the end members 121.

[0035] Figure 2 A partial cross-section of the housing assembly 200, which is configured to be coupled to... Figure 1An example of this is in the electronic device of the eyeglasses device 100. In this exemplary embodiment, the housing assembly 200 is configured to provide an end member 121 of the eyeglasses device 100. The housing assembly 200 includes a housing 206 on which a button mechanism 115 is mounted. The housing 206 has a hollow interior defining a housing cavity 211 in which an associated electronic component 124 is enclosed. In this exemplary embodiment, the electronic component 124 includes a printed circuit board (PCB) 216 supported in the housing cavity 211 by a metal support bracket 221. The PCB 216 includes a push-button switch 227 mounted on the PCB 216 such that it faces the button mechanism 115 for activation.

[0036] The button mechanism 115 is located in a circular button hole 233 defined by the top wall 239 of the housing 206, which aligns with a push-button switch 227 mounted on the PCB 216. The button hole 233 is sealed closed by a composite button insert 645, onto which the housing 206 is overmolded, as shown in the reference... Figure 6 More detailed description.

[0037] Now refer to Figure 3 and Figure 4 Briefly describe the construction of button insert 645, which is a co-molded part pre-formed to be integrated into housing 206. Go to Figure 3 As will be seen, the button insert 645 includes a button frame 303, which, in this exemplary embodiment, is a generally square, tile-shaped component. The button frame 303 is made of a substantially rigid polymeric plastic material and defines a circular central opening 307 that provides an entry point for engagement with the push-button switch 227. Figure 2 The button frame 303 has a pair of main outer surfaces facing opposite directions, in the form of an operable outer surface 311 and an operable inner surface 315, the main outer surface 311 and the inner surface 315 being connected by a circumferential edge surface extending laterally between them.

[0038] The inner surface 315 of the button frame 303 defines a mounting structure, in the form of an example set of thermal posts / riveting posts 319, which project laterally away from the inner surface 315. To briefly reiterate... Figure 2 As will be seen, the thermal anchor 319 is used to mount one or more electronic components 124. In this exemplary embodiment, the thermal anchor 319 is used to mount the PCB 216, passing through complementary alignment openings in the PCB 216 and the metal support bracket 221. The exposed head of the thermal anchor 319 deforms to rivet-lock the PCB 216 and the support bracket 221 into place relative to the button frame 303.

[0039] Now go to Figure 4 As will be seen, the button insert 645 also includes a button membrane 404, which is attached to the radial inner periphery of the button frame opening 307 and thus located within the opening 307. The button membrane 404 is a generally cup-shaped, generally annular member such that a central boss 409 protrudes from the outer surface 311 of the button frame 303. The membrane 404 is made of an elastically deformable polymeric plastic material; in this exemplary embodiment, the membrane 404 is made of a molded elastomeric material, such that the central boss 409 of the button membrane 404 can elastically move back and forth in a direction transverse to the button frame 303, such as... Figure 4 As indicated by arrow 450. The central boss 409 of the button membrane 404 also defines a central circular hole 414 extending laterally through it. From Figure 4 As can be seen most clearly, the operable upper surface of the central boss 409 has a concave, curved recess that forms a decorative keycap or button cover 251. Figure 2 The support on the lower side of the ).

[0040] from Figure 4 It can also be seen that the button insert 645 further includes a floating cover platform 423 provided by a rigid island-shaped portion made of rigid plastic material. In this exemplary embodiment, the cover platform 423 and the button frame 303 are made of the same rigid plastic material. The cover platform 423 is a stepped disc-shaped component located at the center of the opening 307 of the button frame 303, and is combined with the button membrane 404 such that the central hole 414 of the button membrane 404 is sealed closed by the cover platform 423. Thus, the entry opening 307 defined by the button frame 303 is sealed closed by the combination of the button membrane 404 and the cover platform 423.

[0041] As will refer to Figure 6 In more detail, the button insert 645 is a pre-formed co-molded component, wherein the elastomeric button film 404 is bonded to the cover platform 423 and the button frame 303 during the co-molding operation. As used herein, "pre-formed" means that the button insert 645 is formed prior to the overmolding of the housing 206 onto the button frame 303.

[0042] Now back Figure 2 As will be seen, the button mechanism 115 also includes a button cover 251 mounted on the button insert 645 to provide an interface for receiving manual actuation by the user. For this purpose, the upper surface of the button cover 251 defines a gently curved recess that complements the convex lower side of the button cover 251. The button cover 251 has a circular profile and is positioned to have a peripheral gap in the button hole 233, so that when the button membrane 404 is in a stress-free position without being pressed down (e.g., ... Figure 2 As shown), the button cover 251 protrudes from the upper surface 261 of the top wall 239 of the housing 206.

[0043] The lower surface of the button cover 251 has a centrally located axial protrusion or projection 271. The projection 271 extends axially through a central hole 414 in the button diaphragm 404 and is fixedly connected to the cover platform 423. In this way, the button cover 251 is attached to the button insert via the cover platform 423.

[0044] In operation, the button mechanism 115 is activated by the user pressing down on the button cover 251 (when the device 100 is in operation). Figure 2 (As shown in the orientation). This downward pressure causes the cover platform 423 to move inward toward the housing cavity 211, bringing the cover platform 423 into contact with the push-button switch 227, thereby activating the switch 227. During this pressing of the button, the button diaphragm 404 springs back or elastically deforms. When the user releases the button cover 251, the button diaphragm 404 elastically returns to its stress-free position (as shown in the orientation). Figure 2 This causes the cover platform 423 to move outward, disengaging from the push-button switch 227.

[0045] Note that some embodiments do not have a rigid island-like portion such as the cover platform 423, and the button cover 251 is directly mounted on the membrane 404 (in which case the membrane 404 may not be interrupted by the central opening). In other embodiments, the component can operate without a keycap such as the button cover 251, and the user presses directly on the membrane 404 to activate a switch such as the push-button switch 227.

[0046] Note that the structure of the button mechanism 115, the various connections between different parts of the button mechanism 115, and the overmolded connection between the button insert 645 and the housing 206 make the button mechanism 115 essentially waterproof, preventing water from entering the housing cavity 211 through the button hole 233. The elastically resilient button diaphragm 404 provides a spring action for button pressing, providing excellent tactile feedback and recentering.

[0047] Now go to Figure 6 A schematic flowchart of a method 600 for forming a housing assembly with button functionality and an electronic device incorporating the housing assembly, according to an exemplary embodiment, is shown. (Reference: According to Reference) Figure 1-5 The method 601 in this example is described using the housing assembly 200 and the eyeglasses device 100 of the exemplary embodiment.

[0048] In operation 606, the composite button insert 645 is formed in a co-molding operation. In this exemplary embodiment, the formation of the button assembly or insert 645 includes a two-color injection molding process, wherein a flexible button film 404 is overmolded onto a rigid plastic component providing a button frame 303 and a floating cover platform 423. Thus, in operation 606, the formation of the button insert 645 first includes, in operation 612, injection molding the button frame 303 and the cover platform 423 in a two-color injection mold, and then, in operation 618, overmolding the button film 404, made of different elastomeric plastic materials, onto the rigid plastic component.

[0049] In operation 624, the button insert 645 is attached to the housing 206 in an insert molding operation, in which the housing 206 is overmolded to the periphery of the button frame 303 to establish integration of the button insert 645 into the top wall 239 of the housing 206, as in Figure 2 The best view is in the middle.

[0050] Subsequently, in operation 630, the button cover 251 is attached to the button insert 645. In this exemplary embodiment, this attachment is achieved by passing the axial protrusion 271 of the button cover 251 through the central hole 414 of the button diaphragm 404 and connecting the protrusion 271 of the button cover 251 to the cover platform 423. In this exemplary embodiment, the button cover 251 is attached to the cover platform 423 by ultrasonic welding. In other embodiments, the protrusion 271 of the button cover 251 may be attached to the cover platform 423 by liquid adhesive or any other suitable connection mechanism.

[0051] Subsequently, in operation 636, one or more electronic components are installed in the housing cavity 211 of the housing 206. In this exemplary embodiment, this installation includes passing the mounting openings in the PCB 216 and the support bracket 221 through the thermal post 319 of the button insert 645, and then deforming the exposed head of the thermal post 319 to securely position the PCB 216 in place. Finally, in operation 642, the housing assembly 200 thus formed is incorporated into the eyeglasses device 100.

[0052] One advantage of the described techniques is that they offer a wider range of material choices for the elastomers and plastics used in the design than existing mechanisms. This is partly due to the button diaphragm 404 being attached to the housing 206 via the button frame 303. Typically, the elastomer used for the button diaphragm 404 has suboptimal adhesive compatibility with the rigid plastic material used for the housing 206. This adhesive compatibility between the button diaphragm 404 and the housing 206 may require the selection of suboptimal materials for either the diaphragm 404 or the housing 206, or may compromise the integrity of the waterproof seal of the housing 206 at the button hole 233. The disclosed techniques provide a solution to these problems by allowing the selection of the material for the button frame 303 to achieve adhesive compatibility between the button diaphragm 404 and the housing 206, each having a superior adhesive compatibility to that between the button diaphragm 404 and the housing 206. In this way, ease of manufacture is improved while the reliability and integrity of the connection between the button diaphragm 404 and the housing 206 are enhanced.

[0053] Another advantage of some embodiments of the button mechanism 115 is the provision of a hard cover platform 423, which not only makes pressing the button switch 227 easier and more reliable, but also facilitates the attachment of decorative keycaps 251 to the button membrane 404. In particular, the hard plastic cover platform 423 provides a location for ultrasonically welding or otherwise bonding the decorative plastic keycaps 251 to the hard plastic island.

[0054] Another advantage of the button mechanism 115 is that it minimizes the overall size of the button assembly and allows the button membrane 404 to be virtually invisible. Furthermore, the size, shape, and material of the button membrane 404 can be easily modified with little or no impact on the size or shape of the components providing the button frame 303.

[0055] Another benefit of these technologies is that they simplify mold making and reduce the risk of appearance damage caused by conventional methods. Therefore, for example, the button mechanism design allows the co-molded film 404 to be in a position that would be extremely challenging to mold in conventional two-color injection molding or insert molding applications.

[0056] Another advantage is that the button insert design allows the button insert 645 to provide functional features such as thermal anchors, hooks, or other recesses and protrusions that might otherwise be difficult to form in the housing 206.

[0057] Therefore, by pre-molding the elastomer as part of the button insert 645, this disclosure avoids many of the limitations of attempting to directly mold the elastomer film 404 onto the housing 206. As previously stated, these limitations include:

[0058] - Adhesive compatibility of molding the elastomer onto the housing 206. The materials used for the button frame 303 and the cover platform 423 can be selected for molding compatibility with the elastomer of the button diaphragm 404; and

[0059] - Some enclosure geometries make it technically difficult to directly mold elastomeric films onto enclosure components, or increase the risk of finishing or production volume.

[0060] As can be seen, the foregoing description illustrates some exemplary embodiments of this disclosure. Selections of the disclosed exemplary embodiments are listed below. Note that the embodiments listed below are not exhaustive.

[0061] Example 1: A method that includes:

[0062] Form a button insert, the button insert including:

[0063] A button frame, defining an access opening extending through it, is made of a substantially rigid plastic material; and

[0064] A button film, attached to a button frame and covering at least a portion of an access opening through the button frame, the button film being made of a resilient, flexible material; and

[0065] The housing for the electronic component is overmolded onto the composite button insert, such that the housing is attached to the button frame, the button diaphragm is located in the button hole defined by the housing, and the button hole is closed by the button insert.

[0066] Example 2: According to the method of Example 1, wherein the button insert is substantially waterproof, and wherein the overmolding operation establishes a substantially waterproof connection between the button insert and the housing, such that the button insert seals the button hole of the housing.

[0067] Example 3: According to the method of Example 1 or Example 2, forming the button insert includes:

[0068] Molded button frames; and

[0069] The button film is wrapped and molded onto the button frame.

[0070] Example 4: According to any one of Examples 1-3, wherein the button insert is formed in a co-molding operation, the co-molding operation including molding a button frame and overmolding a button film onto the button frame.

[0071] Example 5: According to the method of Example 4, wherein the co-molding operation causes the button insert to further include a rigid island portion, which is incorporated into the flexible button membrane so as to be displaced relative to the button frame in response to elastic deformation of the button membrane. The rigid island portion is made of a substantially rigid plastic material and is positioned to align with a button hole defined by the housing.

[0072] Example 6: The method of Example 5 further includes attaching a button cover to a rigid island portion, the button cover providing an interface for manual user interaction.

[0073] Example 7: According to the method of Example 6, the attachment of the button cover to the rigid island includes an ultrasonic bonding operation.

[0074] Example 8: According to the method of Example 6, attaching the button cover to the rigid island portion includes forming an adhesive between the button cover and the rigid island portion.

[0075] Example 9: According to any one of Examples 1-8, wherein the button frame has a substantially flat body portion, and the access opening is defined by the body portion and is substantially circular.

[0076] Example 10: Based on the method of any one of Examples 1-9, where:

[0077] The button frame defines a pair of opposing main surfaces connected by circumferentially extending edge surfaces. These main surfaces include an outer surface that is bonded to the housing wall during the overmolding operation, and an inner surface pointing inwards towards the housing.

[0078] The inner surface of the button frame defines a mounting structure configured to attach one or more electronic components from the housing to the button frame.

[0079] Example 11: According to the method of Example 10, wherein the mounting structure includes a thermal post configured for connection to a printed circuit board (PCB).

[0080] Example 12: The method according to any one of Examples 1-11, wherein the membrane is made of an elastomeric material.

[0081] Example 13: According to any one of Examples 1-12, wherein the housing is configured to form part of an electronic glasses device.

[0082] Example 14: According to any one of Examples 1-13, wherein the molding compatibility between the button film material and the button frame is greater than the molding compatibility between the button film material and the housing.

[0083] Example 15: A housing assembly for incorporation in an electronic device, the housing assembly comprising:

[0084] Button insert, comprising:

[0085] A button frame defining an access opening extending through it, the button frame being made of a substantially rigid plastic material; and

[0086] A button membrane, attached to a button frame and covering at least a portion of an access opening through the button frame, the button membrane being made of an elastic, flexible material; and

[0087] A molded housing defining a hollow interior for holding electronic components, the housing being molded onto a button insert such that the housing wall of the molded housing is bonded to the button frame, the button diaphragm being located in a button hole defined by the housing.

[0088] Example 16: According to the component of Example 15, the overmolded connection between the button frame and the housing causes the button insert to close the button hole, preventing water from entering the housing.

[0089] Example 17: According to the components of Example 15 or Example 16, the button insert further includes a rigid island portion that is incorporated into a flexible button membrane so as to be able to at least partially displace through an access opening defined by a button frame in response to elastic deformation of the button membrane, the rigid island portion being made of a substantially rigid plastic material.

[0090] Example 18: The components of Example 17 also include a button cover attached to the rigid island portion for receiving manual actuation by the user.

[0091] Example 19: According to the component of Example 18, wherein the button cover is attached to the rigid island portion.

[0092] Example 20: A component according to any one of Examples 15-19, wherein the component is a product of the method of any one of Examples 1-14.

[0093] Example 21: An electronic device comprising:

[0094] The housing assembly according to any one of Examples 15-20; and

[0095] Electronic components located inside the hollow interior of the housing are configured to be operated by elastic deformation of a button diaphragm in response to manual actuation of a button mechanism, wherein the button insert forms part of the button mechanism.

[0096] term

[0097] Throughout this specification, multiple instances may implement components, operations, or structures described as single instances. Although individual operations of one or more methods are shown and described as separate operations, one or more individual operations may be performed simultaneously, and they need not be performed in the order shown. Structures and functions presented as separate components in the example configuration may be implemented as combined structures or components. Similarly, structures and functions presented as single components may be implemented as separate components. These, as well as other variations, modifications, additions, and improvements, all fall within the scope of this document.

[0098] Although an overview of the disclosed subject matter has been described with reference to specific example embodiments, various modifications and changes can be made to these embodiments without departing from the broader scope of embodiments of this disclosure. These embodiments of the subject matter of the invention may be referred to individually or collectively by the term "invention," which is used herein merely for convenience and is not intended to voluntarily limit the scope of this application to any one of the disclosed disclosures or inventive concepts, in fact, more than one.

[0099] The embodiments shown herein have been described in sufficient detail to enable those skilled in the art to practice the disclosed teachings. Other embodiments may be used and other embodiments may be derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Therefore, the detailed description should not be considered limiting, and the scope of the various embodiments is defined only by the appended claims and the full scope of their equivalents.

[0100] As used herein, the term "or" can be interpreted in an inclusive or exclusive sense. Furthermore, multiple instances may be provided for the means, operations, or structures described herein as a single instance. Additionally, the boundaries between various means, operations, modules, tools, and data storage are somewhat arbitrary, and specific operations are illustrated in particular illustrative configurations. Other functional configurations are conceivable and may fall within the scope of various embodiments of this disclosure. Generally, structures and functions presented as separate means in example configurations can be implemented as combined structures or means. Similarly, structures and functions presented as single means can be implemented as separate means. These and other variations, modifications, additions, and improvements fall within the scope of embodiments of this disclosure as represented by the appended claims. Therefore, the specification and drawings should be considered illustrative rather than restrictive.

Claims

1. A method comprising: Form a button insert, the button insert including: A button frame defining an entry opening extending through it; the button frame is made of a rigid plastic material; and A button mechanism, mounted on a button frame, such that the button mechanism closes an access opening in the button frame while allowing manual actuation of the button mechanism through the access opening, wherein the button mechanism includes a membrane made of a flexible material with elasticity, which is attached to the button frame such that the membrane closes the access opening through the button frame. The button insert includes: Molded button frames; and The membrane is overmolded onto the button frame, thus bonding the membrane to the button frame; and The housing for the electronic component is overmolded onto the button insert, such that the housing wall is bonded to the button frame, and the access opening of the button insert provides a button hole in the housing wall, thereby allowing the manually actuated button mechanism to enter the housing through the button hole.

2. The method according to claim 1, wherein, The button insert is waterproof, and the overmolding operation establishes a waterproof connection between the button insert and the housing, such that the button insert seals the button hole of the housing.

3. The method according to claim 1, wherein, The button insert is formed in a co-molding operation, which includes molding the button frame in a two-color injection molding operation and overmolding the film onto the button frame.

4. The method according to claim 3, wherein, The co-molding operation causes the button mechanism to also include a rigid island portion, which is incorporated into the membrane, such that the rigid island portion can be displaced relative to the button frame in response to elastic deformation of the membrane. The rigid island portion is made of a rigid plastic material and is positioned to align with a button hole defined by the housing.

5. The method of claim 4, further comprising attaching a button cover to a rigid island portion, the button cover providing a physical interface for manual user interaction.

6. The method according to claim 5, wherein, The button cover is attached to the rigid island section, including ultrasonic bonding operation.

7. The method according to claim 5, wherein, Attaching the button cover to the rigid island includes forming an adhesive between the button cover and the rigid island.

8. The method according to claim 1, wherein, The membrane is made of an elastomer material.

9. The method according to claim 1, wherein, The molding compatibility between the membrane material and the button frame is greater than the molding compatibility between the membrane material and the housing.

10. The method according to claim 1, wherein, The button frame has a flat body portion, and the access opening extends through the body portion and has a circular outline.

11. The method according to claim 1, wherein: The button frame defines a pair of opposing main surfaces connected by circumferentially extending edge surfaces. These main surfaces include an outer surface that is bonded to the housing wall during the overmolding operation, and an inner surface pointing inwards towards the housing. in, The inner surface of the button frame defines a mounting structure configured to attach one or more electronic components from the housing to the button frame.

12. The method according to claim 1, wherein, The housing is configured to form part of a wearable electronic device.

13. The method according to claim 1, wherein, The housing is configured to form part of an electronic glasses device.

14. A housing assembly for integration into an electronic device, the housing assembly comprising: Button insert, comprising: A button frame defining an access opening extending through it, the button frame being made of a rigid plastic material; and A button mechanism, mounted on a button frame, such that the button mechanism closes an access opening in the button frame while allowing manual actuation of the button mechanism through the access opening, wherein the button mechanism includes a membrane made of a flexible material with elasticity, which is attached to the button frame such that the membrane closes the access opening through the button frame. and A molded housing defining a hollow interior for holding electronic components is molded onto a button insert such that the housing wall is bonded to a button frame, and an access opening for the button insert provides a button hole in the housing wall, thereby allowing a manually actuated button mechanism to enter the housing interior through the button hole. An overmolded connection between the button frame and the housing causes the button insert to close the button hole, and a membrane is overmolded onto the button frame such that the membrane is bonded to the button frame.

15. The housing assembly of claim 14, wherein, The overmolded connection between the button frame and the housing prevents water from entering the housing.

16. The housing assembly of claim 14, wherein, The button insert also includes: A rigid island portion, incorporated into the membrane, is capable of at least partially displaced through the access opening defined by the button frame in response to elastic deformation of the membrane; the rigid island portion is made of a rigid plastic material; and A cover attached to a rigid island section for receiving manually actuated buttons.

17. An electronic device comprising: The housing assembly according to any one of claims 14-16; and Electronic components located inside the hollow interior of the housing are configured to be operated by manually actuating a button mechanism housed in a button insert.

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