Shimless Button Assembly Tolerance Compensation
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Solution Overview
Problem
Tactile button assemblies in computing devices often suffer from inconsistent feel due to varying part tolerances, leading to either excessive or insufficient bias against the switch mechanism, which can affect user perception of device quality.
Innovation Solution
A shimless button assembly utilizing a compressible member that expands and contracts to occupy the volume caused by tolerance stacks between components, with a glue layer inserted to stabilize the bias once the components are in contact, preventing further expansion or contraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional button assemblies are used without compensation for tolerance variations, then manufacturing is simpler, but the button feel becomes inconsistent across devices
Solution Approach 1:
The patent changes the physical state of the compressible member from compressed to expanded, allowing it to dynamically compensate for tolerance variations in component thickness. This parameter change enables the button assembly to maintain consistent button feel across devices without requiring precise manufacturing tolerances on individual components.
Solution Approach 2:
The compressible member acts as an intermediary element between the button component and the switch mechanism. It absorbs the variations in component thickness and provides a consistent interface, eliminating the need for shims or other compensating elements while maintaining manufacturing simplicity.
2Manufacturing precision
If shims are used to compensate for tolerance stacks, then button feel consistency is improved, but manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent extracts the tolerance compensation function from separate shim components and integrates it into the compressible member itself. This eliminates the need for additional shim parts and simplifies the assembly process, as the compressible member is already part of the standard button assembly structure.
Solution Approach 2:
The compressible member serves multiple functions: it provides the necessary compliance for button actuation, absorbs tolerance variations in component thickness, and maintains consistent button feel across devices. This multi-functionality eliminates the need for separate shim components and simplifies manufacturing.
3Adaptability or versatility
If the compressible member remains free to expand and contract, then it can accommodate tolerance variations, but the bias against the switch mechanism becomes unstable
Solution Approach 1:
The glue layer is applied in advance to the compressible member before final assembly, positioning it to maintain the compressed state. This preliminary action ensures that once assembled, the compressible member remains stably biased against the switch mechanism while still accommodating tolerance variations through its controlled compression.
Solution Approach 2:
The glue layer creates a fixed reference state by bonding the compressible member in its compressed position. This copying of the compressed state ensures stable bias against the switch mechanism while the compressible member's material properties allow it to accommodate tolerance variations within that fixed configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution ensures consistent button feel across devices by maintaining the bias established by the compressible member, eliminating the need for shims and addressing tolerance-related deviations in component thicknesses, thereby enhancing user experience.
Implementation Method 1
a compressible member that expands and contracts to occupy the volume caused by tolerance stacks between components
Data Source
AI summary
Embodiments of the present disclosure are directed to a shimless button assembly. According to such embodiments, a shimless button assembly includes a button component and a switch mechanism. The button component includes a compressible member that is configured to expand and contract in order to occupy a volume of space between the button component and the switch mechanism. The volume of space between the button component and the switch mechanism may be caused by differing tolerances between the various components of the button assembly, such as, for example, the button component and the switch mechanism.