# US 9,439,304 B2 · Robust consumer electronic device

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- Number: US 9,439,304 B2
- Document ID: US9439304B2
- Status: Granted
- Kind: B2
- Application number: 13/551,966
- Filed: 2012-07-18
- Published: 2012-11-08
- Granted: 2016-09-06
- Earliest claimed: 2009-11-12
- Assignees: Roche Diabetes Care, Inc.
- Applicants: Matthew Carlyle Sauers
- Inventors: Matthew Carlyle Sauers
- Web page: https://patentgrep.com/patent/US9439304B2

## CPC

- H05K 7/142: {Spacers not being card guides}
- H05K 1/181: associated with surface mounted components
- H05K 1/144: {Stacked arrangements of planar printed circuit boards}
- H05K 2201/0133: Elastomeric or compliant polymer
- H05K 2201/0314: Elastomeric connector or conductor, e.g. rubber with metallic filler
- H05K 2201/042: Stacked spaced PCBs; Planar parts of folded flexible circuits having mounted components in between or spaced from each other
- H05K 2201/10037: Printed or non-printed battery
- H05K 2201/2036: Permanent spacer or stand-off in a printed circuit or printed circuit assembly
- Y02P 70/50: Manufacturing or production processes characterised by the final manufactured product
- Y10T 29/49002: Electrical device making
- H05K: PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method includes providing a molded elastomeric mat having an input protrusion, an output device receiving surface including an output device contact, and a battery receiving indentation including a power supply contact. The method further includes insert molding an output conductive path into the elastomeric mat, the output conductive path electrically coupling a circuit carrier output contact to an output device contact, and insert molding a power supply conductive path into the elastomeric mat, the power supply conductive path electrically coupling a circuit carrier power contact to the power supply contact. The method includes interfacing the elastomeric mat with a circuit carrier, aligning the input protrusion with a circuit carrier input contact, interfacing a display device with the output device receiving surface, electrically connecting the display device with the output device contact, and positioning the elastomeric mat into a housing.

## Claims

### Claim 1

A method of manufacturing an electronic device, the method comprising the steps of:
providing a molded elastomeric mat with:
an input protrusion;
an output device receiving surface comprising an output device contact;
a battery receiving indentation comprising a power supply contact;
insert molding an output conductive path and a power supply conductive path into the elastomeric mat;
interfacing the elastomeric mat with at least one circuit carrier, wherein the at least one circuit carrier comprises a circuit carrier output contact, a circuit carrier power contact and a circuit carrier input contact, wherein the output conductive path of the elastomeric mat electrically couples the circuit carrier output contact to the output device contact, and wherein the power supply conductive path of the elastomeric mat electrically couples the circuit carrier power contact to the power supply contact, and aligning the input protrusion with the circuit carrier input contact;
interfacing a display device of the electronic device with the output device receiving surface of the elastomeric mat and electrically connecting the display device with the output device contact; and
positioning the elastomeric mat into a housing of the electronic device.

### Claim 2 (depends on 1)

The method of claim 1, further comprising providing the elastomeric mat with a plurality of alignment features, and performing at least one of the:
interfacing the elastomeric mat with at least one circuit carrier;
interfacing the display device with the output device receiving surface; and
positioning the elastomeric mat into the housing;
in response to the alignment features.

### Claim 3 (depends on 1)

The method of claim 1, further comprising providing the elastomeric mat with a sealing lip, and interposing the sealing lip in a seam of the housing.

### Claim 4 (depends on 1)

The method of claim 1, further comprising interposing a metal dome between the input protrusion and the circuit carrier input contact, with a convex side of the metal dome facing the input protrusion.

### Claim 5 (depends on 1)

The method of claim 1, further comprising providing the elastomeric mat with a spring rate, coefficient of restitution, and creep rate such that when a physical impulse applied to the housing has a predetermined energy, an acceleration of the circuit carrier in the housing is lower than a threshold.

### Claim 6 (depends on 1)

The method of claim 1, further comprising providing the elastomeric mat with an anisotropic acceleration reduction, wherein the elastomeric mat reduces an acceleration of the circuit carrier in the housing preferentially in a predetermined impulse direction.