Method for forming a housing of an electronic device

• US 8,607,444 B2
• Filed: 09/30/2010
• Issued: 12/17/2013
• Est. Priority Date: 03/06/2010
• Status: Active Grant

• Current Assignee: Apple Inc.
• Original Assignee: Apple Inc.
• Inventors: Jarvis, Daniel W., Zadesky, Stephen Paul, Moolsintong, Pinida Jan, Tan, Tang Yew
• Primary Examiner(s): Nguyen, Donghai D
• Application Number:
  US12/895,822
• Publication Number:
  US 20110215685A1
• Time in Patent Office: 1,174 Days
• Field of Search: 156/242, 264/268, 264/328.1, 345/173, 425/542, 455/575.8, 298/30, 298/31, 298/46, 298/48, 428/156, 428/157, 428/192, 438/57
• US Class Current: 29/830
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29L 2031/3437 Cellular phones
• CPC Class Codes: B32B 37/16 with all layers existing as coherent layers before laminating
• CPC Class Codes: G02F 1/133308 Support structures for LCD panels, e.g. frames or bezels
• CPC Class Codes: H04M 1/0266 for a display module assembly
• CPC Class Codes: H04M 1/0283 for providing a decorative aspect, e.g. customization of casings, exchangeable faceplate
• CPC Class Codes: H05K 5/0017 with operator interface units
• CPC Class Codes: H05K 5/02 Details
• CPC Class Codes: H05K 5/0208 Interlock mechanisms; Means for avoiding unauthorised use or function, e.g. tamperproof
• CPC Class Codes: Y10T 29/49126 Assembling bases
• CPC Class Codes: Y10T 29/49128 Assembling formed circuit to base
• CPC Class Codes: Y10T 29/49158 with molding of insulated base

Abstract

Improved techniques for forming an electronic device housing in which an outer housing member can be assembled with one or more other housing members of the electronic device are disclosed. The one or more other housing members can together with a thin substrate layer (or thin substrate) form a frame to which the outer housing member can be secured. The thin substrate layer facilitates molding of the one or more other housing members adjacent to the outer housing member. In one embodiment, the outer housing member can be made of glass and the one or more other housing members can be made of a polymer, such as plastic. The substrate layer can, for example, be formed of a polymer or a metal. The resulting electronic device housing can be thin yet be sufficiently strong to be suitable for use in electronic devices, such as portable electronic devices.

Claims

1. A method for forming a housing of an electronic device, said method comprising:

forming an adhesive layer on an entire bottom surface of a housing member, wherein the adhesive layer has an area corresponding to a bottom surface area of the housing member;

using the adhesive layer to secure a top surface of a film to the bottom surface of the housing member, the top surface of the film having an area larger than the area of the adhesive layer such that a portion of the top surface remains exposed when the film is adhered to the housing member, wherein the housing member has the bottom surface, a top surface opposite the bottom surface, and a side wall, wherein the top surface and the side wall are separated by a top engaging surface and the bottom surface and the side wall are separated by a bottom engaging surface, wherein the top and bottom engaging surfaces define external shapes of corresponding top and bottom retaining members;

engaging a molding compound with the top and bottom engaging surfaces and with at least a portion of the exposed surface of the film while the top surface of the housing member remains exposed; and

forming the top and bottom retaining members by curing the engaged molding compound such that the top and bottom retaining members lock the housing member in place.

2. A method as recited in claim 1, wherein the housing member is a glass window, and wherein the thickness of the window is about 0.4-2.5 mm.

3. A method as recited in claim 1, wherein the thickness of the housing member is not more than about 1 mm.

4. A method as recited in claim 1, wherein the thickness of the film is about 0.1-0.5 mm.

5. A method as recited in claim 1, wherein the film is formed from a clear polymer.

6. A method as recited in claim 1, wherein a portion of the second retaining member is molded on and engaged with the portion of the exposed surface of the film substrate.

7. A method as recited in claim 6, wherein the adhesive layer is optically clear liquid adhesive.

8. A method as recited in claim 1, wherein the electronic device is a handheld electronic device.

9. A method as recited in claim 1,

wherein the housing member includes at least a top surface and a bottom surface, wherein the film includes at least a top surface and a bottom, and wherein the securing comprises:

securing at least a portion of the bottom surface of the housing member to at least a portion of the top surface of the film.

10. A method as recited in claim 9, wherein an adhesion of the bottom surface of the housing member to the film is greater than an adhesion of the top and bottom engaging surfaces to corresponding top and bottom retaining members.

11. A method as recite in claim 1, wherein the method comprises:

depositing a cosmetic layer on at least a portion of the film.

12. A method as recite in claim 1, wherein the method comprises:

printing a layer of ink on at least a portion of the top surface of the film.

13. A method as recited in claim 1, wherein the housing member is optically clear.

14. A method as recited in claim 1, wherein the film at least partially secures the housing member to the bottom retaining member.

15. The method as recited in claim 1, wherein the top retaining member prevents disengagement from the housing member in a first direction and the bottom retaining member prevents disengagement from the housing member in a second direction opposite the first direction.

16. A method of forming a housing for an electronic device, comprising

forming a layer of adhesive on an entire bottom surface of a window, wherein the layer of adhesive has an area corresponding to a bottom surface area of the window;

securing the window to a top surface of a film substrate using the layer of adhesive, the top surface of the film substrate having an area larger than the area of the layer of adhesive such that a portion of the top surface remains exposed when the film substrate is adhered to the window, wherein the window has the bottom surface, a top surface opposite the bottom surface, and a side wall, wherein the top surface and the side wall are separated by a top engaging surface and the bottom surface and the side wall are separated by a second engaging surface, wherein the first and second engaging surfaces define first and second retaining surfaces of a retaining member; and

forming the first and second retaining surfaces by molding the retaining member on at least the first and second engaging surfaces, respectively, while the top surface of the window remains exposed, wherein the first and second retaining surfaces cooperate to lock the window within the retaining member, wherein a portion of the second retaining member is molded on and engaged with at least a portion of the exposed surface of the film substrate.

17. A method as recited in claim 16, wherein the window comprises a glass cover window.

18. A method as recited in claim 17, wherein the thickness of the glass cover window is about 0.4-2.5 mm.

19. A method as recited in claim 18, wherein the thickness of the film substrate is about 0.1-0.5 mm.

20. A method as recited in claim 17, wherein the film substrate is formed of a metal having an opening adjacent a central region of the glass cover window.

21. A method as recited in claim 16, wherein the electronic device comprises:

a LCD module provided internal to the device housing and adjacent a bottom surface of the film substrate.

22. A method as recited in claim 21, wherein the width of the LCD module is substantially the same as the width of the window.

23. A method as recited in claim 16, wherein the window is secured to the device housing without requiring an internal support flange.

24. A method as recited in claim 16, wherein the film substrate is formed of a polymer.

25. The method as recited in claim 16, wherein the first retaining surface prevents disengagement from the window in a first direction and the second retaining surface prevents disengagement from the window in a second direction opposite the first direction.

26. A method for assembling a device housing of an electronic device, said method comprising:

forming an adhesive layer on an entire bottom surface of a window, wherein the adhesive layer has an area corresponding to a bottom surface area of the window;

securing a top surface of a metal substrate to the bottom surface of the window using the adhesive layer, the top surface of the metal substrate having an area larger than the area of the adhesive layer such that a portion of the top surface remains exposed when the metal substrate is adhered to the window, the metal substrate having a central opening aligned with a central portion of the window, the window having the bottom surface, top surface opposite the bottom surface, and a side wall, wherein the top surface and the side wall are separated by a top engaging surface and the bottom surface and the side wall are separated by a bottom engaging surface, wherein the top and bottom engaging surfaces define external shapes of corresponding top and bottom retaining members; and

engaging a molding compound with the top and bottom engaging surfaces and with at least a portion of the exposed surface of the metal substrate while the top surface of the window remains exposed; and

forming the top and bottom retaining members by curing the engaged molding compound such that the top and bottom retaining members lock the housing member in place.

27. A method as recited in claim 26, wherein the window is comprised of glass.

28. A method as recited in claim 26, wherein the thickness of the window is equal to or less than about 1 mm.

29. A method as recited in claim 26, wherein the thickness of the metal substrate is about 0.1-0.5 mm.

30. The method as recited in claim 26, wherein the top retaining member prevents disengagement from the window in a first direction and the bottom retaining member prevents disengagement from the window in a second direction opposite the first direction.