HK1159800B - Assembly of a display module - Google Patents

Description

Assembly of display module

Technical Field

The described embodiments relate generally to portable computing devices, such as laptop computers, tablet computers, and the like. More particularly, packaging of portable computing devices and methods of assembling portable computing devices are described.

Background

In recent years, portable computing devices, such as laptop computers, PDAs, media players, cellular telephones, and the like, have become small, lightweight, and powerful. While increasing the capacity and/or operating speed of such components in most cases, one factor contributing to this reduction in size can be attributed to the ability of manufacturers to manufacture the various components of these devices in increasingly smaller sizes. The trend to be smaller, lighter, and more powerful presents a continuing design challenge to the design of some components of portable computing devices.

One design challenge associated with portable computing devices is the design of the packaging used to house the various internal components. Such design challenges are often caused by a number of conflicting design goals, including appeal to make the package lighter and thinner, appeal to make the package stronger, and appeal to the aesthetics of the package. Lighter packages (which typically use thinner plastic structures and fewer fasteners) tend to be more flexible and therefore more pliable in use, while stronger and more rigid closure packages (which typically use thicker plastic structures and more fasteners) tend to be thicker and heavier. Unfortunately, however, the weight increase with a more robust package can lead to user dissatisfaction, while the flexing of the package formed from a lightweight material can lead to damage to some of the internal components of the portable device (e.g., the printed circuit board).

Further, a package is a mechanical assembly having multiple parts that are screwed, bolted, riveted, or otherwise fastened together at discrete points. These assembly techniques generally complicate the housing design and create aesthetic difficulties due to undesirable cracks, seams, gaps, or breaks at the mating surfaces and fasteners disposed along the housing surfaces. For example, when using an upper housing and a lower housing, a mating line is created around the entire package. Moreover, the various components and complex processes for manufacturing portable devices can make assembly a time consuming and cumbersome process requiring, for example, highly trained assembly operators to work with special tools.

Another challenge relates to techniques for mounting structures in portable computing devices. Conventionally, structures have been put on a housing (upper or lower housing) and attached to a housing with fasteners such as screws, bolts, rivets, etc. That is, the structure is layered on the shell in a sandwich-like manner and then fastened to the shell. This method has the disadvantage, as mentioned above, that the assembly is a time consuming and cumbersome process.

In view of the foregoing, there is a need for improved component density and associated assembly techniques that reduce costs and improve output quality. Furthermore, improvements in the way handheld devices are assembled, such as improvements that enable the structure to be quickly and easily installed into a package, are needed. It is also desirable to minimize the Z-stack height of the assembled components in order to reduce the overall thickness of the portable computing device and thereby improve the overall aesthetics and feel of the product.

Disclosure of Invention

A portable computing device is disclosed. The portable computing device may take many forms, such as a laptop computer, a tablet computer, and so forth. The portable computing device may include at least a single piece housing. The one-piece housing may be used to enclose and support a plurality of operational components, such as a display module, to provide a desired set of functions.

In certain embodiments, the display module may include a protective glass cover bonded to the display frame and surrounded by a seal coupled to the display frame. The display module may include a touch screen mounted under a protective glass cover. Further, a display panel housing including a display panel and its associated circuitry may be mounted to the display frame such that the display panel is visible through the protective glass cover.

In other embodiments, the display module may be secured to the one-piece housing by a plurality of metal clips secured to the display frame. The metal clip may secure the display module to the metal housing in a manner that allows the display module to move relative to the one-piece housing during an impact event. The display panel housing may be suspended from the display frame using a plurality of mounting tabs. The display panel and the display panel housing may be rectangular. The mounting tabs may be fixed to the display panel housing on only the short sides of the display panel housing, thereby providing the maximum bending length for the display panel. The number of mounting tabs may be selected to allow movement of the display panel housing relative to the display frame.

The display frame may be formed by first providing a plastic display frame and a plurality of inserts. The insert may be made of metal or polymer (e.g., IXEF)^TM) And (4) forming. A combination of metal and polymer inserts may be coupled to the plastic frame and then additional layers of plastic may be added to bond the inserts to the plastic display frame. The insert may be placed at a location where additional structural support is needed, such as adjacent to an opening in the single piece housing.

Drawings

The embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

FIG. 1A illustrates a top view of a portable computing device in accordance with the described embodiments.

FIG. 1B illustrates a perspective top view of a portable computing device in accordance with the described embodiments.

FIG. 2 illustrates a perspective top view of an insert and display frame prior to assembly according to the described embodiments.

FIG. 3 illustrates a perspective top view of a seal frame and a display frame assembled with an insert prior to assembly according to described embodiments.

FIG. 4 illustrates a perspective top view of a display frame assembled with a sealing frame according to described embodiments.

FIG. 5 illustrates a top perspective view of a display frame assembled with a seal, protective top glass, and mounting clip according to described embodiments.

FIG. 6 illustrates a bottom perspective view of mounting a display panel housing to a protective top glass and frame assembly according to described embodiments.

FIG. 7A illustrates a cross-sectional view of a portable computing device with a display frame and a display panel in an assembled position, according to described embodiments.

FIG. 7B illustrates a cross-sectional view of a portable computing device with a display module in a pre-assembled position, in accordance with the described embodiments.

FIG. 8 illustrates a side view of a mounting mechanism in accordance with the described embodiments.

FIG. 9 shows a side view of a clip (texture) assembly according to the described embodiments.

FIG. 10 is a flow chart of a method for assembling a display frame that includes securing a protective glass layer to the display frame.

FIG. 11 is a flow chart of a method for integrating a display module into a portable computing device.

Detailed Description

In the following description, numerous specific details are set forth in order to provide a thorough understanding of the concepts underlying the described embodiments. It will be apparent, however, to one skilled in the art, that the described embodiments may be practiced without some or all of these specific details. In other instances, well known process steps have not been described in detail in order to avoid unnecessarily obscuring the underlying concepts.

An aesthetically pleasing portable computing device that is easily held with one hand and operated with the other is discussed herein. The portable computing device may be constructed of a single piece seamless housing and a pleasing protective top layer in appearance, wherein the protective top layer may be constructed of any of a variety of durable, strong, yet transparent materials, such as highly polished glass or plastic. However, for the remainder of this discussion, the protective top layer may take the form of a highly polished cover glass without any loss of generality. Furthermore, because (unlike conventional portable computing devices) the cover glass can be mounted to a single seamless housing without the use of a bezel, the consistency of the appearance of the portable computing device can be enhanced. The simplicity of this design may also yield many advantages for portable computing devices, in addition to those associated with aesthetics and feel. For example, fewer parts and less time and effort are required for assembly of the portable computing device, and the absence of a gap in the single piece housing may provide good protection of the internal components from environmental contamination. Moreover, the ability of the portable computing device to successfully withstand applied loads (e.g., loads from everyday use) and those from less frequent but potentially more damaging events (e.g., falls) may be radically improved over conventional portable computing devices.

In the described embodiments, the single piece seamless housing may be formed of plastic or metal. Where the single piece seamless housing is formed of metal, the metal may take the form of a single piece (e.g., aluminum). The single piece of metal may be formed into a shape suitable for housing various internal components and providing various openings into which switches, connectors, displays, etc. may be received. The single piece seamless housing may be forged, die cast or otherwise machined to a desired shape. The shape of the housing may be asymmetric, wherein the upper portion of the housing may be formed to have a shape that is completely different from the shape assumed by the lower portion of the housing. For example, the upper part of the housing may have surfaces meeting at a well-defined angle (discontinuity angle) to form a well-defined boundary, while the lower part may be formed as a surface having a rack (spline) shape. The transition area between the upper portion with a sharp edge and the lower portion with a rack shape may take the form of an edge with a rounded shape in order to provide a natural variation from the upper portion of the housing (i.e. the area of the sharp edge) and a smoother surface given by the lower portion of the housing. It should be noted that in addition to providing a more pleasing transition in appearance, the rounded shape of the edges in the transition area may also provide a more comfortable feel when held in a user's hand or simply carried around during use. One advantage of using metal for the housing is the ability of the metal to provide good electrical grounding for any internal components that require a good ground plane. For example, the performance built into an RF antenna may be fundamentally improved when a good ground plane is provided. Moreover, a good ground plane may be used to help mitigate deleterious effects due to, for example, electromagnetic interference (EMI) and/or electrostatic discharge (ESD).

It should be noted that throughout the following discussion, the term "CNC" is used. The abbreviation CNC stands for computer numerical control and refers specifically to the computer controller that reads computer instructions and drives the machine tool (the power machine equipment typically used to manufacture parts by selective removal of material). However, it should be noted that any suitable machining operation may be used to implement the described embodiments, and is not strictly limited to those practices associated with CNC.

These and other embodiments are discussed below with reference to fig. 1-10. However, those skilled in the art will readily appreciate that the detailed description given herein with respect to these figures is for explanatory purposes only and should not be construed as limiting. In particular, with reference to fig. 1A and 1B, a portable computing device is described. In fig. 2 through 6, various stages of assembling display components associated with a portable computing device are described. In fig. 7A-7B, securing an assembled display component to a portable computing device housing is discussed. In fig. 8, an alternative coupling mechanism for securing the assembled display component to a portable computing device housing is discussed. In fig. 9 and 10, a clip assembly and method of securing a protective top glass to a display frame and seal assembly using the clip assembly is described. In fig. 11, a method of assembling a portable computing device is described.

FIG. 1A illustrates a particular embodiment of a portable computing device 100. More specifically, fig. 1A shows a full top view of the fully assembled portable computing device 100. The portable computing device 100 may process data, and more particularly media data, such as audio, video, images, and so forth. By way of example, the portable computing device 100 may generally correspond to a device executable as a music player, a game player, a video player, a Personal Digital Assistant (PDA), a tablet computer, and so forth. In the case of handheld, the portable computing device 100 may be held by a user in one hand and operated with the user's other hand (i.e., without requiring a reference plane such as a desktop). For example, a user may hold the portable computing device 100 in one hand and operate the portable computing device 100 with the other hand, such as by operating a volume switch, a hold switch, or by providing input to a touch-sensitive surface such as a display or panel.

The portable computing device 100 may include a single piece seamless housing 102, where the housing 102 may be formed from any number of materials (e.g., plastic or metal) that may be forged, molded, or otherwise machined to a desired shape. In those instances where the portable computing device 100 has a metal housing and incorporates RF-based functionality, it may be advantageous to provide at least a portion of the housing 102 in the form of a radio (or RF) transparent material (e.g., ceramic or plastic). In any case, the housing 102 can be configured to at least partially enclose any suitable number of internal components associated with the portable computing device 100. For example, the housing 102 may enclose and internally support various structural and electrical components (including integrated circuit chips and other circuitry) to provide computing operations for the portable computing device. The integrated circuit may take the form of a chip, chipset, module, any of which may be surface mounted to a printed circuit board (or PCB) or other support structure. For example, a Main Logic Board (MLB) may have an integrated circuit mounted thereon, where the integrated circuit may include at least a microprocessor, a semiconductor (e.g., FLASH) memory, various support circuits, and the like.

The housing 102 may include an opening 104 for placement of internal components and may be sized to receive a display assembly or system adapted to provide at least visual content to a user, such as through a display. In some cases, the display system may include touch sensitive capabilities, thereby providing the user with the ability to provide tactile input to the portable computing device 100 using touch input. The display system may be formed of multiple layers, including being the uppermost layer of transparent protective layer 106, where transparent protective layer 106 is formed of polycarbonate or other suitable plastic or highly polished glass. With a highly polished glass, the protective layer 106 may take the form of a cover glass 106 that substantially fills the opening 104. The seal 108 may be used to form a gasket between the cover glass 106 and the housing 102. The seal 108 may be formed of an elastomeric material such as plastic along the thermoplastic urethane or TPU family. In this way, the seal 108 may provide protection from environmental contaminants entering the interior of the portable computing device 100. A racetrack 110 may be defined as the uppermost portion of the housing 102 that surrounds the cover glass layer 106. To maintain the desired aesthetics and feel of the portable computing device 100, it is desirable that any offset between the housing 102 and the cover glass 106 be minimized by centering the racetrack 110.

Although not shown, a display panel located below the cover glass 106 may be used to display images using any suitable display technology (e.g., LCD, LED, OLED, electronic ink, etc.). The display assembly may be placed and secured into the cavity using a variety of mechanisms. In one embodiment, the display system is locked (snap) into the cavity. It may be placed flush with the adjacent portion of the housing. As such, the display may present visual content, which may include video, still images, and icons such as Graphical User Interfaces (GUIs) that may provide information (e.g., text, objects, graphics) to the user, and may also receive input provided by the user. In some cases, the displayed icons may be moved by the user to a more convenient location on the display. For example, the GUI may be moved by the user manually dragging it from one location to a more convenient location. The display may also provide tactile feedback to the user provided by a variety of haptic actuators, which are typically, but not always, arranged in an array of haptic actuators incorporated into the display. In this way, the haptic actuator may provide tactile feedback to the user.

In some embodiments, a display cover (not shown) may be applied to or incorporated into or under cover glass 106. The display cover may be used to emphasize an uncovered portion of the display for presenting visual content. The display cover may be used to make the home button 112 less obvious, where the home button 112 is used to provide specific inputs, such as changing display modes, to the portable computing device 100, for example. The display cover may make the home button 112 less visible by, for example, the hue or color closer to the home button 112. For example, if the home button 112 is formed of a material that is darker (e.g., gray or black) than the cover glass 106, using a similarly colored display cover may reduce the visual impact of the home button 112 when compared to the uncovered portion of the cover glass 106. In this way, the visual impact of the home button 112 may be reduced by being integrated into the overall appearance of the display cover. In addition, the display cover may also provide a natural mechanism for directing the viewer's attention to the uncovered area of the display for presenting visual content.

The portable computing device 100 may include a variety of mechanical controls for controlling or otherwise modifying certain functions of the portable computing device 100. For example, the power switch 114 may be used to manually power on or off the portable computing device 100. The mute button 116 may be used to mute any audio output provided by the portable computing device 100, while the volume switch 118 may be used to increase/decrease the volume of the audio output of the portable computing device 100. It should be noted that each of the input mechanisms described above are generally disposed in the housing 102 through an opening so that they may be coupled to internal components. In some embodiments, the portable computing device 100 may include a camera module configured to provide still or video images. The placement may vary widely and may include one or more locations, including, for example, the front or back of the device, i.e., one through the back housing and the other through the display window.

The portable computing device 100 may include mechanisms for wireless communication, as a transceiver-type device or simply as a receiver, such as a radio. The portable computing device 100 may include an antenna that may be positioned inside a radio-transparent portion of the housing 102. In some embodiments, the antenna may be incorporated into the seal 108 or cover glass 106. In other embodiments, a portion of the housing 102 may be replaced with a radio transparent material in the form of an antenna window as described in more detail below. The radio transparent material may comprise, for example, plastic, ceramic, etc. The wireless communication may be based on many different wireless protocols including, for example, 3G, 2G, bluetooth, RF, 802.11, FM, AM, and so forth. Any number of antennas may be used, and a single window or multiple windows may be used depending on the needs of the system. In one embodiment, the system may include at least first and second antenna windows built into the housing.

FIG. 1B illustrates a perspective top view of the portable computing device 100, in accordance with the described embodiments. As shown in fig. 1B, the portable computing device 100 may include one or more speakers 120 for outputting audio sounds. The portable computing device 100 may also include one or more connectors for transferring data and/or power to the portable computing device 100 and from the portable computing device 100. For example, the portable computing device 100 may include multiple data ports, one for each configuration of portrait mode and landscape mode. However, the presently described embodiment includes a single data port 122, which data port 122 may be formed by a connector assembly 124 received in an opening formed along a first side of the housing 102. In this way, when the portable computing device 100 is mounted to a docking station (docking station), the portable computing device 100 may use the data port 122 to communicate with external devices. It should be noted that in some cases, the portable computing device 100 may include an orientation sensor or accelerometer that may sense the orientation or movement of the portable computing device 100. The sensor may then provide an appropriate signal that will cause the portable computing device 100 to present the visual content in the appropriate orientation.

The connector assembly 124 may be any size deemed suitable, such as a 30-pin connector. In some cases, the connector assembly 124 may function as both a data port and a power port, thereby avoiding the need for a separate power connector. The connector assembly 124 may vary widely. In one embodiment, the connector assembly 124 may take the form of a peripheral bus connector, such as a USB or FIREWIRE connector. These types of connectors include both power and data functionality, thereby allowing power transfer and data communication between the portable computing device 100 and a host device when the portable computing device 100 is connected to the host device. In some cases, the host device may provide power to the media portable computing device 100, which may be used to operate the portable computing device 100 and/or to charge a battery included therein while operating.

FIG. 2 illustrates a perspective top view of the display frame 200 and the inserts 202, 204, 206, 208, and 210 prior to assembly. The display frame 200 may be formed of a material such as plastic or metal. For example, the display frame may be formed using thermoplastic urethane or TPU. The insert may be used to provide additional structural support and reinforcement in the area of the display frame proximate the opening in the housing 102 (see fig. 1A and 1B). For example, insert 202 is adjacent to the opening of the mechanism for power on or off, insert 204 is adjacent to the opening of the mechanism for enabling activation of the mute function and the volume control, insert 206 is adjacent to the opening for the multi-pin connector, and insert 210 is adjacent to the opening for the audio output interface, microphone, and start switch.

In certain embodiments, the insert 208 may be eliminated. When included, the insert 208 may provide structural support to the opening. The openings may be associated with a number of different functions. For example, the opening may be used to provide audio output from an internal speaker, to insert or remove a Sim card, to provide external access to an external power supply and/or data pin connector, to provide support for a docking interface, and to provide access to additional actuators (e.g., switches or buttons).

In general, the number, placement, and size of the inserts may vary and are not limited to the example of FIG. 2. For example, in one embodiment, the opening and its associated insert 208 may be eliminated, as described above. In other embodiments, the openings for the mute and volume control mechanisms may be removed from the corners, thereby changing the position of the display frame 200 and the insert 204 to accommodate different positions of the openings. In another example, the insert 206 may be increased in size to accommodate multiple connectors, such as separate power and data connectors.

The insert may be formed of a rigid material, such as a metal (e.g., stainless steel or magnesium), into a suitable shape. In one embodiment, the insert may be made of a polymer (e.g., IXEF manufactured by Solvay Advanced Polymers, LLC)^TM) And (4) forming. As shown in fig. 3, the insert may be incorporated into the display frame 200. In one embodiment, the insert may be mechanically locked into place. In another embodiment, an adhesive such as epoxy may be used to attach the insert to the display frame.

In yet another embodiment, when a metal insert is used with the plastic display frame 200, the insert may be loaded into a molding tool to form an integral assembly (e.g., a plastic/metal assembly). After the display frame 200 and the insert are formed, the insert may be incorporated into the display frame 200, and the combined assembly may be loaded to an over mold (over mold) tool. The molding tool may be used to apply an additional plastic layer that bonds the insert to the display frame 200. When the insert is integrated into the display frame in this manner, a plurality of holes can be designed in the insert with the addition of additional plastic to improve adhesion between the insert material and the display frame material.

Fig. 3 illustrates a perspective top view of the seal frame 108 before assembly and the display frame 200 with the insert assembled according to the described embodiments. Fig. 4 illustrates a perspective top view of a display frame 200 assembled with a sealing frame 108 according to the described embodiments. In one embodiment, the seal 108, when coupled to the display frame 200 (see FIG. 4), may rest on a ledge 205b around the outer perimeter of the display frame. The seal 108 may include a ledge 205a around its perimeter, the ledge 205a resting on the ledge 205b when the two components are sealed to each other.

In certain embodiments, the seal may include a gap, such as 201, that allows components, such as mounting tabs (see fig. 5 and 6), secured to the display frame 200 to extend from the display frame 200. The seal 108 may also include a gap associated with the opening in the housing 102 (see, e.g., the description of the insert with respect to fig. 2 and 3). The seal 108 may have a portion such as 203 that includes a post and ledge that overhangs the top surface of the seal. The posts may align with recesses in the display frame 200 to form a conformal fit (conforma fit) and prevent the seal from sliding relative to the display frame 200. When the seal 108 is coupled to the display frame 200 (see fig. 4), portions such as 203 may extend below the display frame 200 (see the cross-sectional view of fig. 7). For example, portions of the seal 108 may be located below the ledge 205b on the display frame 200. In particular embodiments, the seal 108 may be coupled to the display frame using an adhesive such as epoxy, using fasteners such as screws, or a combination of both.

In fig. 4, the assembled seal 108, display frame 200 and insert are shown. A protective top glass layer may be placed over the assembly. FIG. 5 illustrates a perspective top view of display frame 200 assembled with seal 108, protective top glass 106, and mounting clip 212 according to the described embodiments. The top glass 106 is mounted to the display frame 200, the insert and the seal 108 as shown in fig. 4. A method of mounting the top glass 106 to the display frame 200 is described with reference to fig. 9 and 10. The top glass 106 includes holes 214 for the buttons 112 (see fig. 1A and 1B).

Mounting clip 212 is attached to display frame 200. In one embodiment, mounting clip 212 is coupled to display frame 200 using fasteners, such as screws. Mounting clips 212 may be used to secure the display component shown in fig. 5 in housing 102. Details regarding the display components of the housing 102 and mounting clip 212 are described with reference to fig. 7A.

FIG. 6 illustrates a top perspective view of mounting a display panel housing 220 to a protective top glass and frame assembly according to the described embodiments. As shown in fig. 7, the display panel housing 220 may support and secure a display panel 224 and associated display circuitry 226. The touch screen 222 may be mounted underneath the protective top glass 106. As previously described, the mounting clip 212 may be secured to the display frame 200 via a fastener such as 216.

As described in more detail with reference to fig. 7A, the display panel housing 220 is suspended below the display frame 200 when assembled. The display panel housing 220 includes a plurality of mounting tabs, e.g., 219, having apertures. Fasteners 218 may pass through holes in the mounting tabs and secure to corresponding mounting posts in the display frame 200. In one embodiment, the display panel 224 in the housing 220 may be attached to the bottom of the touch screen 222 using a suitable fixing agent (e.g., epoxy or adhesive tape). The display panel 224 may also be sealed to the back of the protective layer with a gasket, such as 223, which may be adhered to the display with an adhesive material.

In an impact event, such as a fall to a portable computing device, impact stress may be distributed throughout the portable computing device. During an impact event, the stress load experienced by each component may depend on the direction of the impact and how each component is coupled to each other. For example, the mounting tabs 219 are coupled to the display panel housing 220, and the display panel 224 and associated circuitry are coupled to the display frame 200. The coupling between the display panel housing and the display frame may be tighter or looser depending on the number of mounting tabs used. Generally, the tighter the coupling between two components, the more the two components tend to move as a single unit. Tighter couplings may be achieved by employing more mounting tabs, such as 219, between the display panel housings 220, while looser couplings may be achieved by employing relatively fewer mounting tabs.

In the event of an impact, it was found that providing the display panel 224 with greater flexibility reduces the likelihood of stress cracks forming in the display panel 224. In one embodiment, the display panel housing 220 is coupled to the display frame 200 only at the ends to provide more flexibility. The display panel housing 220 is approximately rectangular and the mounting tabs are placed on the short sides, thereby providing a greater distance between the mounting tabs on both sides where the mounting tabs are placed. Thereby, during an impact event, deflection may occur over a greater length and the stress may be more spread out.

It has also been found that placing the field joints 219 in a lower stress region tends to reduce the likelihood of stress cracks forming on the panel during an impact event. The stress distribution of the display panel housing 220 and its associated components may be predicted for different impact events to determine the optimal location for placing the mounting tabs. In another embodiment, mounting tabs such as 219 may be placed in areas where lower stresses are predicted than other areas so that less stress is transferred from the display frame 200 to the display panel housing 220. In addition, the total number of mounting tabs may be reduced to reduce the coupling between the display frame 200 and the display panel housing 220. For example, there are no mounting tabs on two sides of the display panel housing 220, and the number of mounting tabs on other sides, such as the three mounting tabs 219 shown on each side in fig. 6, may be reduced.

FIG. 7A illustrates a cross-sectional view of a portable computing device having a display module 225 including a display frame 200 and a display panel 224 in an assembled position in a housing 102. The display module 225 is assembled from the components shown in fig. 6. The display panel housing 220 includes a frame or one or more brackets for securing the display panel 224 and the display circuitry 226. The seal 108 on the frame is shown in contact with the lip 228 of the housing 102. In the assembled position, the display panel housing 220 and its associated display components hang or hang from the display frame 200 when the device 100 is facing upward (i.e., the protective top glass 106 is facing upward).

To install the display module 225 into the housing 102, the mounting clips 212 (see fig. 5 and 6) distributed around the perimeter of the display frame 200 compress toward the display frame 200, allowing the mounting tabs 212 to move past the lip 228 of the housing. Once the top of the mounting clip 212 clears the lip 228, the mounting tabs may expand outward under the lip 228 and into the recesses 227 of the display housing 102. In the extended position, a mounting clip such as 212 may prevent the display frame 200 and its associated components from being removed from the housing 102. Further details of mounting the display module 225 into a housing are described with reference to fig. 7B.

In a particular embodiment, the notch may be formed by removing a rectangular portion of the housing 102. The width of the notch may be wider than the width of the lip 212 to accommodate the mounting clip 212. A plurality of recesses may be formed around the perimeter of the housing 212 to accommodate each mounting clip 212. The number of mounting clips, and thus the number of recesses formed in the housing between different designs, may vary.

A compressive force such as 229 may be used to keep the protective top glass flush with the top of the enclosure. These forces may be applied to the display frame 200 or other components coupled to the display frame 200, such as the display frame enclosure 220. A force such as 229 may be applied at multiple locations throughout the device 100 and is not limited to the locations indicated by 229. By way of example, in some locations, display frame 200 or its associated components may be in contact with foam or other material (e.g., high strength foam) that is under compression. The material may be placed in compression when display frame 200 is inserted into housing 102.

The compressed material may apply a compressive force upward toward the display frame 200. The compressive force may cause the mounting clips such as 212 to move or expand outward (i.e., toward the housing 102). In another embodiment, one or more springs (not shown) may be employed to provide a compressive force directly to the display frame 200, or the force may be provided through one or more intermediate components linked to the display frame 200. For example, the springs may be located under components that are below the display frame 200. The spring may be oriented to press upward against the component and toward the display frame 200. The member may be in contact with the display frame 200 to transmit a compressive force from the spring to the display frame 200 through the member.

During a fall event, the seal 108 and/or mounting clip such as 212 may allow some lateral movement and provide some force damping. For example, when a force is applied in direction 231, seal 108 and possibly one or more mounting clips such as 212 may be compressed, thereby absorbing a portion of the force. One or more mounting clips on the opposite side (not shown) may be flared or stretched, i.e., elongated. The mounting clip expands outward on the opposite side to hold the display assembly in place. After seal 108 and/or mounting clip 212 are not compressed, the display frame may move in the direction opposite force 231. This type of interaction involving compression and subsequent expansion of the seal 108 and movement of the mounting clip can occur for any resultant force parallel to the top surface of the protective glass 106 (e.g., a resultant force in the opposite direction of 231 or a resultant force perpendicular to 231 (i.e., into the page)).

FIG. 7B illustrates a cross-sectional view of the portable computing device 100 with the display module 225 in a pre-assembled position, according to the described embodiments. During assembly of the display module 225 to the housing 102, a gasket such as 241 may be inserted between the housing 102 and the mounting clip. A spacer such as 241 holds the mounting clip in the compressed position 212 a. In one embodiment, multiple shims may be employed, such as one shim per mounting clip. In other embodiments, a single spacer may be employed for multiple mounting clips. For example, a single spacer may be employed to compress all mounting clips onto one side of the display module 225. In yet another embodiment, a gasket tool along the inner periphery of the housing 102 near the lip 228 may be employed to compress all of the gaskets at once. The shim tool may be removed as a single piece to allow the mounting clip to be engaged.

The display module 225 may be connected to electronic components within the portable device, and the display module 225 may be tested prior to removing the spacer (e.g., 241) to allow the mounting clip, such as 212a, to engage. In addition to the display module 225, other electronic internal components (e.g., a main logic board) may also be tested, since once the display module 225 is installed, it is no longer possible to directly access many of the internal components. Once it is determined that the display module and/or electronic components operate acceptably, the spacer may be removed. The test method is described in more detail with reference to fig. 11.

After the spacer is removed and the mounting clip is expanded into place, the display module 225 and other internal components may be retested. If it is determined that a fault exists, the display module 225 must be removed from the housing 102. An upward force may be applied to pull the display module 225 away from the housing. In one embodiment, an upward force may be applied using a device such as suction cup 243.

In certain embodiments, an upward force may be applied on the display module until one or more mounting clips are broken. For example, an upward force may be applied to one corner of the display module, and the mounting clips may be broken in a zipper-like manner (i.e., one at a time). When enough mounting clips are broken (it is not necessary to break all the mounting clips to remove the display module 225), the display module 225 may be removed from the housing. After the display module 225 is removed, the broken mounting clip portion can be removed from the interior of the housing 102 and the required repair can be determined. If the display module 225 is functioning properly, a new mounting clip may be installed in the display module 225 and the display module 225 may be reinstalled. In some embodiments, the display module 225 may be removed without breaking the mounting clip. An example of this is described below with reference to fig. 8.

FIG. 8 illustrates a mounting mechanism 232 according to the described embodiment. The mounting mechanism 232 includes three trace portions (e.g., 231) that are in contact with the trace 234 and are configured to move along the trace 234. Two bump portions such as 210 are disposed between the three trace portions. The mounting mechanism may be a sheet, such as a metal sheet, having a width and a thickness. The sheet may be bent or contoured to form 232 or some shape that approximates 232. The mounting mechanism is shown in an unloaded configuration 230a and a loaded configuration 230 b.

The mounting mechanism can be configured such that when a force such as 236 is applied and the mounting mechanism is loaded, the raised portion flattens and the mounting mechanism elongates. Elongation of the mounting mechanism causes the end trace portions to move outwardly and slide along traces 234. After unloading the mounting mechanism 232, it can be designed to return to its unloaded configuration 230a, in which the height of the bumps is increased and the end trace portions move inward to allow the mounting mechanism to shorten.

In one embodiment, the mounting mechanism 232 may be used as an alternative to mounting clips such as 212, or may be used in conjunction with mounting clips such as 212 (see fig. 7A and 7B). Like mounting clip 212, mounting mechanism 232 may be disposed on a side of display frame 225. Referring to fig. 7B, in the unloaded position, the mounting mechanism 232 may protrude beyond the housing lip 228 prior to mounting the display module 225. A load may be applied to the mounting mechanism 232 to flatten it and allow the display module 225 to slide over the lip 228.

After passing over the lip 228, the load can be removed from the mounting mechanism. The mounting mechanism 232 then expands to lock the display module 225 in place. For example, the mounting mechanism 232 may be located in the recess 227 when expanded. In this example, rather than forming a separate recess for each projection, recess 227 could also be a slot that receives two projections of mounting mechanism 232.

The display module 225 may be removed after having been installed into the housing 102. With a mounting mechanism such as 232, the display module 225 may be removed by inserting a thin strip such as a thin metal blade between the seal 108 and the lip 228. A thin strip may be inserted between the protrusions of the mounting mechanism 232. The thin strip can be slid to one side or the other to load and flatten one protrusion of the mounting mechanism, which flattens the other protrusion. When the mounting mechanism is flattened, the display module 225 can be lifted such that the mounting mechanism slides over the lip 228 of the housing, allowing the display frame to be removed without disconnecting the mounting mechanism 232.

As previously described with reference to fig. 7B, with mounting clips 212, the display module 200 may be removed by lifting the display frame and disconnecting the mounting clips such as 212. For example, suction cups may be applied to the top of the protective glass 106 to lift off the display module 225. To reinstall the display module 225, a new mounting clip may be attached. One advantage of the mounting mechanism 232 is that the display module 225 can be removed without disconnecting the mounting mechanism 232.

Fig. 9 shows a side view of the clamp assembly 244. Referring to fig. 9, a method is described that may be used to provide uniform spacing between the protective top glass 106 and the seal 108 around the perimeter of the protective top glass 106. The clamps 244 may be used to secure the display frame 200 such that the surface supporting the protective top glass 106 is in a horizontal position. In one embodiment, as shown, a protective roof glass may be mounted over a portion of the seal 108 and a portion of the frame 200.

An adhesive such as 238 may be applied to the display frame 200. For example, a strip of liquid epoxy may be applied around the display frame 200 as an adhesive. Next, the shim ring 240 may be placed in circumferential contact with the inner surface of the seal 108 (the shim ring configured to conform to the inner circumference of the approximately rectangular seal 108). A protective top glass layer may then be placed between the shim rings and in contact with the adhesive 238.

A weight such as 242 may be placed on the protective glass layer 106. In one embodiment, the weights may be held in place by a spacer ring 240. A weight 242 may be used to hold the protective top glass 106 level while the adhesive cures. Finally, in one embodiment, the fixture 244 and its contents may be placed into an oven to aid in curing the adhesive 238. In one embodiment, the cure time may be about 1/2 hours.

FIG. 10 is a flow chart of a method 300 for assembling a display frame, such as 200, that includes securing a protective glass layer, such as 106, to the display frame. In 302, a display frame including a seal as described with reference to fig. 4 may be provided. As previously described, providing a display frame may include: forming a plastic display frame and an insert for structural reinforcement; loading the insert into the display frame; adding a plastic layer over the insert to bond the insert to the display frame; and bonding the seal 108 to the display frame including the insert. At 304, the display frame and seal may be loaded into a clip assembly as described with reference to fig. 9. At 306, an adhesive may be applied to the display frame secured in the clip assembly.

At 308, a shim ring may be placed near the inner edge of the seal on display frame 200. At 310, a protective glass may be placed in the gasket ring and in contact with the adhesive. At 312, a weight may be placed on the protective glass. In 314, the jig assembly with the display frame may be placed in a curing apparatus (e.g., an oven). At 316, the clamp assembly and associated components may be placed in a curing apparatus for a period of time to cause a bond to be formed between the protective top glass and the adhesive. The jig assembly may then be removed from the oven, the weights and spacer rings may be removed, and the display frame with the bonded protective top glass may be removed from the jig assembly.

FIG. 11 is a flow chart of a method 400 for integrating a display module into a portable computing device. In 402, a display module may be electrically connected to at least one operational component of a portable computing device. In 404, the display module may be temporarily secured to the portable device housing (see fig. 7B). In 406, the portable computing device may be functionally tested. At 410, it may be determined whether the device passed the test flow. When the device passes the test flow, the display module may be secured to the housing at 412 (see fig. 7A).

When the device fails the test flow, the display module may be detached and removed from the housing at 414. Since the mounting clip is not yet engaged, the display module can be removed without disconnecting the mounting clip. At 416, necessary repairs to the portable device may be determined and the components may be replaced as needed. The method may then be repeated starting at 402.

The various aspects, embodiments, implementations or features of the described embodiments may be used alone or in any combination. Aspects of the described embodiments may be implemented by software, hardware, or a combination of hardware and software. The embodiments may also be embodied as computer readable code on a computer readable medium for controlling a manufacturing operation or as computer readable code on a computer readable medium for controlling a manufacturing line. The computer readable medium is any data storage device that can store data which can thereafter be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, DVDs, magnetic tape, optical data storage devices, and carrier waves. The computer readable medium can also be distributed over network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the present invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed. It will be apparent to those skilled in the art that many modifications and variations are possible in light of the above teaching.

The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.

Although embodiments have been described with respect to a number of specific embodiments, there are alterations, permutations, and equivalents, which fall within the scope of these general concepts. It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present embodiments. For example, while an extrusion process is the preferred method of making the integrated tubing, it should be understood that this is not a limitation and that other manufacturing methods (e.g., injection molding) may be used. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the described embodiments.

Claims (19)

1. A method of manufacturing a portable computing device, comprising:

forming a plastic display frame and a plurality of inserts configured to provide structural rigidity to the plastic display frame;

coupling an insert to the plastic display frame and molding a layer of plastic over the insert to adhere the plastic display frame to the insert;

coupling a seal to the plastic display frame;

bonding a protective glass cover to the plastic display frame within an inner perimeter of the seal;

securing a touch screen, a display panel, and a plurality of metal clips to a plastic display frame;

inserting a plastic display frame into a one-piece housing, the one-piece housing including an opening having a lip surrounding the opening; and

after the metal clip is moved through the opening, a plastic display frame including a touch screen, a display panel, and a protective glass cover is secured to the one-piece housing by the metal clip engaging under the lip, while the display module is secured to the one-piece housing without a bezel.

2. The method of claim 1, wherein one or more of the inserts are metallic.

3. The method of claim 1, wherein one or more of the inserts are polymers.

4. The method of claim 1, wherein the insert is positioned proximate an opening in a single piece housing.

5. A portable computing device, comprising:

a one-piece housing including an opening surrounded by a lip; and

a display module, the display module comprising:

a display frame;

a protective glass cover bonded to the display frame and surrounded by a sealing frame, wherein the sealing frame is coupled to the display frame;

a touch screen mounted under a protective glass cover; and

a display panel housing which includes a display panel and a display circuit and is hung from the display frame by a plurality of mounting joints; wherein the display module is secured to the single-piece housing without using a bezel such that the display module is movable relative to the single-piece housing during an impact event.

6. The portable computing device of claim 5, wherein the display frame comprises:

a plastic display frame and a plurality of inserts formed separately from the plastic display frame, wherein the inserts are molded to the plastic display frame with a layer of plastic.

7. The portable computing device of claim 6, wherein the insert is formed of a metal or a polymer.

8. The portable computing device of claim 6, wherein the insert is coupled to the plastic display frame to provide structural support in the single piece housing adjacent the opening.

9. The portable computing device of claim 5, wherein the display frame further comprises a plurality of metal clips secured to the display frame, and wherein the metal clips are configured to engage under the lip after the display module is inserted into the one-piece housing to prevent the display module from lifting off the one-piece housing and to allow lateral movement of the display module relative to the one-piece housing.

10. The portable computing device of claim 5, wherein the display panel housing is approximately rectangular and the plurality of mounting tabs are located only on short sides of the display panel housing to increase a bending length of the display panel during an impact event.

11. A portable computing device, comprising:

a one-piece housing including an opening surrounded by a lip; and

a display module, the display module comprising:

a display frame including a plastic display frame and a plurality of inserts formed separately from the plastic display frame, wherein the plurality of inserts are loaded into the plastic display frame and covered with a plastic layer to bond the inserts to the plastic display frame;

a protective glass cover bonded to the display frame and surrounded by a sealing frame, wherein the sealing frame is coupled to the display frame;

a touch screen mounted under a protective glass cover; and

a display panel housing including a display panel and a display circuit and suspended from the display by a plurality of mounting tabs; wherein the display module is secured to the single-piece housing without using a bezel such that the display module is movable relative to the single-piece housing during an impact event.

12. The portable computing device of claim 11, wherein the plurality of interposers includes at least one metal interposer and at least one polymer interposer.

13. The portable computing device of claim 11, wherein one or more of the plurality of inserts are positioned proximate an opening in the single-piece housing to provide structural support.

14. A display module, comprising:

a display frame;

a protective glass cover bonded to the display frame and surrounded by a sealing frame, wherein the sealing frame is coupled to the display frame;

a touch screen mounted under a protective glass cover; and

a display panel housing including a display panel and a display circuit and suspended from the display by a plurality of mounting tabs; wherein the display module is secured to the single-piece housing without using a bezel such that the display module is movable relative to the single-piece housing during an impact event.

15. The display module of claim 14, wherein the display frame comprises:

a plastic display frame and a plurality of inserts formed separately from the plastic display frame, wherein the inserts are molded to the plastic display frame with a layer of plastic.

16. The display module of claim 15, wherein the insert is formed of a metal or a polymer.

17. The display module of claim 15, wherein the insert is coupled to the plastic display frame to provide structural support in the single piece housing adjacent the opening.

18. The display module of claim 14, wherein the display frame further comprises a plurality of metal clips secured to the display frame, and wherein the metal clips are configured to engage under the lip after the display module is inserted into the one-piece housing to prevent the display module from lifting off the one-piece housing and to allow lateral movement of the display module relative to the one-piece housing.

19. The display module of claim 14, wherein the display panel housing is approximately rectangular and the plurality of mounting tabs are located only on short sides of the display panel housing to increase a bending length of the display panel during an impact event.