Handheld computing device.
Abstract
A minimum Z height handheld electronic device and methods of assembly is described. The electronic device includes a single seamless housing having a front opening and a cover disposed within the front opening and attached to the seamless housing without a bezel.
Term
2.8 yearsleft in the term
Expires 16 July 2029.
- Priority
- Filed
- Today
- Expires
20 claims: 2 independent, 18 dependent
- 1REIVINDICACIONES 1. Un dispositivo electrónico portátil, caracterizado porque comprende:un alojamiento individual ininterrumpido que tiene una abertura frontal, el alojamiento individual ininterrumpido tiene un fondo integral y paredes laterales que cooperan para formar una cavidad en cooperación con la abertura frontal, la pared de fondo tiene una superficie de fondo curvada, las paredes laterales están redondeadas de manera tal que forman una superficie lateral curvada y un muescado dentro de la cavidad, un borde de las paredes laterales circunda y define la abertura frontal;y una cubierta colocada dentro de la abertura frontal y conectada al alojamiento ininterrumpido sin un bisel, la cubierta tiene una superficie superior plana y se coloca dentro de la cavidad en el borde frontal, la cubierta llena sustancialmente el borde frontal entre las paredes laterales, la superficie superior plana está sustancialmente a nivel con una superficie superior del borde de las paredes laterales.
- 2El dispositivo electrónico de conformidad con la reivindicación 1, caracterizado porque el alojamiento se forma de acero inoxidable pulido, el alojamiento es de metal ( y la cubierta es de vidrio o cristal.
- 3El dispositivo electrónico de conformidad con la reivindicación 1, caracterizado porque además comprende:una unidad de exhibición colocada dentro de la cavidad del alojamiento;γ una pantalla de exhibición de la unidad de exhibición, que es visible a través de la cubierta de vidrio.
- 4El dispositivo electrónico de conformidad con la reivindicación 3, caracterizado porque una capa sensible al tacto sustancialmente transparente se coloca entre el cristal de cubierta y la pantalla de exhibición de la unidad de exhibición.
- 5El dispositivo electrónico de conformidad con la reivindicación 1, caracterizado porque la cubierta incluye una abertura para un mecanismo de alimentación.
- 6El dispositivo electrónico de conformidad con la reivindicación 1, caracterizado porque la cubierta se conecta a un bastidor y en donde el bastidor se monta al alojamiento dentro de la cavidad del alojamiento.
- 7El dispositivo electrónico de conformidad con la reivindicación 2, caracterizado porque además comprende:una pluralidad de montajes electrónicos insertados en el alojamiento ininterrumpido a través de la abertura frontal y sujeto a la superficie inferior del alojamiento, en donde una tolerancia de altura Z de la pluralidad de montajes electrónicos se reduce al mínimo de manera tal que una superficie superior de un montaje electrónico más superior es sustancialmente coplanar con una superficie superior del alojamiento en donde la pluralidad de montajes electrónicos incluye un primer montaje electrónico que comprende: un primer sub-montaje electrónico, un segundo sub-montaje electrónico, y un circuito flexible sustancialmente planar que conecta en forma operativa y física el primer y segundo sub-montajes electrónicos, el circuito flexible incluye cortes que permiten al circuito flexible torcerse de manera tal que el circuito flexible pueda adaptarse a una forma curvada en múltiples dimensiones.
- 8El dispositivo electrónico de conformidad con la reivindicación 7, caracterizado porque el segundo submontaje electrónico comprende:una antena de RF, en donde una porción de esquina del alojamiento en proximidad inmediata con la antena de RF se retira a fin de eliminar sustancialmente EMI provocada por el alojamiento y reemplazado con una tapa de antena formada de un material que no interfiere RF, además comprende: un refuerzo de porción de esquina dispuesto para reforzar la porción de esquina del alojamiento que tiene la tapa de antena, en donde el refuerzo actúa como un plano de tierra para la antena de RF, en donde el refuerzo incluye un contacto dispuesto para conectar eléctricamente la antena de RF con el plano de tierra formado por el refuerzo.
- 9Un método, caracterizado porque comprende:proporcionar un alojamiento individual ininterrumpido, el alojamiento individual ininterrumpido tiene una abertura frontal, un fondo integral y paredes laterales, en donde el fondo integral y las paredes laterales cooperan para formar una cavidad en cooperación con la abertura frontal;colocar una unidad de cubierta dentro de la abertura frontal, la unidad de cubierta tiene una superficie superior plana y llenar sustancialmente la abertura frontal;y conectar la unidad de cubierta con el alojamiento ininterrumpido sin un bisel.
- 10El método de conformidad con la reivindicación 9, caracterizado porque la pared de fondo integral tiene una superficie de fondo curva, las paredes laterales están redondeadas de manera tal que forman una superficie lateral curva y un muescado dentro de la cavidad, un borde interior de las. paredes laterales circunda y define la abertura frontal.
- 11El método de conformidad con la reivindicación 9, caracterizado porque la superficie superior plana está sustancialmente a nivel con una superficie superior del borde interior de la pared lateral y en donde la unidad de cubierta se conecta a un bastidor.
- 12El método de conformidad con la reivindicación 11, caracterizado porque conectar la unidad de cubierta al alojamiento ininterrumpido sin un bisel, comprende:conectar el bastidor al alojamiento dentro de la cavidad.
- 13El método de conformidad con la reivindicación 9, caracterizado porque la unidad de cubierta además comprende una unidad de exhibición que tiene cuando menos una pantalla de exhibición;un cristal de cubierta a través del cual es visible la pantalla de exhibición;y una capa sensible al tacto sustancialmente transparente colocada entre el cristal de cubierta y la pantalla de exhibición.
- 14El método de conformidad con la reivindicación 13, caracterizado porque el alojamiento se forma de acero inoxidable pulido.
- 15El método de conformidad con la reivindicación 14, caracterizado porque la unidad de cubierta incluye una abertura adecuada para recibir un mecanismo de alimentación.
- 16El método de conformidad con la reivindicación 9, caracterizado porque además comprende conectar una abrazadera de montaje a la pared de fondo integral, la abrazadera de montaje está dispuesta para sujetar al menos un montaje electrónico a la pared de fondo integral del alojamiento.
- 17El método de conformidad con la reivindicación 16, caracterizado porque la abrazadera de montaje comprende:cuando menos un tope de datos de abrazadera de montaje, el tope de datos de abrazadera de montaje como mínimo está dispuesto para reducir la tolerancia de altura Z entre el montaje electrónico sujeto a la pared de fondo integral del alojamiento y una porción plana más superior del alojamiento entre el borde interior y el borde exterior.
- 18El método de conformidad con la reivindicación 17, caracterizado porque la porción plana más superior del alojamiento entre el borde interior y el borde exterior es una guía y en donde el tope de datos de abrazadera de montaje 5 como mínimo y la guía se forman en una sola operación de maquinado utilizando una configuración de máquina sencilla.
- 19El método de conformidad con la reivindicación 18, caracterizado porque la abrazadera de montaje comprende:una pluralidad de topes de ajustes Z de sacrificio que tienen 10 una porción de sacrificio dispuesta sobre la longitud de la abrazadera de montaje.
- 20El método de conformidad con la reivindicación 19, caracterizado porque además comprende separar por maquinado una porción más superior del alojamiento 15 ininterrumpido y la porción de sacrificio de los topes de ajuste Z de sacrificio;y concurrentemente con el maquinado, perforación de una pluralidad de orificios de alineamiento XY, en donde las operaciones por maquinado y el taladrado se realizan en la configuración de máquina sencilla.
Independent claims20
195 paragraphs in 4 sections, as filed
(54) Title: PORTABLE COMPUTER DEVICE.
(54) Title: HANDHELD COMPUTING DEVICE.
(57) Summary
A minimum Z height portable electronic device and assembly methods are described. The electronic device includes a single uninterrupted housing that has a front opening and a cover placed within the front opening and connected to the uninterrupted housing without a bezel.
(57) Abstract
A minimum Ζ height handheld electronic device and methods of assembly is described. The electronic device includes a single seamless housing having a front opening and a cover disposed within the front opening and attached to the seamless housing without a bezel.
PORTABLE COMPUTER DEVICE
BACKGROUND
Field of the Invention
The present invention relates generally to portable computing devices. More particularly, the present invention relates to portable computing device enclosures and methods for assembling portable computing devices.
Description of Related Technique
<td>The</td><td colspan="3">outward appearance</td><td>of</td><td>a</td><td>device</td>
<td>electronic</td><td colspan="2">portable,</td><td>including his</td><td>design</td><td colspan="2">and their weight, are</td>
<td>important</td><td>for</td><td>a</td><td>user of</td><td colspan="2">device</td><td>electronic</td>
<td colspan="2">portable because</td><td>the</td><td colspan="2">external appearance</td><td colspan="2">contributes to the</td>
<td colspan="2">total impression</td><td>than</td><td>the user</td><td>has</td><td>of the</td><td>device</td>
<td>electronic</td><td colspan="2">portable.</td><td>The same</td><td>weather,</td><td>the</td><td>mounting the</td>
<td>device</td><td colspan="4">portable electronic is also</td><td colspan="2">important for</td>
<td>the user,</td><td>as</td><td>a</td><td colspan="3">durable mounting will help</td><td>prolong the</td>
<td>useful life</td><td>total</td><td>of the</td><td>device</td><td colspan="2">electronic</td><td>portable and</td>
<td>will increase your</td><td>value</td><td colspan="2">for the user.</td><td></td><td></td><td></td>
<td>A</td><td>challenge</td><td>of</td><td colspan="2">design associated with</td><td>the</td><td>device</td>
Portable electronic is the design of enclosures used to house the various internal components. This design challenge generally stems from a number of conflicting design goals, including the desirability of making the enclosure lighter and thinner, the desirability of making the enclosure stronger, and making the enclosure more aesthetically pleasing. The lighter enclosures, which typically use thinner plastic structures and fewer fasteners, tend to be more flexible and therefore have a greater propensity to flex or sag and bow when used while the stronger and more rigid enclosures, which they typically use thicker plastic structures and more fasteners, tend to be thicker, and have more weight. Unfortunately, increased weight can lead to user dissatisfaction, and arching can damage internal parts.
Additionally, in most portable electronic devices, enclosures are mechanical assemblies that have multiple parts that are threaded, bolted, riveted, or otherwise fastened together at discrete points. For example, enclosures typically have a. upper enclosure and lower enclosure that are placed one on top of the other and fastened using screws. These techniques typically complicate housing design and create aesthetic difficulties due to undesirable cracks, seams, gaps, or breaks in the mating surfaces and fasteners located on the housing surfaces. For example, a coupling line that goes around the entire enclosure occurs when both upper and lower enclosures are used. Not only that, but assembly is often a time consuming and problematic process. For example, the assembler has to spend a certain amount of time locating the two parts and connecting each of the fasteners. Also, assembly often requires the assembler to have special tools and some general technical prowess.
Another challenge is in techniques for mounting structures within portable computing devices. Conventionally, the structures have been placed on one of the rooms (upper or lower) and connected to one of the rooms with fasteners such as screws, bolts, rivets, etc. That is, the structures are located in a sandwich-like shape, layered on top of the enclosure and subsequently attached to the enclosure. This methodology has the same disadvantages as mentioned above, that is, the assembly is time consuming and problematic.
Therefore, it will be beneficial to provide a portable electronic device that is aesthetically pleasing and lightweight, yet durable. It would also be beneficial to provide methods for assembling the portable electronic device.
<td colspan="4">SUMMARY OF THE INVENTION</td>
<td>The</td><td>invention is</td><td>refers in</td><td>one modality, one</td>
<td>device</td><td>electronic</td><td>portable.</td><td>The devices</td>
<td>electronic</td><td colspan="2">laptops include the</td><td>minus one accommodation</td>
Simple uninterrupted that has a front opening and a cover or lid placed inside the front opening and connected to the uninterrupted housing without a bezel.
The invention relates in another embodiment, to a
5- uninterrupted housing formed from a single sheet of metal.
The unbroken housing includes a top opening, an integral bottom, and side walls cooperating to form a cavity in cooperation with the top opening, the bottom wall has a curved bottom surface, the 10 side walls are rounded such that they form a curved side surface and a notch within the cavity, an inner edge of the side walls that surrounds and defines the upper opening, and an outer edge, a mounting bracket connected to the bottom wall 15 suitable for attaching an electronic mount to the bottom wall of the housing and an opening in at least one side wall having a depth of cut at least greater than that provided by the housing alone.
The invention relates in another embodiment to a small form factor electronic device including at least one uninterrupted housing with an integral bottom and side walls cooperating to form a cavity in cooperation with a front opening having a flat top surface, the bottom wall has a curved bottom surface, the side walls are rounded in such a way that they form a curved side surface and a notch within the cavity, an edge of the side walls that surrounds and defines the front opening and a plurality of electronic assemblies inserted into the housing uninterrupted through the front opening and fastened to the bottom surface of the housing, where a height tolerance Z of the plurality of electronic assemblies is minimized, such that a top surface of a higher electronics assembly is substantially coplanar with the flat top surface of the housing.
Also described is a method of self-centering a higher glass or crystal unit in a small form factor electronic device. The small form factor electronic device is made of an uninterrupted housing having a front opening with a flat top surface and side walls where an edge of the side walls surrounds and defines the front opening and where the glass unit includes a environmental seal having a tapered portion, wherein at least some of the tapered portion of the environmental seal extends beyond an inner edge of the front opening. The method can be carried out by inserting the glass unit into the front opening and self-aligning the glass unit during insertion by interaction of the inner edge of the front opening extending the portion of the environmental seal beyond the inner edge of the opening, and concurrently with the interaction of the inner edge and the extended portion of the environmental seal, glass unit fasteners cooperating with a terminal on the device.
In another embodiment, a suitable integrated horn mount is described for use in a small form factor handheld portable device. The built-in horn mount includes at least one piezo horn arranged to produce at least audible sounds, an acoustic seal that has a plurality of acoustic seal spaces that work in cooperation with the piezoelectric horn to direct the sound produced by the piezoelectric horn to a desired location in the small form factor portable handheld device and an acoustic barrier arranged to prevent Audible sounds leak to unwanted places on the electronic device with small form factor.
The invention relates in yet another embodiment to a minimum height Z mounting bracket system for clamping an operational component in a portable computing device having an uninterrupted enclosure. The mounting bracket includes a plurality of sacrificial z adjusting stops, which have a sacrificial portion disposed over the length of the mounting bracket where after the mounting bracket is connected to the unbroken enclosure, an upper portion of the enclosure uninterrupted and the sacrificial portion of the sacrificial adjustment stops z, are machined concurrently with a drilling of a plurality of xy alignment holes, where machining and drilling are performed in a single machine configuration, thus minimizing alignment tolerance in the 10 x, y, and z directions.
The invention relates in another embodiment to a method of centering a guide between a formed edge and an inner edge of an uninterrupted enclosure used to support a portable computing device. The method is carried out by optically determining a plurality of reference points at the formed edge of the unbroken enclosure and cutting the inner edge using the plurality of optical reference points.
The invention relates in another embodiment to a method for centering a guide between a formed edge and an inner edge of an unbroken enclosure having a single open end, wherein the unbroken enclosure supports a portable computing device having a portion of friction located at the simple open end. Method 25 is performed by determining a center point of the display portion, determining an angle of inclination of the display portion, and cutting the inner edge based on the center point and angle of inclination.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be readily understood from the following detailed description in conjunction with the accompanying drawings, in which like reference numerals designate like structural elements and wherein:
Figures 1A-IB are perspective diagrams of a portable computing device in its assembled form.
Figure 1C is a cross-sectional view of the housing highlighting the nature of the snap geometry.
Figures 2A-2E are exploded perspective diagrams of an electronic device in its unassembled form.
Figures 3A-3B are housing view diagrams showing the guide.
Figures 4A-4B graphically illustrate centering of a guide according to an embodiment of the invention.
Figures 5A-5C show an integrated bass speaker system. Z height suitable for use in a small form factor electronic device.
Figures 6A-6B show an audio plug opening in accordance with the embodiment of the invention.
Figures 7A-7C show the assembly of the G unit according to an embodiment of the invention.
Figures 8Ά-8B show gas relief structures according to an embodiment of the invention.
Figure 9 shows a representative cross-sectional view of the housing where the docking or charger base opening is formed by folding a portion of the housing according to an embodiment of the invention.
Figures 10A-10B show a representative cross-sectional view of the housing where the opening of the docking base is to be created by a punching / forming / machining process.
<td></td><td>The</td><td colspan="2">Figures 11A - 11C</td><td colspan="2">illustrate</td><td>graphically</td><td>the</td>
<td>process</td><td>for</td><td>form a</td><td>opening</td><td>of</td><td>short</td><td>extension in</td><td>the</td>
<td colspan="2">accommodation.</td><td></td><td></td><td></td><td></td><td></td><td></td>
<td></td><td>The</td><td colspan="2">Figures 12A - 12C</td><td colspan="2">illustrate</td><td>graphically</td><td>the</td>
<td>process</td><td>for</td><td>form a</td><td>opening</td><td>of</td><td>long</td><td>extension in</td><td>the</td>
<td colspan="2">accommodation.</td><td></td><td></td><td></td><td></td><td></td><td></td>
<td></td><td>The</td><td>Figure 13</td><td>shows</td><td>a</td><td>tensor</td><td>corner</td><td>of</td>
according to an embodiment of the invention.
Figure 14 shows representative sacrificial Z alignment stops before and after machining.
Figure 15 shows a flow diagram detailing a process for installing mounting clamps in a housing, in accordance with an embodiment of the invention.
Figure 16 shows a flow diagram detailing a process for assembling the device according to an embodiment of the invention.
DETAILED DESCRIPTION OF THE MODALITIES
Reference will now be made in detail to a preferred embodiment of the invention. An example of the preferred embodiment is illustrated in the accompanying drawings. While the invention will be described in conjunction with a preferred embodiment, it will be understood that it is not intended to limit the invention to a preferred embodiment. Rather, it is intended to cover alternatives, modifications and equivalents as may be included within the spirit and scope of the invention, as defined by the appended claims.
The described modalities refer to an aesthetically pleasing portable electronic device. The portable electronic device is formed from an uninterrupted curved housing and an aesthetically pleasing, polished flat glass or top glass layer. The uniformity of the appearance of the portable electronic device is improved since unlike conventional portable electronic devices, the polished top glass layer mounts in the housing uninterrupted without the use of a bezel. The uninterrupted nature of the housing and the lack of a bezel provide several advantages in addition to uniformity and pleasing appearance. These advantages include the fact that fewer components are required for assembly, the portable electronic device is able to more easily withstand the impact of a fall event, and better protection is provided to the top layer of polished glass and any or any operational components. sensitive there.
The uninterrupted housing is formed from a single sheet of metal (such as stainless steel). The housing has a notched geometry, where the linear dimensions of an opening into which the operating components are inserted during assembly are less than the linear dimensions of the body of the housing itself. Still further, the curvature of the housing is asymmetric in that an upper portion of the housing is formed to have a deep groove or groove (i.e., higher curvature) while a lower portion of the housing is formed to have a shallower groove or groove. This asymmetry aids in a user's tactile feel in part because it provides a better fit for the user's hand. Furthermore, the metallic nature of the housing provides good electrical ground for a built-in RF antenna, as well as mitigating the effects of electromagnetic interference (EMI) and electrostatic discharge (ESD).
Unlike conventional portable electronic device mounting where components are assembled in a top-down manner (i.e. components are inserted into the housing before the bezel is mounted), the notched geometry of the housing requires that all the components fit within the smallest dimensions of the window opening in the housing. Still further, the assembly of the portable electronic device is carried out in a bottom-up manner using what is referred to as a blind assembly or mount. In order to facilitate the blind bottom-up or bottom-up assembly of the portable electronic device and to minimize any displacement between the top polished glass layer and a higher portion of the housing (referred to as the guide), various techniques Appliances and systems are present that minimize stacking tolerance (i.e. z-direction). For example, portions of clamps used to mount sub-assemblies have welds to the housing and are subsequently machined at the same time and in the same configuration as the uppermost portion of the housing. In this way, accurate Z data is provided for mounting various components.
It should be noted that machining is preferred since machined tolerances in the order of 0.05 mm can be achieved while conventional weld location tolerances are typically in the order of
0.2 mm.
Other aspects of the invention are specific approaches to minimize the assembled components. In other words, both the aesthetic aspect and the consistent device of the user.
refer to Z height of maintaining feel, Z height of portable electronic with providing a
This can be accomplished in addition to those the minimum Z clamps can be piezoelectric horizontally.
already discussed montaj e. A manufactured combination is maintained at a favorable experience value for in an amount with respect to horn mounting of example shapes at height using a horn with an acoustic barrier
Spaces in the horizontal acoustic barrier have the effect of directing the sound produced by the horn or piezoelectric speaker to any accommodation site. For example, sound can specific openings in the related may include coupling and / or broadcasting eg audio jack opening.
the sound housing.
desired in an opening
<td>to be</td><td>managed</td><td>to</td>
<td>other</td><td>shape</td><td>not</td>
<td>These</td><td colspan="2">openings</td>
<td>l of</td><td>base</td><td>of</td>
<td>The</td><td>to get better</td><td>the</td>
Sound perceived by providing posterior volume (i.e. using the posterior surface of the housing as a resonator) can be achieved using existing components and an appropriately placed posterior volume acoustic seal. In order to ensure that the integrity of the posterior volume seal is maintained despite the variance in Z tolerance between the shield and housing changing from device to device, adapters are placed in close proximity to the posterior volume acoustic seal.
Other aspects of the invention that retain the available Z height relate to the organization of circuits associated with the battery and the display screen. In particular, as described below, the battery and display screen circuits co-exist in the same Y location thereby reducing the total Y component of the circuits.
As described, the display security circuit circuits may include a particular modalities, liquid crystal, LCD, and the
In the controller modes, the battery and battery controller display
<td colspan="2">they can</td><td>include</td><td>a</td>
<td>the</td><td colspan="2">circuits</td><td>of</td>
<td>of</td><td colspan="2">display</td><td>(in</td>
<td> is</td><td>a</td><td>exhibitor</td><td>of</td>
<td>is</td><td>a</td><td colspan="2">controller</td>
the circuit of
LCD).
Battery safety is placed in a central portion of the battery and the LCD controller does not line up on a far edge of the merchandiser (this will likely increase line width and parasitic capacitance by reducing the available boost from the LCD controller). Also, in order to conform to the groove or groove in the housing to reduce the overall Z of the product, the flexible CD driver folds around the battery.
Furthermore, providing gas relief structures in a plastic frame used to mount the protective glass or glass layer improves the adhesion of the glass layer to the plastic frame. These structures can be formed, for example, by removing predetermined sections of the plastic frame at appropriate locations by punching holes of a predetermined size and location. In this way, any trapped gases, such as air, can escape providing a more even distribution of adhesive, resulting in a stronger and more reliable bond between the glass layer and the plastic frame.
These and other embodiments of the invention are discussed below with reference to Figures 1-16. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for purposes of explanation as the invention extends beyond these limited embodiments.
Through the following discussion, the term
CNC is employed.
The abbreviation CNC stands for computer numerical control and specifically refers to a computer controller that reads computer instructions and drives a machine tool (an energized mechanical device typically used to manufacture components by selective removal of material).
It should be noted however that any appropriate machining operation can be used to implement the described modalities and is not strictly limited to those practiced associated with CNC.
The
Figures 1A
IB are perspective diagrams showing various views of the fully assembled portable electronic device 10 in accordance with an embodiment of the invention. The portable electronic device 10 can be sized for one-hand operation and placement in small areas such as a bag, ie, the portable electronic device 10 can be a pocket-sized or portable bag-size electronic device. By way of example, the portable electronic device 10 may correspond to a computer, media device, telecommunications device and / or the like. Portable electronic device 10 is capable of processing data and more particularly media such as audio, video, images, etc. The portable electronic device 10 can generally correspond to a music player, game player, video player, personal digital assistant (PDA), and / or the like. With respect to being portable, the portable electronic device 10 can only be operated with the user's hand or hands, ie no reference surface such as a desk is required. In some cases, the portable device is sized to fit in a user's pocket. Being pocket-sized, the user does not have to directly carry the device and therefore the device can be carried almost anywhere the user travels (i.e. the user is not limited to carrying a large, bulky and heavy).
The portable electronic device 10 can be varied widely. In some embodiments, the portable electronic device 10 may perform a single function (eg, a device dedicated to executing and storing media), and in other cases, the electronic device may perform multiple functions (eg, a device that executes / stores media) , receives / transmits phone calls / text messages / internet, and / or performs network viewing).
In some embodiments, the portable electronic device 10 is capable of wireless communication (with or without the aid of an accessory system not wirelessly enabled) and / or via wired routes (eg, using traditional electrical cables).
In some embodiments, the portable electronic device 10 can be extremely portable (eg, small profile, light weight).
portable electronic form factor, slim,
In some cases, the device can be sized to be portable. The portable electronic device 10 can even be sized for one-handed operation and placed in small areas such as a pocket, ie, the portable electronic device 100 can be a portable pocket-size electronic device.
By way of example, the portable electronic device 10 may correspond to consumer electronic products such as computers, media players, personal digital assistants (PDAs), telecommunications (telephone) devices, personal e-mail or messaging devices and / or the like. . In one example, the electronic device may correspond to any of these electronic devices: an iPod ™, an iPod Nano ™, an iPod Shuffle ™, an iPod ™ Touch, or an iPhone ™ available from Apple Inc. of Cupertino, California.
The portable electronic device 10 includes a housing 100 configured to at least partially circumscribe any convenient number of components associated with the portable electronic device 10. For example, the housing may circumscribe and support various electronic components internally (including integrated circuit chips and other circuits). ) to provide compute operations for the device. Integrated circuit chips and other circuits can include a microprocessor, memory, a battery, a circuit card, I / O (I / O = input / output), various input / output (I / O) support circuits ( I / O) alike. Although not shown in this figure, housing 100 can define a cavity within which components can be located and housing 100 can also physically support any convenient number of mechanisms within housing 100 or within openings through the surface of the accommodation 100.
In addition to the above, the housing can also define at least in part the external appearance of the portable electronic device 10. That is, the shape and structure of the housing 100 can help define the overall shape and structure of the portable electronic device 10 or the contour. of the housing 100 can incorporate the external physical appearance of the portable electronic device 10. Any convenient shape can be employed. In some embodiments, the size and shape of housing 100 can be sized to fit comfortably within a user's hand. In some embodiments, the shape includes a slightly curved back surface and highly curved side surfaces. The shape will be described in more detail below.
In one embodiment, housing 100 is integrally formed such that it constitutes a single complete unit. Being integrally formed, housing 100 has an uninterrupted appearance unlike conventional housings which include two parts that are held together, thereby forming an exposed seam between them. That is, unlike conventional housings, housing 100 does not include interruptions, thus making it stronger and more aesthetically pleasing.
Housing 100 can be formed from any number of materials including for example plastics, metals, ceramics, and the like. In one embodiment, housing 100 may be formed of stainless steel, to provide a pleasing, aesthetic look and feel, as well as provide structural integrity and support for all sub-assemblies installed there. When metal, housing 100 can be formed using conventional collapse core metal forming techniques well known to those skilled in the art.
Portable electronic device 10 also includes a cover 106 that includes a planar outer surface. The outer surface may for example be flush with an edge of the housing wall surrounding the edge of the cover. Cover 106 cooperates with housing 100 to circumscribe portable electronic device 10. Although the cover may be positioned in a variety of ways relative to the housing, in the illustrated embodiment, the cover 106 is positioned within and proximate the mouth of the cavity of the housing 100. That is, the cover 106 fits into an opening 108. In a. In alternate mode, cover 106 may be opaque and may include a touch sensitive mechanism that forms a touch screen or touch panel. Guide 122 is defined as the uppermost portion of housing 100 surrounding the polished top glass layer 106. In order to maintain the desired aesthetic appearance and feel of portable electronic device 10, it is desirable that any displacement between housing 100 and The top polished glass layer 106 is minimized and the guide 122 is centered.
Cover 106 can be configured to define / transport the user interface of electronic device 10. Cover 106 can for example provide an observation region for display screen 104 used to display a Graphical User Interface (GUI). as well as other information to the user (for example, text, objects, graphics). The display screen 104 may be part of a display unit (not shown) that is assembled and contained within housing 100. The display unit for example can be internally connected to a metal frame (eg, 302). The cover may also provide a user click power button 114 (home button) which can be used to provide a user power event to the portable electronic device 10. These user power events can be used for any number of purposes, such as resetting the portable electronic device 10, selecting from display screens displayed on display screen 104, and so on. In one embodiment, cover 106 is a protective top layer of transparent or semi-transparent (clear) material such that display screen 104 is visible therethrough. That is, cover 106 serves as a window for display screen 104 (i.e., the transparent cover overlaps the display screen). In a particular embodiment, the cover is formed of glass or crystal (for example cover glass), and more particularly highly polished glass. It will be appreciated however, that other transparent materials such as clear plastic can be employed.
In one embodiment, the viewing region may be touch sensitive to receive one or more touch feeds that help control various aspects of what is displayed on the display screen. In some cases, the one or more feeds can be received simultaneously (eg multiple contacts). In these embodiments, a touch sensitive layer (not shown) can be located below the cover glass 106. The touch sensitive layer can for example be placed between the cover glass 106 and the display screen 104. In some cases, the touch sensitive layer is applied to the display screen 104, while in other cases the touch sensitive layer it is applied to the cover glass 106. The touch-sensitive layer can for example be connected to the inner surface of the cover glass 106 (printed, deposited, laminated or otherwise bonded thereto). The touch-sensitive layer generally includes a plurality of sensors that are configured to activate as the finger touches the top surface of the cover glass 106. In the simplest case, an electrical signal occurs each time the finger passes a sensor . The number of signals in a given time frame can indicate the location, direction, speed and acceleration of the finger in the touch-sensitive portion, that is, the more signals, the more the user moved his finger. In most cases, the signals are monitored by an electronic interface that converts the number, combination, and frequency of the signals into location, direction, speed, and acceleration information. This information can then be used by the portable electronic device 10, to perform the desired control function with respect to the display 104.
Portable electronic device 10 may also include one or more switches including power switches, switches or switches for volume control, user power devices, and the like. A power switch 110 can be configured to turn the portable electronic device 10 on and off, while a volume switch 112 is configured to modify the volume level produced by the portable electronic device 10. The portable electronic device 10 may also include one or more connectors for transferring data and / or power to and from the portable electronic device 10. The portable electronic device 10 may include an audio plug 116 and a data / power connector 118. The Audio 116 allows audio information to be output from the portable electronic device 10 via a wired connector. Connector 118 allows data to be transmitted and received to and from a host device such as a general-purpose computer (eg, desktop computer, laptop). Connector 118 can be used to upload or download audio, video and other image data as well as operating systems, applications and the like to and from portable electronic device 10. For example, connector 118 can be used to download songs and playlists, audio books, photographs, and the like to the storage mechanism (memory) of portable electronic device 10. Connector 118 also allows power to be supplied to portable electronic device 10.
Connector 118 may receive a corresponding external connector (not shown) that is capable of plugging into a host device (and / or power supply) in order to allow communications (eg data / power transfer) between the portable electronic device 10 and the host device. The connector can vary widely. In one embodiment, the connector is a peripheral collector connector, such as a USB or FIREWIRE connector. These types of connectors include both power and data functionality, thus allowing both power supply and data communications to occur between the portable electronic device 10 and the host device when the portable electronic device 10 is connected to the host device. In some cases, the host device may provide power to the portable electronic media device 10 that can be used to operate the portable electronic device 10 and / or charge a battery included there concurrently with the operation. In a particular embodiment, the connector is a 30-terminal connector as used in many products manufactured by Apple Inc. of Cupertino, CA. Audio jack 116 can receive an audio pole (not shown) that can provide audio signals to external audio display devices, such as headphones, speakers, etc.
Although the device can be connected through various wired connections, it should be appreciated that this is not a limitation. In one embodiment, the portable electronic device 10 also includes a mechanism for wireless communications. For example, as shown, portable electronic device 10 may include an antenna (ie, antenna 222). The antenna can be placed internal to housing 100. Wireless communications can be based on many different wireless protocols including for example Bluetooth, RF, 802.11, and the like. In order to minimize any adverse impact on wireless communications in modes where the housing is metallic and therefore conductive, the portable electronic device 10, a portion of the housing 100 may be replaced with a transparent radio cap 120 formed of a non-conductive material , such as plastic.
Figure 1C shows a cross-sectional view of housing 100 highlighting the nature of the modified geometry. Although in general, the interior cross-sectional shape of housing 100 may be the same or different from the external cross-sectional shape of housing 100, the interior shape of housing 100 is substantially adapted to the exterior shape of housing 100. Housing 100 can be formed with a notched, curved geometry that more easily receives a user's hand (eg shape adjustments). In particular, an interior wall of housing 100 substantially conforms to the shape of an exterior wall of housing 100. More specifically, the side wall 121 (both interior and exterior) is rounded and curved inward to form a concave notched region 123, formed in an upper portion of the side wall 121 in proximity to the cutting edge 128. Notched is understood. that the side wall 121 curves back inward into the housing 100. Thus, the window opening 108 has at least one X dimension and Y dimension smaller than the body of the housing 100. In one example, the housing 100 may have dimensions of approximately (x, y) housing = (61.8 mm, 111 mm) while opening 108 may have dimensions of approximately (x, y) opening = (58.3 mm, 107.5 mm).
Figures 2A-2E show various exploded perspective diagrams of the portable electronic device 10 in its unassembled form. Portable electronic device 10 includes housing 100 illustrated in Figure 2A, into which a number of operational and / or structural components are connected. Housing 100 can take the form of an unbroken enclosure. The uninterrupted nature of housing 100 provides an aesthetic appearance and feel of portable electronic device 10 as well as providing added resistance to deformation and possible damage to internal components caused by the impact of a fall event. In the embodiments described herein, housing 100 is formed of stainless steel and is approximately 0.5 mm thick. It should be noted, however, that this configuration is representative in nature only and does not provide limitations that restrict the final scope of the invention.
Housing 100 extends on a vertical axis (Y) and a horizontal axis (X) having a height Z. Housing 100 can be of various sizes. For example, housing 100 may have a height (Z) of approximately 8.5 mm, an X dimension of approximately 61.8 mm, and a Y dimension of approximately lll mm. Housing 100 includes a cavity 124 that is sized and configured to receive the internal components of portable electronic device 10. The internal components are assembled through the window opening 108. The notched geometry of the housing 100 provides the linear dimensions of the window opening 108 into which the operational components during assembly are inserted that are smaller than the linear dimensions of the body. of housing 100. For example, window opening 108 may have an X dimension of approximately 58.3 mm and a Y dimension of approximately 107.5 mm.
One aspect of the desired feel and sight is the symmetry in design and conformation appearance of the portable electronic device 10. One aspect of the symmetry of the portable electronic device 10 refers to guide 122. Guide 122 is the metal strip-around of the cover 106 on the front face of the device. The width of the guide 122 is defined by an outer guide profile and an inner guide profile. Since the housing 100 is made of a sheet metal material, the outer guide profile is achieved by the sheet metal that is formed while the inner guide profile is achieved by machining where the formation tolerance is much greater than the machining tolerance. In the disclosed embodiment, the outer guide profile is consistent with a formed edge 126 while the inner guide profile is consistent with and cutting edge 128 of housing 100 as illustrated in Figure 3, showing a representative cross section and top view of the portable electronic device 10, which highlight the relationship of the guide 122 and both the formed edge 126 and the cutting edge 128.
In order to maintain the desired appearance of the portable electronic device 10, it may be desirable to properly center the guide 122. This centering can however be achieved in a number of ways depending on what is considered an important factor in the overall design aesthetics of the portable electronic device 10. In any case, a series of optical measurements is carried out using, for example, a CCD camera to measure the outer guide profile after a rough cut of the same. Once the CCD measurements have been taken, any one of a number of approaches can be employed to center the guide 122. However, depending on which approach is taken it may give somewhat different results. For example, as shown in Figure 4A, centering the guide 122 using the external guide profile (i.e. formed edge 126) will produce a consistent guide width, however the space 130 of the housing to the glass will be less consistent . Moreover, guide 122 may also be centered when creating the inner guide profile shape by cutting cutting edge 12 8 by 3D CAD, but using CCD measurements to find the center (xq, i) and any rotation angle φ, to cut the inner profile as shown in Figure 4B. This particular centering approach will give a less consistent guide width but more consistent spacing 130 from the housing to the glass.
Figures 2B-2E illustrate the operational components of the portable electronic device 10. In a described embodiment, the components of the portable electronic device 10 are arranged in layers. The ratio and organization of the components within each layer and the relationship between the layers can be used to facilitate both assembly and optimization of Z height tolerances of the portable electronic device 10. By minimizing Z height tolerance, the portable electronic device 10 is manufactured to be extremely compact, rugged, aesthetically pleasing, and ergonomic at a relatively low cost. For example, the fact that the portable electronic device 10 is assembled without the need for a bezel, reduces manufacturing and assembly costs. The layers may include a first layer (main electronics) 200, a second layer (metal frame or M frame) 300 and a third layer (glass or G unit) 400 each of which is described in greater detail below.
Figure 2B shows a detailed view of the first layer 200 (referred to below as the PCB layer
200) according to an embodiment of the invention.
PCB layer 200 includes a first assembly 204 and a second assembly 206, which are physically and operatively connected by a flexible circuit 202. The first assembly 204 includes a Printed Circuit Board 205 in which flexible circuit 202 is connected. Printed circuit board 205 is configured to carry multiple components including for example the processor, memory and the like. The printed circuit board 205 is also configured to carry an RF shield 207 that is placed over the various components. RF 207 shielding is formed of metal and configured to cover and surround components. The first assembly also includes a 209 speaker system that is not a separate discrete system but rather a system that integrates with other components to properly output sound. At its core, the speaker system includes a piezoelectric speaker 210, acoustic seal 212, and acoustic barrier. Piezoelectric horn 210 connects to RF shield 207, acoustic seal 212 closes the gaps to form an acoustic volume between the RF shield and housing. This modality will be described in greater detail in Figures 5A-5C. Printed circuit board 205 is also configured to carry connector 118 and audio plug assembly 116. In the described embodiment, the audio plug 116 fits or fits within the audio plug opening 117 and acts as an interface to an external circuit (such as headphones) via a cable or other type of connector. For a proper fit of the audio plug 116 in the audio plug opening 117, the audio plug opening 117 should have a shape that conforms to both the slot in the housing 100 and the shape of the audio plug 116 described with more detail in Figures 6A-6B.
PCB layer 2 00 can fit into cavity 124 of housing 100 and be secured to an interior wall of housing 100 using fasteners such as screws 208a and 208b that connect directly to housing 100 (it should be noted that screw 208b also facilitates donning grounding of the RF antenna discussed in more detail below). It should be noted that prior to assembly, the power button 110 is connected to the housing using a power or power button board 228 and the volume button 112 is connected to the housing 110 using a volume button board 230 each of which are electrically connected to each other using flexible device 232.
One of the problems with having an active RF antenna mount in close proximity to a number of active circuits is the generation of electromagnetic interference (EMI) that can misadjust or otherwise adversely affect the performance of the RF 222 antenna. For example, the relatively long conductors present in flexible device 202 that can act as a source of EMI that can adversely affect the performance of RF antenna 222. To substantially reduce or even eliminate this source of EMI it would be desirable to RF ground the PCB 200. Therefore, to provide a good RF ground, portions 226 of the flexible insulating layer 202 facing the inner surface of the housing 100, they are removed in order to expose the conductive layer there. The portions 226 of the flexible 202 that are typically removed are those regions that are relatively large and contiguous, thus having a greater potential to provide good RF ground when contacted with the metal of the housing 100. In the disclosed embodiment, after the portions 22 6 of the flexible 202 have been removed, the exposed conductive material is pressed down onto the housing 100. The presence of Pressure Sensitive Conductive Adhesive (PSCA) placed between hose 202 and housing 100 provides the necessary electrically conductive and mechanical bond. In addition to providing good RF ground, the conformation of flex 202 to the interior surface of housing 100 reduces the overall Z profile of PCB 200.
Figures 2C and 2D show an unassembled top view and an assembled bottom view of the third layer
300 previously referred to as the metal frame mount (M) 300, respectively, in accordance with one embodiment of the invention. Turning first to Figure 2C, the M 300 rack mount can include the M 302 rack, the battery
304 connected to frame M 302 by pressure sensitive adhesive (PSA) and display circuit 306 including display 104. In the described mode, the height requirements Z for frame M 300 can be reduced using what is referred to as stockings shears 310. The)
Half shears 310 can be formed by removing portions of the M 302 frame at those sites around the threading holes in the M 300 frame used to house screws 312a and 312b that connect the M 302 frame to the housing 100. In the described embodiment, a quantity Sufficient material is removed from the M 302 frame such that an upper portion of each of the screws 312a and 312b is essentially level as a top surface 314 of the M 3 02 frame. As described in more detail below, each half shear 310 is aligned with a Z height data stop described in greater detail below, thereby further minimizing the Z height requirements for the portable electronic device 10. Furthermore, the alignment holes for display unit 316 are provided to accept alignment pins (not shown) in display unit 306 which provides x alignment, to housing 100 via alignment holes 140 in mounting brackets 136a and 136b.
In addition to minimizing the height requirements Z, the total component Y of battery circuits and display circuits can be reduced as shown in Figure 2D, which graphically illustrates the arrangement of circuits associated with battery 304 and the display circuit. 306. In particular, battery circuits 318 and display circuits 320 co-exist at the same location Y thereby reducing the total Y component of the circuits. In the described embodiments, the battery circuits 318 can take the form of a battery safety circuit 318 and the display circuit can include an LCD controller 320. Conventional designs dictate that the battery safety circuit 318 be placed in a central portion of battery 304 and because the LCD controller 320 should not be aligned with a far edge of display circuit 306 (as this will likely increase the line width and the parasitic capacitance reducing the available impulse of the LCD controller). However, by modifying the design of both the battery safety circuit 318 and the LCD controller 320, the two circuits can be placed in the same Y location.
X.
Thus, the total Y component of the two Circuits taken together can be reduced. Furthermore, in order to adapt to the groove of the housing 100 and to reduce the total Z of the portable electronic device 10, the flexible LCD controller 322 is wrapped around and placed under the batteries 304 so that the display connector 324 and the connector of 326 batteries correspond as shown in Figure 2D.
The portable electronic device 10 includes a crystal or G 400 unit shown in Figure 2E. The G 400 unit includes the cover glass 106. The G 400 unit also includes the cover glass PSA 404, used to adhere the cover glass 106 to the plastic frame 406. The environmental seal 408 can be used to prevent dust or other unwanted environmental contaminants enter the portable electronic device 10 after assembly. During assembly, the G 400 unit can be placed within the window 108 of the housing 100 on the M 3 00 rack mount as shown in Figures 8A-8C. The G 400 unit self-aligns during the insertion process and fastens to the M 302 frame using the input end of the M 324 frame. The G 400 unit includes a double-shot mount formed from the plastic frame 406 and an environmental or cosmetic seal 408 made for example of thermoplastic urethane (TPU = thermoplastic urethane), rubber and the like, which can act to protect the portable electronic device 10 against dust and humidity. As described below, the shape of the environmental seal 408 relative to the housing 100 aids in self-aligning the G 400 unit with the window opening 108 during assembly. During the assembly process as shown in Figure 8A, the G 400 unit is inserted into the window opening 108 by bringing the plastic frame 406 into contact with the input end of the M 324 frame. In the disclosed embodiment, both the environmental seal 408 and the inlet end of the M 324 frame have corresponding tapered shapes that allow the G 400 unit to self-align. For example, in Figure 8B, as unit G 400 is inserted into window opening 108, plastic frame 406 finds the tapered shape of the inlet end of frame M 324. The inlet end of the M 324 frame has the effect of both aligning and clamping the G 400 unit until such time as shown in Figure 8C that the tapered edge of the environmental seal 408 meets the inside, or cutting edge 128 of the housing 100 . A portion 410 of environmental seal 408 extends beyond cut edge 128: In the disclosed embodiment, portion 410 has a tapered edge that can cause the G 400 unit to self-center with window opening 108 as shown in Figure 8C until the G 400 unit is captured by the input end of the M 324 rack.
During assembly, when pressure is applied to the G 400 unit, entrapped gases coalesce into gas bubbles that result in minimizing the bond area between the pressure sensitive adhesive (PSA) and the glass 106. The gas is entrapped due in part to the fact that due to assembly tolerances, the PSA will touch seal 402 closing a gas escape route (see Figure 9A). Therefore, it would be advantageous to provide gas relief structures or assembly techniques in the plastic frame.
406, thus improving glass or glass 106 by
Techniques for gas relief predetermined sections of the frame from appropriate sites eg. punching the adhesion of the plastic frame layer 406. may include removing plastic 404 into holes of a predetermined size and location or removing small amounts of PSA from the corners of the portable electronic device 10, allowing trapped gas to escape more easily. as shown in Figure 9B. In this way, a more even distribution of adhesive resulting in a stronger and more reliable bond between the glass layer 106 and the plastic frame 404 can be achieved.
Figure 5A shows a minimum or integrated Z height speaker assembly 500 which is a particular embodiment of the integrated speaker assembly shown in
Figure 2B. The minimum Z height 500 speaker assembly includes at least one piezoelectric speaker 210 in combination with the acoustic seal 212 and a horizontal acoustic barrier (Y) 502. The spaces 504 in the acoustic seal have the effect of directing the sound produced by the piezoelectric horn 210 to any desired location in housing 100. For example, sound may be directed to specific openings in housing 100 otherwise unrelated to sound diffusion. These openings may include for example the dock opening 119 and / or audio plug opening 117. The horizontal acoustic barrier 502 ensures that substantially no sound leaks to unwanted portions of the housing 100, such as spaces associated with the volume knob 112, power button 110, or antenna cap 120. Furthermore, as shown in Figure 5B, a posterior volume seal 506 can form an acoustic cavity 508, also referred to as a posterior volume, in cooperation with housing 100. Thus, when using existing components, Z height requirements for creating the rear volume 508 are reduced and the rear side portion of the housing 100 can act as a resonator arranged to enhance a user's audio experience. Since the posterior volume 508 is created using existing components (i.e. housing 100 and acoustic barrier 502), there is no adverse impact on the overall Z height of the portable electronic device 10.
Figure 5C shows select compression or crush zones 510 which are provided for adjustment of variations in Z tolerances and to ensure the integrity of the posterior volume 508. During assembly of the portable electronic device 10, pressure can be exerted on PCB 200 ** which has the effect to compress, or crush, the crush zones 510. In this way, any variations in height Z of the various components of PCB 200 can be tolerated without understanding the integrity of the posterior volume 508. It should be noted that the crush zones 510 can take any of a number of shapes and sizes and be formed from any elastic material capable of forming a seal between housing 100 and posterior volume seal 506.
As shown in Figure 6A, one of the problems with the asymmetric geometry of housing 100 is that as the lower cut surface (point A) of audio plug opening 117 moves upward in the positive Z direction , the edge of the cut passes into a negative Y direction due to the high curvature of the housing 100. In other words, a small change in the positive Z direction results in a large change in the negative Y direction. Since the audio plug 116 is fixed in the Z direction, the size of the audio plug opening 117 should not be too close to the top portion of the housing 100 to present a hazard to the glass plate 106 as would be the case if the audio plug opening 117 were to form too far in the shallow portion of the housing 100. In either case, having a fully circular portion in the shallow geometry of housing 100, can result in very sharp edges (as shown in Figure 6A) that must be machined. Conventional machining processing, however, will cause housing 100 in this region to become unacceptably thin, posing a risk of damage in an impact event. Therefore, in order to accommodate the circular shape of the audio plug 116, the groove of the housing 100, as well as to decrease the trim for the audio plug (the material around the audio plug structure itself) as small as possible As possible, a non-symmetrical audio plug opening 117 is formed as shown in Figure 6B, having the circular portion 602 and a non-circular portion 604 that provides the non-symmetrical shape for the audio plug opening 117. In this way, the audio plug opening 117 allows the plug. Audio 116 and the audio jack opening maintain a centered and circular appearance especially when viewed from above. It should be noted that it has been discovered that subsequent to the formation of the audio plug opening 117 in this manner, a deburring process for touch-up can be performed using materials that are considered unconventional in the deburring technique. These materials may include, for example, a bamboo wooden bar, wooden chopsticks, and the like.
In order to accommodate various interfaces (docking station, audio jack, volume, power, for example), openings of various sizes must be created in the z
housing 100. There are a number of approaches that can be employed to create these openings and make the finish of the opening appear thinner than the thickness (0.5 mm) of the sheet metal used to create housing 100. One approach is based in directing or bending the sheet metal that forms the housing 100 as shown in Figure 9. In either case, creating these openings in housing 100 can result in long, thin wefts of metal that can be deformed by the impact of a fall event, for example. In order to reinforce these areas, any one of a number of different techniques can be employed to add an additional layer of material (referred to as minor material) to the precursor material, which in this case is stainless steel with a thickness of approximately 0.5mm. In some embodiments, the minor material can be attached to the parent material by welding, autogenous welding, brazing, or glue. Once the minor material is attached to the precursor material, a one-stage cut is performed (laser or machine cutting or punching, for example) to create the current hole geometry.
Figures 10A-10B show a representative cross-sectional view of the housing 100 in the area of the docking base opening 119. However, due to the thickness (about 0.5 mm), the material (stainless steel) from which it is formed the described housing, and the geometry (ie, deep groove) of housing 100 obtaining the desired deep cut is difficult to achieve a large scale manufacturing environment. In particular, looking at Figure 10A, due to the geometry of the housing 100, using a conventional punching operation to create the opening of the dock 119 will result in an unacceptable asymmetric cut between the steep opening of the top portion and the shallow groove. depth of the lower portion of the housing 100. Therefore, as illustrated in Figure 10A, a metal support bracket 1002 having a thickness of approximately housing 100 (which in this embodiment is approximately .5 mm), can be connected to the interior wall of housing 100 using material welding or brazing or glue. By using the brazing or welding material or glue, the support clamp 1002 can be securely connected to the housing 100 as well as providing a good cosmetic result since the brazing or welding material blocks the gap between the housing 100 and the clamp support 1002. FIG. 10B shows a result of the punching operation to form the opening of the docking station 119. By using the support clamp 1002, a double wall is formed in the area of the housing 100, where the opening of the docking station 119 (or any opening in the housing 100, in fact). In the disclosed embodiment, since any gaps between the support clamp 1002 and the housing 100 are filled with solder or braze, it can be maintained in both the desired cosmetic appearance and the desired structural integrity and strength. It should be noted that to provide optimum strength for holes having large extensions (volume knob opening), the respective support brackets are positioned such that the assumed hole is located approximately halfway through the support bracket.
Figures 11A-11C graphically illustrate the process for forming the dock opening. Figure 11A illustrates the placement of the support clamp 1002 in the housing 100 in relation to the opening of the proposed coupling base 117. The support clamp 1002 can be welded to the housing 100. Figure 11B shows in profile view, juxtaposition support bracket 1002 and base opening of
<td>coupling</td><td>proposal. In this case, the clamp</td>
<td>support 1002</td><td>covers the entire area of the base opening</td>
<td>coupling</td><td>proposal to provide maximum support</td>
CNC post. Accordingly, Figure 11C shows in profile the post punching and CNC operation of the opening of the coupling base 119, the support clamp 1002 has an upper portion 1102 and a lower portion 1104. It will be noted that in order to hide cosmetically the space between the support bracket and the housing 100, material
<td>welding</td><td>or brazing can be used to fill</td>
<td>any</td><td>Post CNC spaces.</td>
<td>In</td><td>the case of openings that have long</td>
<td>extensions,</td><td>such as the volume control button,</td>
<td>Figures 12A -</td><td>- 12C graphically illustrate the process of forming</td>
<td>An opening</td><td>long extension such as button opening</td>
<td>of volume.</td><td>Figure 12A illustrates the placement of the</td>
support bracket 1202 in housing 100 relative to the opening of the proposed volume knob. It should be noted that in this case, the support clamp 1202 only extends approximately halfway in the y direction, since the primary area requiring support is that thin ribbon 1204 over the proposed volume control knob.
Thin tape 1204 is susceptible to deformation during an impact event. Figure 12B shows a profile view of the bracket clamp juxtaposition
1202, the accommodation
100, and the proposed location of the volume control button.
Figure 12C shows the post laser cut of the volume control knob, illustrating the upper bracket bracket that provides the necessary support for any long-span openings in the housing.
100 such as the volume button.
It should be noted, however, that the above procedures are predicated on materials, such as stainless steel, and geometries (i.e., those with steep grooves) that do not lead to providing symmetrical cuts or adequate depth of cut in a type operation. punching. However, it is contemplated that using materials other than stainless steel, such as aluminum, the necessary symmetry can be provided.
In these cases, a one-piece punching and CNC can be used. In addition it should be noted that the thickness of the support clamps can be varied but it is found that having a thickness close to that of the housing 100 works well.
In order to avoid interference with RF antenna
222, the housing material is removed from the housing 100 to form the antenna hole 126. The antenna hole
126 when withdrawing. the conductive housing material using a laser and replacing with the non-conductive material such as plastic to form the antenna cap 120. In this way, interference caused by the presence of a conductive material such as metal in the immediate vicinity of the RF antenna 222. However, this shear detachment can cause corner portion 128 of housing 100 to weaken to the point where it becomes susceptible to deformation or damage due to an impact event. Therefore, a corner gusset or reinforcer 130 can be employed to provide structural support for corner portion 128 of housing 100, by reinforcing the side wall of housing 100 of corner portion 128 as shown in Figure 13. Corner gusset 130 is welded or otherwise connected to housing 100. However, in contrast to other support clamps such as those for the volume knob and dock, corner gusset 130 serves to Two purposes, one to provide additional structural integrity to corner 128 of housing 100, where material is to be removed, and the other as an RF antenna ground 222. In the described embodiment, antenna ground 132 is connected to RF antenna 222 by antenna screw 208b. In order to provide good electrical connection between the RF antenna
222 and corner reinforcement 130, antenna ground 132 must remain substantially intact both to mechanically receive antenna screw 208b and to provide good electrical connection to corner reinforcement 130 (and housing 100).
Due to the size and location of antenna hole 126, a laser is employed to remove the required amount of material from housing 100 to form antenna hole 126. However, antenna ground 132 extends in the region in immediate proximity to the material to be laser cut. Since antenna ground 132 must remain relatively intact, antenna ground 132 is protected against any debris or remnants generated by the laser that removes material to form antenna hole 126 by shielding made of, for example, foam, or any other protective material that can be easily removed subsequent to the formation of the antenna hole 126.
Returning to Figure 2A, which shows a detailed view of housing 100. As illustrated, housing 100 includes a number of connection accessories used to connect sub-assemblies to housing 100. These connection features may include, for example, accessories for secure the PCB 134a and 134b, and 134c subassembly, which can be used to connect the assembly
PCB 200 to housing 100 using fasteners such as screws 310b and screw 208a, respectively. It should be noted that screws 310b connect the M 300 frame mount and PCB 200 to housing 100 using mounting hardware 134a and 134b as opposed to screws 310a connecting the M 300 frame mount directly to mounting clamps 136a and 136b. As discussed above, RF ground 132 is used to both clamp PCB 200 to housing 100 as well as provide a ground plane for RF antenna 222.
Mounting clamps 13 6a and 13 6b are used to attach the M 300 frame subassembly to housing 100. However, conventional approaches to connecting mounting clamps to housing 100 utilize high temperature connection processes, such as laser welding, which can and usually results in cosmetic damage to the outer surface of the housing 100. This cosmetic damage may require costly and time consuming remedy, such as polishing, which can increase the cost of and time required to assemble the portable electronic device 10. Therefore, to avoid creating cosmetic damage, only processes are employed. of connecting the housing clamps 100.
low temperature connection for process triggered
So
<td>of</td><td>mounting</td>
<td>of</td><td>remove</td>
<td>of</td><td>Connection</td>
at high temperature
136a and 136b al (such as laser welding), mounting clamps 136a and 136b are placed at appropriate locations on the inner surface of housing 100 using a low temperature welding process. Once located, mounting clamps 136a and 136b securely connect to the inner surface of housing 100, using a low-temperature soldering process. By using brazing and low temperature welding processes, any damage, cosmetic or otherwise, to the outer surface of housing 100 that would have been caused by connecting mounting brackets 136a and 136b to housing 100 is eliminated using conventional methods such as high temperature processes. Therefore, in contrast to the conventional approach of using high temperature connection processes, using low temperature connection processes eliminates the need for subsequent connection polishing or other remedy on the outer surface of housing 100. Thus In a manner, the aesthetic appearance and feel of the portable electronic device 10 are preserved. In this way, mounting clamps 136a and 136b provide reference surfaces to receive and support some portion of the internal components. In addition, mounting clamps 136a and 136b provide Z 138 data stops that minimize the Z height, or stacking, tolerance of the assembled internal components discussed in more detail below.
During the assembly of the portable electronic device 10, the PCB 200, rack mount M 300 and unit G 400 are placed one on top of the other during what is referred to as a blind assembly operation where each layer must align with each of the other layers with minimal Z height tolerance. As is well known in the art, each time a manufacturing operation requires a number of different configurations, each separate configuration has an associated tolerance, each of which is in addition to all other tolerances. By minimizing the number of configurations in a manufacturing operation, the total Z height tolerance for the operation can be kept to a minimum. Therefore, in order to minimize Z-height tolerances in the assembly of the portable electronic device 10, a number of novel approaches have been devised. For example, to minimize Z height tolerance when connecting frame mount M 300 to housing 100, mounting brackets 136a and 136b include the aforementioned Z data stops 138 (where two Z data stops are located on both sides of the threaded hole of the frame M 146). It should be noted that the Z 138 data stops, the machined top surface 140 of the housing
100, and the alignment holes of display unit 142 are machined at the same time using a simple configuration (as illustrated in Figure 14). In this way, a Z height tolerance relative to the top surface 140 of housing 100 of approximately .05 mm can be achieved (compared to a Z height tolerance of approximately .2 mm using a standard welding approach with multiple configurations) .
Figure 15 shows a flow diagram detailing a process 1500 for installing mounting clamps in a housing in accordance with an embodiment of the invention. Process 1500 starts at 1502 by providing mounting clamps that have sacrificial Z-fit stops located on top. In the described embodiment, adjusting stops z are arranged to have a portion of which can be machined by peeling off during a subsequent machining process during which a portion of the housing is also machined apart. At 1504, the mounting clamps are located inside the housing, using a low-energy connection process such as low-energy solder. Later in 1506, the located clamps are joined by welding in place. The following operations are performed during a single setup, where at 1508 the upper portion of the housing is machined, the sacrificial portion of the adjustment stops z is removed at 1510, and the x, y alignment holes of the exhibit was drilled into the clamp in 1512.
FIG. 16 shows a flow diagram detailing a process 1600 for assembling the portable electronic device 10 in accordance with an embodiment of the invention. First, in 1602, a pre-assembled housing is received. In the described embodiment, the housing has all the appropriate openings formed, the supporting clamps and the fixed connection accessories. In 1604, the PCB mount is placed inside the housing cavity. Since the window opening is smaller than the body of the housing, insertion of the PCB assembly is performed by first inserting either the first or second portion followed by the remaining portion. For example, when the PCB mount is inserted, if the first portion of the PCB mount is inserted first, then the dock and the audio plug are inserted into their appropriate openings in the housing. Once the dock and audio jack are properly seated, then the second portion of the PCB mount is inserted, which in this case includes the RF antenna mount. Once the PCB assembly is in place, then a portion of the conductive layer of the flexible portion of the PCB assembly is exposed in 1606. It should be noted that this step can be performed at any time prior to insertion of the PCB into the housing. By exposing a portion of the conductive layer of the flexible portion, an RF ground plane can be established by the housing. Once the conductive layer of the flexible portion has been exposed, the PCB assembly is attached to the housing at 1608. In the described mode, the PCB mount can be fastened using screws to connect the first portion of the PCB mount, including the dock and the audio plug to the housing, directly using PCB connection accessories. Once the PCB has been attached to the housing, the exposed conductive layer of the flexible tube is pressed to conform to the interior surface of the housing at 1610. In the described embodiment, conductive pressure sensitive adhesive can be employed to adhere the exposed portions to the housing. Furthermore, to provide good electrical contact thus providing a good RF ground, by pressing the hose onto the inner surface of the housing, the hose is mechanically fastened to the housing and also the amount of space occupied by the hose is reduced so concomitant.
Once the PCB is in place and attached, a pre-assembled M-frame and battery are received in 1612. Pre-assembled means that the battery has already been connected to the M-frame using the Pressure Sensitive Additive (PSA). In 1614, the display unit is placed on the side of the M frame opposite that of the battery. It should be noted that the display unit does not connect to frame M at this point, as the display unit must be tilted in order to gain access to the display hose. The display hose is then placed under the battery and electrically connects to the 1616 battery power connector. Once the battery and display unit have been electrically connected to each other, the M rack mount, including the battery and display unit, are fastened to the housing using a number of screws available in 1618. Again, since the display unit does not connect directly to M-frame, display unit is lifted up to gain access to threaded holes in M-frame.
It should be noted that in the described embodiment, a number of available screws used to connect the M-frame mount to the housing use mounting clamps connected directly to the housing. These mounting brackets include a number of Z height data stops that provide a Z reference for the M-frame assembly. Also, some of the remaining available screws are used to connect the M-frame mount as well as the PCB to the housing. Once the frame M has been attached to the housing, the display unit is aligned using a number of alignment pins positioned diagonally to each other on either or both sides of the display unit at 1620. The alignment pins can be used to couple with the alignment holes in the mounting brackets. In 1622, the touch panel is electrically connected to the battery and in 1624, the glass unit is inserted into the window opening and attached to the M frame in 1626.
While this invention has been described in terms of various preferred embodiments, there are alterations, permutations, and equivalents that fall within the scope of this invention. It should also be noted that there are many alternate ways to implement the methods and apparatus of the present invention. For example, although a die casting process is preferred as the preferred manufacturing method for the unbroken enclosure, it should be noted that this is not a limitation and that other manufacturing methods may be employed. Therefore it is intended that the appended claims be interpreted to include all these alterations, equivalent permutations that fall within the spirit and real scope of the present invention.
In the described embodiments, a portable electronic device includes a single uninterrupted housing having a front opening, the single uninterrupted housing has an integral bottom and side walls cooperating to form a cavity in cooperation with the front opening, the bottom wall having a curved bottom surface, the side walls are rounded such that they form a curved side surface and a notch within the cavity, an edge of the side walls surrounds and defines the front opening; and a cover placed inside the front opening and connected to the uninterrupted housing without a bevel, the cover has a flat top surface and is placed inside the cavity in the front opening, the cover substantially fills the front opening between the side walls, the flat top surface is substantially flush with a top surface of the edge of the side walls. The housing is made of polished stainless steel, the housing is metal and the cover is glass or crystal, and the portable electronic device also includes a display unit placed inside the housing cavity and a display screen of the display unit It is visible through the glass cover. A substantially transparent touch-sensitive layer is placed between the cover glass and the display screen of the display unit and the cover includes an opening for a wire drive and the cover connects to a frame, and where the frame is Mounts in the housing within the housing cavity.
The electronic device also includes a plurality of electronic assemblies inserted into the housing uninterrupted through the front opening and attached to the bottom surface of the housing, where a height tolerance Z of the plurality of electronic assemblies is minimized in such a way than a higher surface of a higher electronic mount, it is substantially coplanar with an upper surface of the housing where the plurality of electronic assemblies. The first subassembly includes a first electronic subassembly, a second electronic subassembly, and a substantially planar flexible circuit that operatively and physically connects to the first and second electronic subassemblies, the flexible circuit includes cuts in which they allow the flexible circuit to twist, so that the flexible circuit can fit into a curved shape in multiple dimensions. The second electronic sub-assembly includes an RF antenna, where a corner portion of the housing is removed in close proximity to the RF antenna, in order to substantially eliminate EMI caused by the housing and replaced with an antenna cap formed of a material that does not make RF interference. The antenna cap includes a corner portion reinforcement arranged to reinforce the corner portion of the housing that has the antenna cap, where the reinforcement acts as a ground plane for the RF antenna where the reinforcement includes a contact arranged to electrically connect the RF antenna to the ground plane formed by the reinforcement.
One method can be performed by providing a single uninterrupted housing, the single uninterrupted housing having a front opening, an integral bottom, and side walls, wherein the integral bottom and side walls cooperate to form a cavity in cooperation with the front opening, by placing a cover unit inside the front opening, the cover unit has a flat top surface and substantially fill the front opening, and connect the deck unit to the uninterrupted housing without a bezel. The integral bottom wall has a curved bottom surface., The walls
<td>lateral</td><td colspan="2">are rounded</td><td>of</td><td>such way</td><td>that are part of</td>
<td>surface</td><td>side</td><td>curved</td><td>and</td><td>a notch</td><td>within</td>
<td colspan="2">cavity, an edge</td><td>inside</td><td>of</td><td>the walls</td><td>lateral</td>
One that surrounds and defines the front opening and the flat top surface is substantially flush with a top surface of the inner edge of the side wall and where the deck unit connects to a frame.
Connecting the deck unit to the uninterrupted housing without a bezel can be accomplished by connecting the rack to the housing within the cavity. In the disclosed embodiment, the cover unit includes a display unit having at least one display screen, a cover glass through which the display screen is visible, and a substantially transparent touch-sensitive layer placed between the cover glass and display screen and housing 'is formed from polished stainless steel and the cover unit includes a suitable opening to receive a wire drive.
Contents4
3 priority claims, no other members on record
Priority claims3
| Document | Office | Kind | Date |
|---|---|---|---|
| 20582408 | United States of America | A | |
| 20582608 | United States of America | A | |
| 2009050879 | United States of America | W |
1 legal event, as the office reported them to INPADOC
Events
| Event | Code | |
|---|---|---|
| Grant or registrationFG | FG |
Numbers
- Application
- 2011002425
Titles2
- English
- HANDHELD COMPUTING DEVICE.
- Spanish
- DISPOSITIVO DE COMPUTO PORTATIL.
Classification
- CPC, 11
- G06F1/1626
- H04M1/026
- G06F1/16
- G06F1/1656
- G06F1/182
- H01Q1/243
- H04R1/2811
- H04R17/00
- H04R2499/11
- H04B1/38
- H05K5/00
- IPC, 1
- G06F1 16