Method of manufacturing a handheld computing device

• US 8,146,244 B2
• Filed: 10/13/2010
• Issued: 04/03/2012
• Est. Priority Date: 07/02/2004
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Zadesky, Stephen Paul, Lynch, Stephen Brian
• Primary Examiner(s): Banks, Derris
• Assistant Examiner(s): Carley, Jeffrey T
• Application Number:
  US12/903,944
• Publication Number:
  US 20110023287A1
• Time in Patent Office: 538 Days
• Field of Search: 298/32, 298/54, 298/76, 298/30, 361/679.02, 361/679.09, 361/679.26, 361/679.3, 361/679.56, 174/535, 174/542
• US Class Current: 29/832
• CPC Class Codes: G06F 1/1635 Details related to the integration of battery packs and other power supplies such as fuel cells or integrated AC adapter
• CPC Class Codes: G06F 1/1684 Constructional details or arrangements related to integrated I/O peripherals not covered by groups G06F1/1635 - G06F1/1675
• CPC Class Codes: H04M 1/0202 Portable telephone sets, e.g. cordless phones, mobile phones or bar type handsets constructional features of telephone transmitters or receivers, e.g. of speakers or microphones H04M1/03
• CPC Class Codes: H04M 1/026 Details of the structure or mounting of specific components
• CPC Class Codes: H04M 1/0277 for a printed circuit board assembly
• CPC Class Codes: Y10T 29/49002 Electrical device making
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/4913 Assembling to base an electrical component, e.g., capacitor, etc.
• CPC Class Codes: Y10T 29/49169 Assembling electrical component directly to terminal or elongated conductor
• CPC Class Codes: Y10T 29/49208 by assembling plural parts
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/5313 Means to assemble electrical device

Abstract

A method of manufacturing a handheld computing device that includes an electronic component assembly including at least one user interface component and an enclosure. The enclosure is a tube that is extruded. The extruded tube defines an internal lumen between open ends, and has a substantially uniform cross section along a longitudinal axis thereof. The extruded tube includes a front face, a back face, side portions connecting the front face and the back face, at least one access opening provided on the front face, and a pair of guide rails formed in the lumen along the side portions in parallel with the longitudinal axis. The electronic component assembly is slidably inserted into the lumen along the guide rails. The guide rails support the electronic component assembly and provide a reference surface for positioning the electronic component assembly relative to the front face such that the user interface is placed right behind the access opening to provide user access therethrough.

Claims

1. A method of manufacturing a handheld device, the method comprising:

providing an elongated enclosure having a substantially uniform cross-section along a longitudinal axis thereof, the enclosure defining an internal lumen configured for slidable receipt of at least one electronic component along internal rails formed in the lumen parallel to the longitudinal axis, wherein the enclosure has at least one open end, wherein the enclosure is formed from an extruded tube, the extruded tube having at least one access opening formed on a front face thereof;

assembling electronic components into the extruded tube through the open end by sliding the electronic components along the internal rails, the internal rails providing a reference surface to position the electronic component assembly relative to the front face, wherein the electronic components include a first assembly having a display, and a second assembly having an input device, wherein the first assembly further includes;

a printed circuit board having the display on a top surface thereof; and

a memory component provided on a bottom surface of the printed circuit board, wherein each of the internal rails has a top surface and a bottom surface opposite to the top surface, a pair of the top surfaces defining a top reference surface and a pair of the bottom surfaces defining a bottom reference surface, and wherein assembling the electronic components comprises;

inserting the first assembly into the lumen through a top open end of the extruded tube, the first assembly being positioned by the bottom reference surface such that the display is placed right behind a first access opening and wherein, in inserting the first assembly, the top surface of the printed circuit board abuts the bottom surface of the internal rails; and

inserting the second assembly into the lumen through a bottom open end of the extruded tube, the second assembly being positioned by the top reference surface such that the input device is placed right behind a second access opening; and

covering the open end of the enclosure with an end cap.

2. The method as recited in claim 1, wherein the first assembly further comprises an audio subassembly and a battery provided on the bottom surface of the printed circuit board, and wherein the first assembly is inserted so as to occupy a space between the pair of the internal rails above and below the bottom reference surface beneath the first access opening.

9. The method as recited in claim 1, wherein the electronic components include a first assembly having a display, and a second assembly having an input device,

wherein each of the internal rails has a top surface and a bottom surface opposite to the top surface, a pair of the top surfaces defining a top reference surface and a pair of the bottom surfaces defining a bottom reference surface,

and wherein assembling the electronic components comprises:

inserting the first assembly into the lumen through a top open end of the extruded tube, the first assembly being positioned by the bottom reference surface such that the display is placed right behind a first access opening; and

inserting the second assembly into the lumen through a bottom open end of the extruded tube, the second assembly being positioned by the top reference surface such that the input device is placed right behind a second access opening.

10. The method as recited in claim 9, wherein the second assembly further includes a frame for carrying the input device,

and wherein, in inserting the second assembly, a bottom surface of the frame abuts the top surface of the internal rails.

11. The method as recited in claim 9, wherein the second assembly is inserted in a space between the pair of the internal rails above the bottom reference surface beneath the second access opening, while part of the first assembly is inserted in a space under the bottom reference surface beneath the second access opening.

3. A method of manufacturing a handheld device, the method comprising:

providing an elongated enclosure having a substantially uniform cross-section along a longitudinal axis thereof, the enclosure defining an internal lumen configured for slidable receipt of at least one electronic component along internal rails formed in the lumen parallel to the longitudinal axis, wherein the enclosure has at least one open end, wherein the enclosure is formed from an extruded tube, the extruded tube having at least one access opening formed on a front face thereof, wherein the providing the enclosure formed from an extruded tube further includes;

extruding a tube having the front face, a back face, and side portions connecting the front face and the back face, the pair of internal rails formed in the lumen along the side portions;

cutting the extruded tube to a desired length, forming a top open end and a bottom open end;

forming access openings on the front face of the extruded tube; and

forming a recessed area on a top surface of the extruded tube;

removing a portion of the internal rails from the internal wall of the lumen in a vicinity of the bottom end the extruded tube;

forming slots on the internal wall of the lumen in the vicinity of the bottom open end; and

mounting a window in one of the access openings;

assembling electronic components into the extruded tube through the open end by sliding the electronic components along the internal rails, the internal rails providing a reference surface to position the electronic component assembly relative to the front face, wherein the electronic components include a first assembly having a display and a top plate, and wherein assembling electronic components comprises inserting the first assembly into the lumen through the top open end of the extruded tube, the first assembly being positioned relative to the longitudinal axis by the top plate abutting the recessed area such that the display aligns with a first access opening; and

covering the open end of the enclosure with an end cap.

4. The method as recited in claim 3, wherein the electronic components further include a second assembly having an input device, and the window includes a flange having stop members, and wherein assembling electronic components further comprises:

inserting the second assembly into the lumen through the bottom open end of the extruded tube, the second assembly being positioned relative to the longitudinal axis by abutting the stop members such that the input device aligns with a second access opening.

5. The method as recited in claim 4, wherein the second assembly further includes a tab, and wherein assembling electronic components further comprises:

locking the second assembly by engaging the tab with one of the slots formed on the internal wall of the lumen.

6. A method of manufacturing a handheld device, the method comprising:

providing an elongated enclosure having a substantially uniform cross-section along a longitudinal axis thereof, the enclosure defining an internal lumen configured for slidable receipt of at least one electronic component along internal rails formed in the lumen parallel to the longitudinal axis, wherein the enclosure defines an internal lumen between open ends, the enclosure including at least one access opening provided on a front face of the enclosure, and wherein the lumen is configured to engage with an electronic component to secure it in its desired position within the lumen; and

the method further comprises assembling electronic components into the enclosure through the open ends, wherein at least one electronic component includes at least one user interface component, wherein the at least one electronic component further comprises;

a printed circuit board having a display on a top surface thereof; and

a memory component on a bottom surface of the printed circuit board; and

covering the open ends of the enclosure with an end cap.

7. A method of manufacturing a handheld device, the method comprising:

providing a main body of an elongated enclosure having a substantially uniform cross-section along a longitudinal axis thereof, the main body defining an internal lumen configured for slidable receipt of at least one electronic component along internal rails formed in the lumen parallel to the longitudinal axis, wherein the main body has a first open end and a second open end opposite the first open end and wherein the main body forms a portion of an exterior of the enclosure of the handheld device; and

covering the open ends of the enclosure with end caps.

8. The method as recited in claim 7, wherein the enclosure is formed from an extruded tube, the extruded tube having at least one access opening formed on a front face thereof;

the method further comprises;

assembling electronic components into the extruded tube through an open end by sliding the electronic components along the internal rails, the internal rails providing a reference surface to position the electronic component assembly relative to the front face.

12. The method as recited in claim 8, wherein the providing the enclosure formed from an extruded tube includes:

extruding a tube having the front face, a back face, and side portions connecting the front face and the back face, the pair of internal rails formed in the lumen along the side portions;

cutting the extruded tube to a desired length, forming a top open end and a bottom open end;

forming access openings on the front face of the extruded tube; and

forming a recessed area on a top surface of the extruded tube.

13. The method as recited in claim 12, wherein the electronic components include a first assembly having a display and a top plate, and wherein assembling electronic components comprises:

inserting the first assembly into the lumen through the top open end of the extruded tube, the first assembly being positioned relative to the longitudinal axis by the top plate abutting the recessed area such that the display aligns with a first access opening.

14. The method as recited in claim 7, wherein the enclosure defines an internal lumen between open ends, the enclosure including at least one access opening provided on a front face of the enclosure, and wherein the lumen is configured to engage with an electronic component to secure it in its desired position within the lumen;

and the method further comprises assembling electronic components into the enclosure through at least one of the open ends, wherein at least one electronic component includes at least one user interface component.

15. The method as recited in claim 14, wherein the rails are configured for slidably guiding and receiving an electronic component, wherein the rails support the electronic component and provide a reference surface, the reference surface positioning the electronic component relative to the front face such that the user interface component is positioned behind the access opening to provide user access therethrough.

16. The method as recited in claim 14, wherein providing the elongated enclosure comprises extruding the enclosure.

17. The method as recited in claim 14, further comprising engaging a tab of the electronic component with a recess on an inner wall of the lumen.

18. The method as recited in claim 7, wherein the enclosure includes at least one access opening formed on a front face thereof.

19. The method as recited in claim 18, wherein the at least one electronic component comprises a first assembly having a display and a second assembly having an input device, and wherein the method further comprises positioning the first assembly such that the display is positioned behind a first access opening and positioning the second assembly such that the input device is behind a second access opening.

20. The method as recited in claim 7, wherein each of the internal rails has a top surface and a bottom surface opposite the top surface, a pair of the top surfaces defining a top reference surface and a pair of the bottom surfaces defining a bottom reference surface.

21. The method as recited in claim 7, further comprising:

sliding the electronic component into the lumen; and

after sliding the electronic component into the lumen, engaging a tab on the electronic component with a slot in an inner wall of the lumen before covering the open ends.

22. The method as recited in claim 7, wherein providing the elongated enclosure comprises:

extruding a tube having the front face, a back face, and side portions connecting the front face and the back face; and

cutting the extruded tube to a desired length, forming a top open end and a bottom open end.

23. The method as recited in claim 22, further comprising forming at least one access opening on the front face of the extruded tube.

25. The method as recited in claim 22, further comprising providing a positioning mechanism on the enclosure for positioning an electronic component, wherein the positioning mechanism is a recessed area provided at one of the open ends, wherein the electronic component is attached to a top plate, and wherein a bottom surface of the top plate abuts the recessed area so as to position the electronic component relative to the direction of the longitudinal axis.

24. A method of manufacturing a handheld device, the method comprising:

providing an elongated enclosure having a substantially uniform cross-section along a longitudinal axis thereof, the enclosure defining an internal lumen configured for slidable receipt of at least one electronic component along internal rails formed in the lumen parallel to the longitudinal axis, wherein the enclosure has at least one open end, wherein providing the elongated enclosure comprises;

extruding a tube having the front face, a back face, and side portions connecting the front face and the back face; and

cutting the extruded tube to a desired length, forming a top open end and a bottom open end;

forming at least one access opening on the front face of the extruded tube, wherein the at least one access opening includes a window component including;

a clear window portion; and

a flange portion having a pair of stop members providing a reference surface to position en electronic component relative to the direction of the longitudinal axis; and

covering the open end of the enclosure with an end cap.