Method of mounting thumbwheel switch on printed circuit board and handheld electronic device incorporating same

1. A handheld electronic device comprising:

a housing having a front face; and

components supported by the housing comprising:

an user interface comprising a thumbwheel switch having a body and a thumbwheel, the body having a top face, a recess formed in the top face, and the thumbwheel seated in the recess of the top face, the thumbwheel rotatably mounted on the top face of the body; and

a printed circuit board having a planar substrate and electronic components mounted on the planar substrate and electrically connected by electrical traces, the planar substrate being mounted in the housing generally parallel to the front face and an edge cutout formed in the planar substrate, the planar substrate having a first face and a second face, the top face of the body being both mechanically and electrically connected essentially by solder to the first face of the substrate such that the body is positioned on the planar substrate with the top face of the body seated on the first face of the planar substrate, the top face of the body abutting the first face of the substrate, and the electrical traces with the thumbwheel seated in and rotatable with in the edge cutout, and wherein the thumbwheel extends above the top face of the body about a thickness of the planar substrate such that the thumbwheel is about flush with the second face of the planar substrate.

2. The handheld electronic device of claim 1 wherein the substrate has solder pads and the thumbwheel switch has leads extending from the body that are embedded in the solder pads.

3. The handheld electronic device of claim 2 wherein some of the leads are mechanical leads only.

4. The handheld electronic device of claim 3 wherein the substrate has holes filled with solder in which at least some of the mechanical leads are embedded.

5. The handheld electronic device of claim 4 wherein the body extends beyond the thumbwheel in at least two opposite directions and at least two of the mechanical leads are located on the body beyond the thumbwheel in the two opposite directions.

6. The handheld electronic device of claim 3 wherein the body has some L-shaped mechanical leads having a first flange secured to a sidewall of the body and a second flange flush with and secured to a first face of the substrate with the solder.

7. The handheld electronic device of claim 2 wherein the substrate has locating holes and the body has locating pins that seat in the locating holes.

8. The handheld electronic device of claim 7 wherein the body extends beyond the thumbwheel in at least two opposite directions and at least two of the locating pins are located on the body beyond the thumbwheel in the two opposite directions.

9. The handheld electronic device of claim 1 wherein the user interface further comprise a display mounted in the front face of the housing, the printed circuit board being mounted in the housing with the planar substrate generally parallel to the front face and with the thumbwheel switch extending partially behind the display with the thumbwheel accessible through a side opening in the housing.

10. The handheld electronic device of claim 9 wherein the housing has two parts joined along a parting line generally in a plane substantially parallel to the front face and the side opening is at the parting line.

11. A method of assembling a thumbwheel switch having a body and a thumbwheel and electronic components on a printed circuit board for a handheld electronic device, the printed circuit board having a substrate with electrical traces and an edge cutout formed therein, the substrate having a first face and a second face, the body having a top face, a recess formed in the top face, the body being positioned on the substrate with the top face of the body seated on the first face of the substrate, the top face of the body abutting the first face of the substrate, the thumbwheel body and electronic components having leads thereon at least some of which are circuit leads, the method comprising:

applying solder paste to spots on the first face of the substrate to form solder pads, that for at least the circuit leads engage selected electrical traces;

positioning the body of the thumbwheel switch, and the electronic components on the first face of the substrate with at least the circuit leads engaging solder pads to form an assembly and with the thumbwheel seated in the edge cutout, the thumbwheel seated in a recess of a top face of the thumbwheel body, the thumbwheel extending above the top face of the body about a thickness of the planar substrate such that the thumbwheel is about flush with a second face of the planar substrate; and

securing the leads to the printed circuit board essentially by:

heating the assembly to melt the solder pads and wet the leads with solder; and

solidifying the solder by cooling to mechanically secure and electrically connect the thumbwheel switch and the electronic components to the first face of the substrate.

12. The method of claim 11 wherein the positioning of the body of the thumbwheel switch and the other components on the substrate is performed by a machine.

13. The method claim 12 wherein the body of the thumbwheel switch has locating pins and the substrate has locating holes, and wherein positioning comprises engaging the locating pins in the locating holes.

14. The method of claim 13 wherein the locating pins are sized to be press fit in the locating holes.

15. The method of claim 11 wherein some of the leads are mechanical leads that project from the body of the thumbwheel switch and the substrate has corresponding recesses in which solder paste is applied, the body of the thumbwheel switch being positioned with the mechanical leads extending into the solder in the corresponding recesses.

16. The method of claim 15 wherein the body of the thumbwheel switch has locating pins and the substrate has locating holes, and locating includes engaging the locking pins in the locating holes.

17. The method of claim 11 wherein some of the leads are mechanical leads and project from the body of the thumbwheel switch, and wherein the substrate has corresponding recesses in which the mechanical leads are positioned.

18. A printed circuit board assembly comprising:

a printed circuit board having a planar substrate with electronic components mounted thereon and having an edge cutout formed therein, said substrate having a first face and a second face, said electronic components being electrically connected by electrical traces; and

a thumbwheel switch having a body and a thumbwheel, the body having a top face, a recess formed in the top face, the body being positioned on the substrate with the top face of the body seated on the first face of said substrate, the top face of the body abutting the first face of said substrate, said body being both mechanically and electrically connected essentially by solder to said first face of the substrate and said electrical traces, wherein said thumbwheel is seated in a recess in the top face of the thumbwheel body such that the thumbwheel extends above the top face of the body about a thickness of the planar substrate such that the thumbwheel is about flush with the second face of the planar substrate, the thumbwheel rotatably mounted on the top face of the body, and said thumbwheel is seated and rotatable within said edge cutout.

19. The printed circuit board assembly of claim 18 wherein the substrate has solder pads and the thumbwheel switch has leads extending from the body that are embedded in the solder pads.

20. The printed circuit board assembly of claim 19 wherein some of the leads are mechanical leads only.

21. The printed circuit board assembly of claim 20 wherein said substrate has holes filled with solder in which at least some of the mechanical leads are embedded.

22. The printed circuit board assembly of claim 21 wherein the body extends beyond the thumbwheel in at least two opposite directions and at least two of the mechanical leads are located on the body beyond the thumbwheel in the two opposite directions.

23. The printed circuit board assembly of claim 20 wherein the body has some L-shaped mechanical leads having a first flange secured to a sidewall of the body and a second flange flush with and secured to a first face of the substrate with the solder.

24. The printed circuit board assembly of claim 19 wherein the substrate has locating holes and the body has locating pins that seat in the locating holes.

25. The printed circuit board assembly of claim 24 wherein the body extends beyond the thumbwheel in at least two opposite directions and at least two of the locating pins are located on the body beyond the thumbwheel in the two opposite directions.